ABB ACS1000i air-cooled User manual

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SYSTEM DRIVES
ACS1000i air-cooled
User manual
OWNING ORGANIZATION
ABB Switzerland Ltd.
DATE
2022-03-17
STATUS
Approved
SECURITY LEVEL
Public
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS206977 E01
REV.
J
LANG.
en
PAGE
1/146
© Copyright 2009 ABB All rights reserved.

PRODUCT
ACS1000i
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS206977 E01
REV.
J
LANG.
en
PAGE
2/146
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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
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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
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In no event shall ABB be liable for any damages inclusive but not limited to indirect, special, incidental or
consequential damages of any nature or kind whatsoever arising from the use of this document, nor shall
ABB be liable for any damages inclusive but not limited to indirect, special, incidental or consequential
damages arising from the use of any software or hardware described in this document.
This document and parts thereof must be kept strictly confidential and must not be reproduced or copied
without the prior 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 © 2009 ABB
All rights reserved

CONTENTS
PRODUCT
ACS1000i
DOCUMENT KIND
User manual
DOCUMENT ID.
3BHS206977 E01
REV.
J
LANG.
en
PAGE
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Contents
1. About this manual................................................................................................................... 3
1.1. Equipment covered by this manual ........................................................................................3
1.2. Structure of the user documentation ....................................................................................3
1.3. Terms and definitions ............................................................................................................... 4
1.4. Related documents ....................................................................................................... 6
1.5. Target groups and required qualification.............................................................................7
1.5.1. Handling.............................................................................................................................7
1.5.2. Mechanical installation...................................................................................................7
1.5.3. Electrical installation.......................................................................................................7
1.5.4. Operation...........................................................................................................................7
1.5.5. Maintenance..................................................................................................................... 8
1.6. User’s responsibilities............................................................................................................... 8
1.7. Intended use of equipment ..................................................................................................... 8
1.8. Quality certificates and applicable standards.................................................................... 9
1.9. Items covered by delivery ........................................................................................................10
1.10. Identifying the delivery ............................................................................................................10
2. Important safety information ........................................................................................... 11
2.1. Safety standards........................................................................................................................ 11
2.2. Safety messages........................................................................................................................ 11
2.3. Product safety labels ................................................................................................................12
2.4. General safety instructions.....................................................................................................13
2.5. The 7 steps that save lives.......................................................................................................14
2.6. Possible residual risks ..............................................................................................................16
2.7. Main circuit breaker protection device ................................................................................ 17
2.7.1. Safety and protection requirements ........................................................................18
2.7.2. Minimum requirements for MCB and MCB control...............................................18
2.8. Maintenance recommendation............................................................................................. 20
3. Power electronics and cabinet features ............................................................................ 21
3.1. Overview ......................................................................................................................................21
3.2. Main components of the drive system ............................................................................... 22
3.3. Power supply configurations ................................................................................................ 23
3.3.1. Main power supply configurations .......................................................................... 23
3.3.2. Auxiliary power supply configurations.................................................................... 24
3.4. Drive topology........................................................................................................................... 25
3.4.1. Overview.......................................................................................................................... 25
3.4.2. Terminal compartment ................................................................................................27
3.4.3. Control compartment and terminal compartment ............................................. 28
3.4.4. Transformer and rectifier compartment................................................................ 29
3.4.5. Rectifier ........................................................................................................................... 29
3.4.6. Grounding switch .........................................................................................................30
3.4.7. Trapped key interlock (option).................................................................................. 32
3.4.8. Protection IGCTs ........................................................................................................... 32
3.4.9. Inverter............................................................................................................................. 33
3.4.10. Filter ................................................................................................................................. 33
3.4.11. Cooling system.............................................................................................................. 34

CONTENTS
PRODUCT
ACS1000i
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DOCUMENT ID.
3BHS206977 E01
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3.4.12. Optional Braking Chopper ......................................................................................... 38
3.5. Cabinet design...........................................................................................................................41
3.5.1. Mechanical design.........................................................................................................41
3.5.2. Additional cabinets ...................................................................................................... 42
3.6. Door locking system................................................................................................................ 43
3.6.1. Optional cabinets ......................................................................................................... 43
3.7. Arc resistant design (optional) .............................................................................................44
3.7.1. Internal arc classification ............................................................................................44
3.7.2. Power compartment doors........................................................................................ 45
3.7.3. Associated protection requirement......................................................................... 45
3.8. Space heaters............................................................................................................................46
4. Control system...................................................................................................................... 47
4.1. Overview ..................................................................................................................................... 47
4.2. Main components ....................................................................................................................48
4.2.1. Local control panel .......................................................................................................48
4.2.2. AMC circuit board .........................................................................................................49
4.3. I/O interfaces ............................................................................................................................ 53
4.3.1. IOEC I/O modules......................................................................................................... 53
4.3.2. Serial communication interface (fieldbus)............................................................. 58
4.3.3. Pulse encoder interface NTAC (option)...................................................................58
5. Transportation, storage and disposal ...............................................................................59
5.1. Safety ......................................................................................................................................... 59
5.2. Transport conditions............................................................................................................... 59
5.3. Unpacking and inspection ..................................................................................................... 59
5.4. Lifting and transportation ..................................................................................................... 59
5.4.1. General notes on transportation ............................................................................60
5.4.2. Using a crane .................................................................................................................60
5.4.3. Using rollers ................................................................................................................... 62
5.5. Storage........................................................................................................................................ 63
5.5.1. Storage conditions....................................................................................................... 63
5.5.2. Storing the drive ........................................................................................................... 63
5.5.3. Storage and handling of spare parts ......................................................................64
5.6. Disposal of packaging materials and components ........................................................64
6. Mechanical installation ........................................................................................................65
6.1. Safety ......................................................................................................................................... 65
6.2. Overview of installation work................................................................................................ 65
6.3. General notes on installation ................................................................................................ 65
6.3.1. Dimensions and clearances ....................................................................................... 65
6.3.2. Cabinet roof ................................................................................................................... 65
6.3.3. Fire protection............................................................................................................... 65
6.3.4. Cable duct material...................................................................................................... 65
6.4. Preparing the floor................................................................................................................... 66
6.5. Fixing the cabinet to the floor ..............................................................................................66
6.6. Installing the fans..................................................................................................................... 67
6.6.1. Additional cabinet compartments............................................................................72
7. Electrical installation ........................................................................................................... 73
7.1. Safety ......................................................................................................................................... 73
7.2. Overview of installation work................................................................................................ 73
7.3. Cable requirements ................................................................................................................. 73

CONTENTS
PRODUCT
ACS1000i
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7.4. Ground cable connection and cable shield connections ............................................... 74
7.5. Power cables, ground cables and equipotential bonding conductor ........................ 75
7.5.1. Safety ........................................................................................................................... 75
7.5.2. Determining the cable length.................................................................................... 75
7.5.3. MV cable entry from top ............................................................................................. 76
7.5.4. MV cable entry from bottom ..................................................................................... 79
7.5.5. Connecting the cables................................................................................................. 82
7.6. Auxiliary power, control and serial communication cables ...........................................84
7.6.1. Preparing the cable entry and the cables...............................................................84
7.6.2. Preparing cables for cable entries with cable glands ......................................... 85
7.6.4. Connecting additional cabinets................................................................................ 86
7.7. Final checks................................................................................................................................ 86
8. Commissioning ..................................................................................................................... 87
8.1. Overview ..................................................................................................................................... 87
8.1.1. Required qualification ............................................................................................... 87
8.1.2. Commissioning procedure ....................................................................................... 87
8.1.3. Commissioning checklist .......................................................................................... 87
8.1.4. Customer assistance ................................................................................................. 87
8.1.5. Customer acceptance ................................................................................................ 87
8.2. Commissioning checklists .....................................................................................................88
8.2.1. Mechanical installation checklist ..............................................................................88
8.2.2. Electrical installation checklist ..................................................................................88
8.2.3. Main circuit breaker (MCB) checklist........................................................................89
8.2.4. Motor checklist.............................................................................................................. 89
8.2.5. Insulation tests checklist ............................................................................................89
8.2.6. Power supply checklist ................................................................................................89
8.2.7. Miscellaneous checklist...............................................................................................90
9. Operation............................................................................................................................... 91
9.1. Safety ..........................................................................................................................................91
9.2. Overview ......................................................................................................................................91
9.3. Operating conditions ...............................................................................................................91
9.4. Local operator panel.................................................................................................................91
9.5. Status messages ...................................................................................................................... 93
9.5.1. Start sequence of the drive ......................................................................................94
9.5.2. Stop sequence of the drive ...................................................................................... 95
9.5.3. Emergency off sequence of the drive ...................................................................96
9.6. Starting the drive ....................................................................................................................96
9.6.1. Checks before starting the drive ..............................................................................96
9.6.2. Starting the drive remotely ........................................................................................ 97
9.6.3. Starting the drive locally ............................................................................................. 97
9.7. Stopping the drive ...................................................................................................................99
9.8. Emergency-off .......................................................................................................................... 99
9.8.1. Initiating an emergency-off ..................................................................................... 100
9.8.2. Starting the drive after an emergency-off ........................................................... 100
10. CDP control panel ............................................................................................................... 101
10.1. Overview ....................................................................................................................................101
10.2. CDP control panel functions................................................................................................ 102
10.3. CDP control panel modes..................................................................................................... 102
10.3.1. Identification mode.................................................................................................... 102
10.3.2. Actual signals mode................................................................................................... 103

CONTENTS
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ACS1000i
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DOCUMENT ID.
3BHS206977 E01
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10.3.3. Parameters mode ......................................................................................................110
10.3.4. Functions mode ...........................................................................................................115
10.4. Local and remote control ......................................................................................................118
10.4.1. Local control..................................................................................................................118
10.4.2. Remote control.............................................................................................................118
10.5. Operational commands......................................................................................................... 119
10.5.1. Setting the direction of rotation.............................................................................. 119
10.5.2. Entering a reference value ......................................................................................... 121
11. Preventive and corrective maintenance........................................................................... 123
11.1. General information................................................................................................................123
11.1.1. Required qualification ................................................................................................123
11.1.2. Maintenance schedule................................................................................................123
11.1.3. Logbook .........................................................................................................................123
11.1.4. Spare parts ....................................................................................................................123
11.2. Identifying electrical equipment ........................................................................................ 124
11.2.1. Device identification .................................................................................................. 124
11.2.2. Cables and wires......................................................................................................... 124
11.2.3. Understanding wiring diagrams ............................................................................ 124
11.3. Alarm / fault indications........................................................................................................125
11.3.1. Messages .......................................................................................................................125
11.3.2. Error message levels ...................................................................................................125
11.3.3. Fault handling.............................................................................................................. 126
11.3.4. Standard troubleshooting procedure ....................................................................127
11.4. Removing the CDP control panel........................................................................................ 128
11.5. LEDs and switches on circuit boards................................................................................ 129
11.5.1. AMC circuit board ....................................................................................................... 129
11.5.2. IOEC I/O modules....................................................................................................... 130
11.6. Corrective maintenance......................................................................................................... 131
11.6.1. Safety .......................................................................................................................... 131
11.6.2. De-energizing the drive locally .................................................................................132
11.6.3. Grounding......................................................................................................................133
11.6.4. Grounding switch is not released ......................................................................... 134
11.6.5. Checking the release conditions for the grounding switch ...........................135
11.6.6. Visual checks on the drive..........................................................................................137
11.6.7. Cleaning the drive ......................................................................................................137
11.6.8. Checking wire and cable connections................................................................... 138
11.6.9. Cleaning and replacing filter mats......................................................................... 138
11.6.10. Inspecting and replacing batteries........................................................................ 140
11.6.11. Replacing a fan unit ................................................................................................ 142

FIGURES
PRODUCT
ACS1000i
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3BHS206977 E01
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Figures
Figure 1–1 Delivered items ............................................................................................. 10
Figure 2–1 Product warning label examples
(label placement depends on the drive) ........................................................................ 12
Figure 2–2 Drive system overview ................................................................................... 17
Figure 2–3 MCB opening timing diagram .................................................................... 19
Figure 3–1 ACS1000i air-cooled ...................................................................................... 21
Figure 3–2 Block diagrams of the drive ....................................................................... 22
Figure 3–3 Drive overview with power supplies .......................................................... 23
Figure 3–4 ACS1000i air-cooled with combined input disconnector and
grounding switch ........................................................................................................... 25
Figure 3–5 ACS1000i air-cooled with grounding switch ............................................ 26
Figure 3–6 Terminal compartment with input disconnector (A) and
without input disconnector (B) .................................................................................... 27
Figure 3–7 Control compartment with open door ...................................................... 28
Figure 3–8 Transformer and rectifier compartment with combined input
disconnector (A) and with grounding switch (B) ....................................................... 29
Figure 3–9 Switchgear of the drive .............................................................................. 30
Figure 3–10 Grounding switch unlocked lamp (1) ......................................................... 31
Figure 3–11 Grounding the drive ..................................................................................... 31
Figure 3–12 Trapped key interlocking system (1).......................................................... 32
Figure 3–13 Three-level voltage source inverter principle ........................................... 33
Figure 3–14 Voltage and current waveforms at drive output ...................................... 33
Figure 3–15 Fan configurations and air flow ............................................................... 34
Figure 3–16 Fan groups - AC and EC fans .................................................................... 35
Figure 3–17 Fan groups - EC fans only ........................................................................ 35
Figure 3–18 Operating times of the AC fan units during continuous drive
operation (A) and Intermittent drive operation (B) .................................................... 36
Figure 3–19 Operating principles of redundant EC fans ........................................... 37
Figure 3–20 ACS1000i with braking chopper (1) ........................................................... 38
Figure 3–21 Principle diagram ...................................................................................... 38
Figure 3–22 Braking chopper design ........................................................................... 39
Figure 3–23 ACS1000i with an additional cabinet (1) ................................................... 42
Figure 3–24 Door locks .................................................................................................. 43
Figure 3–25 IAC label example ....................................................................................... 44

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Figure 3–26 Door bolts .................................................................................................... 45
Figure 3–27 Optional space heaters ...............................................................................46
Figure 4–1 Block diagram of control system with customer interface (A),
control system (B) and power electronics (C) ............................................................. 47
Figure 4–2 Control compartment .................................................................................48
Figure 4–3 AMC circuit board ........................................................................................49
Figure 4–4 Direct torque control ..................................................................................50
Figure 4–5 PID control mode ........................................................................................ 52
Figure 4–6 IOEC interfaces overview ........................................................................... 53
Figure 4–7 IOEC module ................................................................................................ 56
Figure 4–8 IOEC module identification ....................................................................... 57
Figure 4–9 NTAC-02 pulse encoder interface ................................................................ 58
Figure 5–1 Transporting the cabinet by crane (lift spreader example) ................... 61
Figure 5–2 Moving the drive with rollers ..................................................................... 62
Figure 5–3 Moving the drive backwards or forwards ................................................. 62
Figure 6–1 Position of mounting holes .......................................................................... 66
Figure 6–2 Leveling the drive .......................................................................................... 66
Figure 6–3 Fixing the cabinet to the floor .................................................................... 67
Figure 6–4 Cutouts in drive roof - back (A) and front (B) .......................................... 67
Figure 6–5 Standard fan installation ............................................................................ 68
Figure 6–6 Lifting point locations on fan unit .............................................................. 69
Figure 6–7 Large fan installation .................................................................................... 70
Figure 6–8 Small fan installation over a roof cutout for a large fan .......................... 71
Figure 6–9 Fan installation material .............................................................................. 71
Figure 6–10 Bolt location at the back of a fan unit ...................................................... 72
Figure 7–1 Grounding the drive system ....................................................................... 74
Figure 7–2 Top cable entry – installation material ...................................................... 76
Figure 7–3 Bolt locations for cable entry box on terminal compartment
roof (A is the back and B is the front of the compartment) ..................................... 77
Figure 7–4 Insulating barrier placement for top cable entry .................................... 78
Figure 7–5 Bottom cable entry – Installation material ............................................... 79
Figure 7–6 Bolt locations on terminal compartment roof for the
galvanized steel plate ................................................................................................... 80
Figure 7–7 Bracket location on insulating barrier ...................................................... 81
Figure 7–8 Insulating barrier placement for bottom cable entry ............................... 81
Figure 7–9 Power cable terminals in a terminal compartment without an
input disconnector (A) and a terminal compartment with an input
disconnector (B) ............................................................................................................... 82

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Figure 7–10 Bolted busbar connections ...................................................................... 83
Figure 7–11 Cable entry from top (A), from bottom (B) ............................................... 84
Figure 7–12 Top entry for auxiliary power and control cables .................................... 85
Figure 7–13 Preparing control cables for cable glands ................................................ 85
Figure 7–14 Shield grounding point for encoder cable ..............................................86
Figure 9–1 Local operator panel ..................................................................................... 92
Figure 10–1 CDP control panel ...................................................................................... 101
Figure 10–2 Control panel - Actual signals mode ....................................................... 105
Figure 10–3 Control panel - Parameters mode ............................................................ 112
Figure 10–4 Control panel - Functions mode ............................................................... 116
Figure 11–1 Device identification .................................................................................. 124
Figure 11–2 AMC circuit board ..................................................................................... 129
Figure 11–3 IOEC module ............................................................................................... 130
Figure 11–4 Location of I/O modules and fuses ....................................................... 134
Figure 11–5 Cleaning and replacing filter mats N ...................................................... 139
Figure 11–6 Control compartment – battery location .............................................. 140
Figure 11–7 Control compartment - replacing the batteries ..................................... 141
Figure 11–8 Lifting point locations on fan unit ........................................................... 143