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11 PREVENTIVE AND CORRECTIVE MAINTENANCE

3BHS213401 E01 REV H

ACS1000 AIR-COOLED

USER MANUAL

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8. If the new fan housing does not have screw holes for the mounting supports, drill holes into

the underside of the fan housing.

9. Check that all screws are properly fastened.

10. Install the new fan in reverse order of removal.

For information on the exact hole positions, see drawing number 3BHS128478
E01 in “Appendix C – Mechanical drawings”.

Summary of Contents for ACS 1013-A1

Page 1: ... MEDIUM VOLTAGE AC DRIVES ACS1000 air cooled User manual ...

Page 2: ... reliability you expect Document name ACS1000 air cooled user manual Document owner ABB Switzerland Ltd Medium voltage AC drives Document number 3BHS213401 E01 Rev H Number of pages 184 Release date 2020 03 18 new abb com drives medium voltage ac drives ...

Page 3: ...Contents ACS1000 air cooled User manual ...

Page 4: ... electronics and cabinet features 27 04 Control system 51 05 Transportation storage and disposal 67 06 Mechanical installation 75 07 Electrical installation 83 08 Commissioning 107 09 Operation 113 10 CDP control panel 127 11 Preventive and corrective maintenance 151 ...

Page 5: ... 01 About this manual 01 3 14 ...

Page 6: ...7 Target groups and required qualification 9 1 7 1 Handling 9 1 7 2 Mechanical installation 9 1 7 3 Electrical installation 9 1 7 4 Operation 9 1 7 5 Maintenance 9 1 8 User s responsibilities 10 1 9 Intended use of equipment 10 1 10 Cyber security disclaimer 10 1 11 Quality certificates and applicable standards 11 1 12 Items covered by delivery 12 1 13 Identifying the delivery 13 ...

Page 7: ...d beyond the instructions in this manual refer the matter to ABB 1 3 Structure of the user documentation The complete set of user documentation of a standard drive consists of this manual and supplementary documentation that is provided in the following appendices Appendix A Additional manuals Appendix A provides manuals about additional equipment delivered with the drive such as project specific ...

Page 8: ...veWare software tools for drives using the DDCS communications protocol DriveDebug runs on computers with Windows operating systems DriveDebug is a specialist s tool used to diagnose tune and troubleshoot ABB drives DriveWindow DriveWindow is a DriveWare product DriveWindow is a 32 bit Windows application for commissioning and maintaining ABB drives equipped with optical communication links Equipm...

Page 9: ...rth PPCS Power plate communication system PPCS is an acronym for a serial communication protocol designed for data transfer via optical fibers between AMC circuit board and INTerface circuit boards RTD Resistance temperature detector or device The RTD is a temperature sensor where the change in electrical resistance is used to measure the temperature Supervisory signal Indicates the operating cond...

Page 10: ... Reference number Document Document number 4 Retrofit guideline 3BHS301179 E01 5 Input circuit breaker engineering guideline 3BHS104785 E01 6 Main transformer specification 3BHS356582 E01 7 Induction motor specification 3BHS260163 E01 8 Power cable specification 3BHS189994 E01 9 Power cables engineering guideline 3BHS542290 E01 10 Auxiliary power and control cables guideline 3BHS813742 E01 Referen...

Page 11: ...t requirements and to perform the installation accordingly 1 7 3 Electrical installation The personnel must have a sound knowledge of the relevant electrical codes and specifications covering low and medium voltage equipment be experienced with electrical wiring principles and know the electrical symbols typically used in wiring diagrams 1 7 4 Operation The personnel include all persons who operat...

Page 12: ...s recommended and approved by ABB must be used Unauthorized modifications and constructional changes of the drive are not permitted 1 10 Cyber security disclaimer This product is designed to be connected to and to communicate information and data via a network interface It is the customer s sole responsibility to provide and continuously ensure a secure connection between the product and Customer ...

Page 13: ...fety signs Registered safety sign 19 EN 50110 European standard code for electrical work safety 20 ISO 13849 1 Safety of machinery Safety related parts of control systems Part 1 General principles for design section 6 2 6 Category 3 21 IEC 60204 1 Safety of machinery Electrical equipment of machines Part 1 General requirements 22 IEC 60721 3 1 Classification of environmental conditions Classificat...

Page 14: ...lifting rail 1 in Fig 1 1 Set of door keys inside the drive Rating label 2 in Fig 1 1 Box with USB stick 3 in Fig 1 1 which contains the user manual and related documents Strain relief rails Air exhaust hood Redundant fan unit option Set of bolts nuts and washers Figure 1 1 Delivered items Note For a complete list of the items in the delivery see the shipping note 1 Door keys 2 Rating label 3 Box ...

Page 15: ...NUAL 13 184 1 13 Identifying the delivery The drive and accessories are identified by the type code printed on the rating label The label provides information on the type of drive the rated voltage the frequency and the current of the main and the auxiliary power supply ...

Page 16: ......

Page 17: ... 02 Important safety information 02 15 26 ...

Page 18: ... 4 Product safety labels 18 2 5 General safety instructions 19 2 6 The 7 steps that save lives 20 2 7 Possible residual risks 22 2 8 Important note main circuit breaker 23 2 8 1 Safety and protection requirements 24 2 8 2 Minimum requirements for MCB and MCB control 24 2 8 3 Maintenance recommendation 25 ...

Page 19: ...ety colours and safety signs Registered safety sign 18 EN 50110 European standard code for electrical work safety 19 2 2 Safety messages The following safety messages are provided to help prevent personal injury and damage to the equipment The indicated hazard level is based on the ANSI Z535 6 standard DANGER WARNING CAUTION 2 3 Damage prevention information NOTICE DANGER Indicates a hazardous sit...

Page 20: ...gn can also have additional text below it eg High voltage Hot surface Crushing of hands No access for people with active implanted cardiac device The magnetic field of the drive can influence the functioning of pacemakers The pacemaker sign should be installed at the entrance to the drive room or at a minimum distance of 6 m from the drive to stop personnel with pacemakers approaching the drive Fi...

Page 21: ...ety ground connections are in place Ensure that the appropriate personal protective equipment PPE is available and used when required Inform the involved personnel about the potential safety hazards Wear hearing protection when a drive is running Before working simultaneously on the drive and on other drive system equipment Observe the relevant safety codes and standards Turn off all energy source...

Page 22: ...ns etc Ensure the competence of workers Check for proper tools for the job Determine and select the proper arc rated Personal Protective Equipment PPE Decide of the appropriate work methods and initiate the Permit To Work PTW process 2 Clearly identify the work location and equipment Use your senses sight hearing and smell to identify problem areas Define the work area via barriers and barricading...

Page 23: ...ensure that this equipment is properly earthed as a part of the integration verification and during step 7 when the PICW walks the PTW 6 Protect against adjacent live parts and take special precautions when close to bare conductors Determine minimum approach distances apply screening or shrouding and when applicable padlock both cable and busbar shutters If working within the restricted approach b...

Page 24: ...ed or installed equipment Wrongly connected cables External influence on or damage of the equipment Wrong parameter settings Software errors Faulty hardware Hazardous touch voltages can be present on drive system components which can be caused by Operation of the equipment outside the scope of the specifications External influence on or damage of the equipment Induced voltages by external equipmen...

Page 25: ...sformer Figure 2 2 Drive system overview The MCB is a switching device that disconnects the power supply whenever required by the process or when a fault occurs Typical MCBs are Vacuum circuit breakers SF6 circuit breakers Fused contactors or motor control centers A dedicated protection relay is used for Transformer or converter primary cable protection DTL Transformer protection if applicable Tra...

Page 26: ... from the drive to the MCB It is not permitted to wire the trip command through any PLC or DCS system if it is not certified to meet SIL three level requirements and to fulfill the timing requirements outlined below Opening of the MCB by the drive must be possible at any time It is not permitted to interrupt the open and or trip command eg by a local remote switch in the MCB When the MCB is in ser...

Page 27: ...tream protection coordination scheme is provided which uses the breaker failure ANSI 50BF signal to automatically trip the upstream breaker in case the MCB does not open The upstream breaker must open within the maximum safety trip time after a failure has occurred 2 8 3 Maintenance recommendation The MCB trip circuits should be checked annually 1 Short circuit occurs 2 Open and or trip command is...

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Page 29: ... 03 Power electronics and cabinet features03 27 50 ...

Page 30: ...ions 33 3 4 Drive topology 33 3 4 1 Overview 34 3 4 2 Control compartment and terminal compartment 35 3 4 3 Rectifier and inverter compartment 36 3 4 4 Grounding switch 37 3 4 5 Rectifier 37 3 4 6 Protection IGCTs 37 3 4 7 Inverter 38 3 4 8 Filter 38 3 4 9 Optional Braking Chopper 38 3 5 Cooling system 42 3 5 1 Fan configurations 42 3 5 2 Type of fan 42 ...

Page 31: ...erating principles 44 3 5 6 Air flow overview AC and EC fans 45 3 5 7 Monitoring the air pressure 46 3 5 8 Adjustable parameters 47 3 6 Cabinet design 47 3 7 Door locking system 48 3 8 Arc resistant design optional 49 3 8 1 Internal arc classification IAC 49 3 8 2 Associated protection requirement 49 3 9 Space heaters 50 ...

Page 32: ...e following sections provide an overview of Drive topology and main features Available main and auxiliary power configurations Power electronic components of the drive Cooling system Cabinet features such as the grounding switch and the electro mechanical door interlock Figure 3 1 ACS1000 air cooled For information on the power and voltage range of the drive see the Technical specifications and th...

Page 33: ...owing main components Main circuit breaker MCB For more information see 2 8 Important note main circuit breaker on page 23 Transformer For more information see the Transformer specification Drive Asynchronous motor For more information see the motor specification 1 Medium voltage switchgear including main circuit breaker and transformer protection 2 Transformer 3 Rectifier 4 Protection IGCTs 5 DC ...

Page 34: ...ower electronic components Auxiliary power supply for the control and cooling system Figure 3 3 Drive overview with power supplies 1 Auxiliary power supply 2 ACS1000A 3 Control and cooling system 4 Auxiliary power distribution 5 Cooling system 6 Control system 7 Main power supply 8 MCB 9 Transformer 10 Power electronic components 11 Rectifier 12 DC link 13 Inverter 14 Motor 1 2 3 4 5 6 7 8 9 10 11...

Page 35: ...ling the drive to ride through and or to perform a controlled shutdown Through separate power supplies The auxiliary power is supplied to the drive by a three phase AC power supply and by an UPS to a separate one phase AC or DC input Feeding the control power separately by an UPS has the advantage that the main control hardware will remain energized the full ride through capabilities of the drive ...

Page 36: ... AND CABINET FEATURES 3BHS213401 E01 REV H ACS1000 AIR COOLED USER MANUAL 34 184 3 4 1 Overview Figure 3 4 ACS1000 air cooled topology 1 Control compartment and terminal compartment 2 Rectifier and inverter compartment 1 2 ...

Page 37: ...e For more information on the control hardware see 04 Control system on page 51 Terminal compartment 2 in Fig 3 5 The terminal compartment in the back contains the busbars for the feeder and motor cables the ground cable and the cable screens A hinged bolted partition separates the terminal compartment from the control compartment For more information on cable entry and cable connection see 07 Ele...

Page 38: ...fier and inverter compartment Figure 3 6 Rectifier compartment 1 Second 12 pulse rectifier 2 12 pulse rectifier with protection IGCTs 3 Inverter phase U 4 Inverter phase V 5 Inverter phase W 6 Grounding switch 7 Common mode choke option 8 Filter choke 9 Filter capacitors 10 DC link capacitors 1 2 3 4 5 6 7 8 9 10 ...

Page 39: ... unlocked 1 in Fig 3 7 on the door of the control compartment lights up and the grounding switch can be turned to position grounded 2 in Fig 3 7 Figure 3 7 Grounding switch When the grounding switch is in position grounded the doors of the medium voltage compartments are released and the doors can be opened 3 4 5 Rectifier The diode rectifier converts the AC voltage of the main power supply and co...

Page 40: ...and the frequency continuously from zero to maximum using direct torque control For more information see 4 2 2 4 Direct torque control on page 58 Figure 3 8 Three level voltage source inverter principle 3 4 8 Filter The filter at the drive output reduces the harmonic content of the motor voltage and generates a nearly sinusoidal motor friendly voltage waveform The filter also eliminates all high d...

Page 41: ...chopper cabinet connects to the right side of the drive as well as to the braking resistors which are external to the ACS1000 and not part of the product scope Figure 3 10 ACS1000 air cooled with braking chopper 1 The braking chopper is controlled and monitored by the ACS1000 Figure 3 11 Principle diagram 1 Rectifier 2 Braking chopping 3 Inverter 4 Braking resistor 1 1 2 3 4 Rb VC1 VC2 VCs2 C2 C1 ...

Page 42: ... any defective component in the circuit The current can become imbalanced if one of the IGCTs conducts a current permanently or if an IGCT fails to be switched on If a short circuit or an imbalance is detected in the braking chopper the drive is shut down 3 4 9 2 2 Thermal protection The braking chopper and the braking resistors are monitored for over temperature by the ACS1000 In addition an exte...

Page 43: ...2 5 MW a cooling time of one hour is required If two braking sequences of 30 s are necessary within an hour the maximum braking power has to be reduced to 50 of the maximum possible braking power Table 3 1 Braking ratings ACS1000 Braking chopper Type Max DC link voltage V Max braking power MW Max braking power MW Max braking energy MW ACS1012 A1 ACS 1013 A1 ACS 1014 A1 4200 6000 7270 0 426 0 426 0...

Page 44: ...ing types AC fans The AC fans are turned on and off with digital signals which switch contactors to connect or disconnect the 3 phase auxiliary power The AC fan speed is not controlled EC fans The electronically commutated EC fans are controlled via an analog signal from the drive based on the inverter current The EC fan speed is controlled depending on the required cooling 3 5 3 Starting stopping...

Page 45: ...its during continuous drive operation A and Intermittent drive operation B When the drive operates continuously AC fan 1 switches off after six hours and fan 2 switches on for four hours When the drive operates intermittently the AC fan that is due for operation is switched on and off in the same pattern as the drive until the programmed operating time has elapsed If one AC fan fails the second AC...

Page 46: ...speed typically the minimum speed When one EC fan fails the second EC fan will speed up to ensure the required cooling Figure 3 14 Operating principles of redundant EC fans Both fans are running Fan 1 fails fan 2 increases speed Fan 1 is stopped Fan 2 is running at nominal speed Fan 1 resumes operation fan 2 decreases speed 1 Fan 1 2 Fan 2 3 Drive load 4 Nominal fan speed 5 Reduced fan speed 6 Min...

Page 47: ... FEATURES 3BHS213401 E01 REV H ACS1000 AIR COOLED USER MANUAL 45 184 3 5 6 Air flow overview AC and EC fans Figure 3 15 Air flow non redundant fan 1 configuration Figure 3 16 Air flow redundant fan configuration 1 Fan 1 2 Fan 2 1 1 2 ...

Page 48: ...h non redundant fan configuration The alarm FanDiffPres displays on the local control panel and the drive shuts down Drives with redundant fan configuration The alarm FanDiffPres displays on the local control panel and the drive switches on the stand by fan When the stand by fan also fails the drive shuts down 3 5 7 2 Air pressure across filter mat AC and EC fan types A separate optional air press...

Page 49: ...ign consisting of folded galvanized sheet metal plates approximately 2 mm thick and minimizing the space between the rivets The inside walls of the cabinet are not painted because paint tends to reduce the effectiveness of metallic bonding which is important for successful EMC Accordingly only the front of the cabinet is painted while all other walls are galvanized However the cabinet can be order...

Page 50: ...tro mechanically secured Additionally the doors of the medium voltage compartments have locks with different inserts than the control compartment door The different lock inserts ensure that these doors can only be opened by personnel authorized to do so Figure 3 18 Door locks 1 Door of control compartment lockable Partition of terminal compartment behind control compartment bolted 2 Doors of recti...

Page 51: ...that are not included in the scope of the delivery ie a main circuit breaker For information on the arc resistant design class of your drive see the project specific Converter Data Sheet Appendix B of the ACS1000A user manual ABB class Description Class I Protection based on arc prevention NOT certified according to IEC 62477 2 Class II Protection based on arc resistant cabinet structure 1 1 IAC c...

Page 52: ...HS213401 E01 REV H ACS1000 AIR COOLED USER MANUAL 50 184 3 9 Space heaters The optional space heaters protect the cabinet from condensation The drive switches on the space heaters when the cooling system is switched off Figure 3 20 Space heaters ...

Page 53: ... 04 Control system 04 51 66 ...

Page 54: ... 2 Main components 54 4 2 1 Local control panel 56 4 2 2 AMC circuit board 56 4 3 I O interfaces 61 4 3 1 IOEC I O modules 61 4 3 2 Serial communication interface fieldbus 65 4 3 3 Pulse encoder interface NTAC option 65 ...

Page 55: ...g on the control concept of the drive system the remote control devices include a higher level control system and or remote operator stations Figure 4 1 Block diagram of control system with customer interface A control system B and power electronics C 1 ABB Ability 2 Higher level control system 3 Fieldbus 4 DDCS 5 RS485 6 CDP control panel 7 PC tools 8 AMC circuit board 9 Fiber optics 10 INT circu...

Page 56: ...he main hardware components of the control system and their interconnection Figure 4 2 Control compartment 1 Control power supply 2 AMC circuit board and INT circuit board 3 Pulse encoder option 4 Fieldbus interface option 5 IOEC1 module 6 Motor starters and circuit breakers 7 Control power supply 8 Local control panel 8 1 2 3 4 5 6 7 ...

Page 57: ...MANUAL 55 184 Figure 4 3 Control compartment I O devices 1 IOEC2 module standard 2 IOEC4 module option 3 Auxiliary voltage terminals 4 IOEC3 module option For more information on the devices present in the control compartment see Appendix D Wiring diagrams 1 2 3 4 ...

Page 58: ...ication channels are used for high speed data transfer via the INT circuit board to the inverter Figure 4 4 AMC circuit board 4 2 2 1 Control tasks The AMC circuit board has specific control and closed loop tasks assigned to it It processes drive and status information performs the speed and torque control tasks and monitors the operation of the drive All relevant drive variables eg speed torque c...

Page 59: ...alues are adjusted during commissioning to the specific application of the drive in order to activate the specific control monitoring and protection functions for the driven process and to define the signals and data transferred between drive and external equipment 4 2 2 3 Main circuit breaker The main circuit breaker MCB is an important switching and protection device of the drive system Therefor...

Page 60: ...lers Depending on the outputs from the hysteresis controllers the switching logic directly determines the optimum switch positions every 50 microseconds and initiates switching whenever required 4 2 2 5 Peripheral I O devices The peripheral input and output devices connected to the AMC circuit board include Local CDP control panel IOEC I O modules for parallel signal transfer to external devices s...

Page 61: ...e of the drive The control mode can be used for applications where constant speed is required such as pumps fans and conveyors Torque control mode used for processes that require torque control eg mixers and slave drives The torque reference comes from a process control system or a control panel PID control mode controls the process variable eg pressure level or flow by adjusting the speed of the ...

Page 62: ...n 4 2 2 7 Operating modes The drive provides the following operating modes Master follower operating mode used for applications with several drives where the motor shafts are coupled to each other eg gearing chain belt Owing to the master follower operating mode the load can be evenly distributed between the drives or at some adjustable other ratio which depends on the process Hand auto operating ...

Page 63: ... extra inputs and outputs for control and supervision as may be required by the drive or the customer to support various control options Figure 4 7 IOEC interfaces overview 4 3 1 1 IOEC module configuration Each IOEC module is configured with both analog and digital inputs and outputs as shown in Table 4 1 Table 4 2 Table 4 3 and Table 4 4 Table 4 1 IOEC module configuration analog inputs 1 IOEC 1...

Page 64: ...range 0 20 mA load impedance max 250 Ω Resolution 12 bit Isolation level 350 V AC No of I O 14 Signal level 22 120 V DC for the 80 120V range an IOEC adapter board is required 22 250 V AC Logical threshold 13 V AC or DC 0 16 V AC or DC 1 Input current 13 mA steady state 14 mA max inrush at 24 V DC 11 5 mA steady state 80 mA max inrush at 120 V DC 10 5 mA steady state 92 mA max inrush at 230 V AC I...

Page 65: ... DO3 X11 1 X11 2 DI1 X11 3 X11 4 DI2 X11 5 X11 6 DI3 X11 7 X11 8 DI4 X11 9 X11 10 DI5 X12 1 X12 2 DI6 X12 3 X12 4 DI7 X12 5 X12 6 DI8 X12 7 X12 8 DI9 X12 9 X12 10 DI10 X13 1 X13 2 DI11 X13 3 X13 4 DI12 X13 5 X13 6 DI13 X13 7 X13 8 DI14 DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 DI9 DI10 DI11 DI12 DI13 DI14 24 VIR OVIR V IR OK OFF ON X13 9 X13 10 AI1 OV AI2 AI3 AI4 AO1 AO2 AI1 10V AI2 AI3 AI4 AI1 20mA AI1 10V...

Page 66: ...an be seen in Fig 4 9 The letter A represents the kind of part we have an assembly the next three digits are the page number the part is located on page 191 and the last digit 1 means that our part is the first assembly on the page This identification label number is the key to track electrical devices throughout the drive and in ABB documentation The designation for each IOEC module is shown in T...

Page 67: ...r more information on the device consult the relevant manual Modbus TCP Ethernet NETA 21 remote monitoring tool user manual 11 Modbus RTU Modbus NMBA 01 installation and start up guide 12 Profibus Profibus NPBA 12 installation and start up guide 13 DeviceNet DeviceNet NDNA 02 installation and start up guide 14 For more information on the device see Installation and Start up Guide for the Pulse Enc...

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Page 69: ... 05 Transportation storage and disposal05 67 74 ...

Page 70: ...ansportation 69 5 4 1 General notes on transportation 69 5 4 2 Using a crane 70 5 4 3 Cabinets without redundant fan unit 71 5 5 Storage 72 5 5 1 Storage conditions 72 5 5 2 Storing the drive 72 5 5 3 Storage and handling of spare parts 72 5 6 Disposal of packaging materials and components 73 ...

Page 71: ...and transportation 5 4 1 General notes on transportation NOTICE The drive must only be handled by personnel who are skilled and experienced in unpacking and transporting heavy equipment It is recommended to have the following information which is in Appendix C mechanical drawings at hand before transporting the cabinet Layout drawing document Fixing and Lifting details document Risk of component d...

Page 72: ...184 5 4 2 Using a crane 5 4 2 1 Cabinets with redundant fan unit NOTICE Risk of component damage Do not attach lifting equipment to the eye bolts of the redundant fan unit If the cabinet is lifted at the eye bolts the fastening screws of the fan unit tear off and fan unit and cabinet are damaged ...

Page 73: ... the outer fastening holes of the rails arrows in Fig 5 1 The rails can be removed after the cabinet has been installed at its final location To attach a sling use appropriate safety hooks or shackles Maximum slope angle is 60 1 in Fig 5 1 Figure 5 1 Transporting the cabinet by crane Lift the cabinet slowly and steadily to the required clearance height maintaining the cabinet in upright position C...

Page 74: ... a desiccant of the appropriate quality 1 unit desiccant 30 g absorbs 6 g water vapor Note The following quantity is needed when using a polyethylene foil 10 units m2 foil 4 Close and lock the doors of the cabinet 5 Use polyethylene or equivalent for packaging 0 3 g m2 24h water vapor diffusion 6 Attach humidity indicators to the packaging The storage conditions and the packaging should be checked...

Page 75: ...and vermin and insects Free of corrosive gases salt or other impurities that could damage electronic equipment Dry with no condensation Relative air humidity 5 85 If in doubt whether the maximum allowed humidity is exceeded protect the spare parts by an external heater Do not touch a component without wearing a wrist grounding strap Put the component on a grounded working surface protected against...

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Page 77: ... 06 Mechanical installation 06 75 82 ...

Page 78: ...ation 77 6 3 1 Dimensions and clearances 77 6 3 2 Cabinet roof 77 6 3 3 Fire protection 77 6 3 4 Cable duct material 77 6 4 Preparing the floor 78 6 5 Fixing the cabinet to the floor 78 6 6 Assembling and installing the air exhaust hood 79 6 7 Installing the redundant fan unit 80 ...

Page 79: ... 6 3 4 Cable duct material Use non flammable material with non abrasive surface To prevent dust humidity and animals entering the cabinet protect the cable entries All installation work must be carried out by qualified personnel according to the site and equipment requirements and in compliance with local regulations Risk of component damage Foreign matter and particularly metallic dust can cause ...

Page 80: ...yout drawing 2 When the cabinet is in place check if the doors are misaligned Note If the doors do not open and close properly place leveling plates at the appropriate points arrows in Fig 6 1 Recommended size 80 x 300 x 0 5 mm Figure 6 1 Leveling the drive 3 Fix the cabinet to the floor Note Floor fixings are not supplied Anchor bolts as illustrated or screws and nuts of size M16 are recommended ...

Page 81: ...gure 6 2 Fixing the cabinet to the floor 6 6 Assembling and installing the air exhaust hood This section applies to drives with an internal fan Assemble and install the air exhaust hood as illustrated Use the supplied screws Figure 6 3 Assembling and installing the air exhaust hood 1 2 3 4 ...

Page 82: ...tion before you install the redundant fan unit 1 Remove the lifting rails 1 2 and 3 in Fig 6 4 2 Remove the cover 4 in Fig 6 4 Figure 6 4 Redundant fan unit Removing lifting rails and cover Figure 6 5 Redundant fan unit Installation 4 Orientate the redundant fan unit with the cable pointing to the left 5 Lift the redundant fan unit above the cabinet 300 kg 3 Attach the lifting gear to the eye bolt...

Page 83: ...es to the cabinet roof 8 Attach the sound absorbing panels to the right side of the redundant fan unit Note Recommended sequence 1 2 3 9 After the power supply cable of the redundant fan unit and the transformer and motor cables have been entered into the cabinet attach the sound absorbing panels to the left side of the redundant fan unit 10 Continue with the electrical installation of the power s...

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Page 85: ... 07 Electrical installation07 83 106 ...

Page 86: ...glands 88 7 5 Power cables ground cables and equipotential bonding conductor 89 7 5 1 Preparing the cable entry and the cables 89 7 5 2 Connecting the cables 93 7 5 3 Minimum creepage distance between cable and busbar 96 7 5 4 Bolted connections 97 7 6 Auxiliary power control and serial communication cables 98 7 6 1 Preparing the cable entry and the cables 98 7 6 2 Connecting the cables 103 7 7 Po...

Page 87: ...er work could lead to life threatening injury or death The electrical installation must be carried out by qualified personnel according to the site and equipment requirements and the relevant electrical codes When the electrical installation is completed the main and auxiliary power supply to the drive must not be switched on without the consent of the ABB commissioning personnel Take appropriate ...

Page 88: ...ng conductors Auxiliary power cables and control cables Included in delivery galvanized plate with net like EMC sleeves 1 in Fig 7 1 and sealing grommets 2 Figure 7 1 EMC plate example EMC cushions 1 Fig 7 2 on the underside of the EMC plate if the cable entry is used for control cables Figure 7 2 EMC cushion 1 EMC sleeves 2 Sealing grommets Ø45 mm 1 5 mm 1 2 1 ...

Page 89: ...try with type 1 sealing modules Usage power cables ground cables and bonding conductors Included in delivery cable entry frame 1 in Fig 7 3 Not included in delivery sealing modules 2 in Fig 7 3 accessories and tools Figure 7 3 Type 1 sealing modules example 1 Cable entry frame 2 Sealing modules 1 2 2 ...

Page 90: ...ls accessories and EMC sealing modules 2 in Fig 7 4 Supplier Roxtec AB www roxtec com Figure 7 4 Type 2 sealing modules example 7 4 4 Cable entry with cable glands Usage Power cables ground cables and bonding conductors Auxiliary power cables and control cables Included in delivery undrilled plate for cable glands Not included in delivery cable glands tools and accessories Figure 7 5 Cable entry w...

Page 91: ...fore connection See layout drawing in Appendix C Mechanical drawings for information on Project specific cable entry Distance between point of cable entry and terminals Busbar and fastening hole dimensions Busbar designations See Appendix D Wiring diagrams for information on Conventions for cross reference and device identification Risk of damage or malfunction Waste inside the cabinet can cause d...

Page 92: ...reparing cables for cable entries with cable glands on page 93 7 5 1 4 Preparing cables for EMC plates As a standard the cabinet is delivered for cable entry through the roof of the terminal compartment If cables are entered through the floor swap entry plate and cover plate The orientation of the EMC plates is the same for cable entry through the roof and through the floor ie the sealing grommets...

Page 93: ...ure 7 6 Preparing cables for EMC plates A cables with an outer screen or shield B cables without an outer screen or shield 5 Route the equipotential bonding conductor through an unused hole of the entry plate Note If all of the holes are used for conductors route the equipotential bonding conductor together with a conductor 1 Grommet 2 EMC sleeve 3 Cable tie 4 Heat shrinkable termination 5 Outer c...

Page 94: ...he metal enclosure of the cabinet as illustrated in Fig 7 7 Figure 7 7 Preparing power cables for sealing modules Install the sealing modules according to the instructions of the sealing module supplier 1 Sealing module 2 Frame 3 Conductive foil of sealing module 4 Cable clamp 5 Shrinkable sheath seal 6 Heat shrinkable termination 7 Outer cable sheath 8 Cable sheath removed to expose cable shield ...

Page 95: ...or cable glands 7 5 2 Connecting the cables 7 5 2 1 Checking the cable insulation Check the insulation of each cable before connection and verify that the results are within the specification of the cable manufacturer Leave the cable conductors unconnected at both ends until the commissioning engineer has given permission 1 Outer cable sheath 2 Cable gland 3 Conductor insulation removed to expose ...

Page 96: ...nnect the screens of all conductors and the shields of all cables to the PE ground busbar 1 in Fig 7 9 Connect the equipotential bonding conductor to the PE ground busbar Tie the cables to the strain relief rails 2 in Fig 7 9 Risk of flashover High voltages will be present in the terminal compartment High voltages can cause flashover between conductors with different electric potential and between...

Page 97: ...Figure 7 9 Power cable terminals in 12 pulse ACS1000 top row and 24 pulse ACS1000 bottom row 1 PE ground busbar 2 Strain relief rails 2U1 2V1 2W1 U2 V2 W2 1U1 1V1 1W1 2U1 2V1 2W1 U2 V2 W2 1U1 1V1 1W1 A B 2U1 4U1 2V1 4V1 2W1 4W1 U2 V2 W2 1U1 3U1 1V1 3V1 1W1 3W1 A B 2 2 1 2 2 1 2 2 1 2 2 1 ...

Page 98: ...the comparative tracking index CTI of the insulation material of the cable the following minimum creepage distances apply Table 7 2 Minimum creepage distance between cable and busbar 1 Input transformer 2 Drive 3 Motor 4 Earth electrode 5 Ground cable 6 Cable screen 7 Equipotential bonding conductor 8 Motor PE U V W PE 2U1 ACS1000 2V1 2W1 1U1 1V1 1W1 PE U2 V2 W2 U2 V2 W2 U1 V1 W1 U2 V2 W2 1 2 3 4 ...

Page 99: ...ig 7 11 and flat washer 2 in Fig 7 11 on each side of the busbar 3 in Fig 7 11 Note Other washers can be used provided they maintain the required contact pressure Figure 7 11 Bolted busbar connections Use cable lugs suitable for M12 bolts 7 5 4 3 Lubrication If stainless steel bolts and nuts are used lubricate the thread and head contact surface of the bolt using recommended pasts eg Molykote D pa...

Page 100: ...en the point of entry and the connection point 1 in Fig 7 12 inside the cabinet 2 Cut the cable to the required length before connection Figure 7 12 Cable entry from top A from bottom B See Layout drawing in Appendix C Mechanical drawings for information on Project specific cable entry Dimensions between point of cable entry and terminals See Appendix D Wiring diagrams for information on Conventio...

Page 101: ...if cables are entered through the floor 3 If necessary remove the entry plate and pull the cable through the entry holes 4 Loosen the screws of the EMC cushion brackets and push the cushions apart arrows 5 If the outer cable screen is non conductive a Cut open the cable screen in the middle of the stripped area 1 b To turn the conductive side inside out pull the cable screen ends over the cable in...

Page 102: ...creen and tighten the screws 7 6 1 3 Preparing cables for cable entries with sealing modules 1 Unscrew the frame and remove the sealing modules Figure 7 14 Frame with sealing modules For information on removing and installing the sealing modules and using the compression wedge 1 see Appendix A Additional manuals 1 Sealing modules 2 Compression wedge 1 2 ...

Page 103: ...an outer cable screen for EMC bonding with the metal enclosure of the cabinet as illustrated in Fig 7 15 Figure 7 15 Preparing control cables for sealing modules 1 Sealing module 2 Conductive foil 3 Cable sheath removed to expose cable shield 4 Conductor screen extension to be connected to PE terminal 1 2 3 4 4 4 ...

Page 104: ...Prepare the cables with an outer cable screen for EMC bonding with the metal enclosure of the cabinet as illustrated in Fig 7 16 Figure 7 16 Preparing control cables for cable glands 1 Outer cable sheath 2 Cable gland 3 Conductor insulation removed to expose cable shield 4 Plate 5 Conductor screen extension to be connected to PE terminal 1 5 2 3 4 ...

Page 105: ...ends as short as possible not longer than 50 mm 7 6 2 3 Cable shields Connect the shield of serial communications cables to the fieldbus adapter Connect the overall shield and the individual shields of the encoder cable to the separate shield grounding bracket 2 in Fig 7 17 Do not connect the shields directly to the encoder adapter 1 in Fig 7 17 Note To accommodate encoder cables of different diam...

Page 106: ...ry If necessary seal the gaps according to the type of cable entry used 2 Route the wires to the terminals 2 and 3 in Fig 7 18 as illustrated Note Connection 3 in Fig 7 18 depends on the type of fan eg AC or EC Figure 7 18 Routing connecting the cable of the redundant fan unit 3 Connect the wires according to the terminal number on the marker sleeves For information on the cable connection see App...

Page 107: ... COOLED USER MANUAL 105 184 7 8 Final checks Check that the entry plates are properly fastened If EMC entry plates with grommets are used check that the grommets fit tightly arrows to prevent water from entering the cabinet If necessary seal gaps with silicone ...

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Page 109: ... 08 Commissioning 08 107 112 ...

Page 110: ...Customer acceptance 109 8 2 Commissioning checklist 110 8 2 1 Mechanical installation checklist 110 8 2 2 Electrical installation checklist 110 8 2 3 Main circuit breaker MCB checklist 111 8 2 4 Input transformer checklist 111 8 2 5 Motor checklist 111 8 2 6 Insulation tests checklist 111 8 2 7 Power supply checklist 112 8 2 8 Miscellaneous checklist 112 ...

Page 111: ...ipment are ready for commissioning Reviewing and completing the items in the 8 2 Commissioning checklist on page 110 before the commissioning personnel arrive on site will help to achieve this During the commissioning period the customer is requested to provide qualified personnel for assistance who are Experienced with medium and low voltage equipment and with the local safety regulations Familia...

Page 112: ...nd cross sections of control cables suitable for the signal type and signal level 2 Types and cross sections of power cables selected according to the instructions in this user manual 3BHS213401 E01 Rev H 3 Pulse encoder connected according to the relevant manual only applicable for drives with pulse encoder interface 4 Cable entry prepared according to the instructions in this user manual 3BHS213...

Page 113: ... tested and in operation 1 Motor installed aligned and alignment protocol available 2 Motor not coupled to driven load 3 Ground connection completed 4 Motor auxiliaries eg bearing lubrication heater cooling ready 5 Control and monitoring signals connected 1 All power cables to converter transformer between converter transformer and drive and from drive to motor insulation resistance tested Megger ...

Page 114: ...hecklist 8 2 8 Miscellaneous checklist 1 Medium voltage available for start up of drive 2 Low voltage auxiliary power available for start up of drive 1 Sufficient number and correct type of spare parts available 2 Air conditioning of drive room ready for load run of drive 3 Optional equipment ready ...

Page 115: ... 09 Operation 09 113 126 ...

Page 116: ...the drive 118 9 6 2 Stop sequence of the drive 119 9 6 3 Emergency off sequence of the drive 120 9 7 Starting the drive 121 9 7 1 Checks before starting the drive 121 9 7 2 Starting the drive remotely 121 9 7 3 Starting the drive locally 121 9 8 Stopping the drive 124 9 9 Emergency off 125 9 9 1 Initiating an emergency off 125 9 9 2 Starting the drive after an emergency off 126 ...

Page 117: ...ntal parameters and their severities Section 3 Stationary use at weather protected location 24 Conditions 3K22 3B1 3S6 3M11 9 4 Sound pressure level Single fan 75 dB A Redundant fan 85 dB A 9 5 Overview of local operator panel The operator panel on the control compartment door enables the operator to control the drive without restrictions if all requirements for normal operation are met The functi...

Page 118: ...ens the main circuit breaker 3 Main supply on Illuminated pushbutton charges the DC link and closes the main circuit breaker 4 Grounding switch unlocked Lights up to indicate that the grounding switch of the drive can be turned to the grounded or ungrounded position 5 Emergency off Latching pushbutton prevents starting when pressed at standstill of the drive Main circuit breaker opens immediately ...

Page 119: ...e drive is energized and ready for operation As soon as the start command is initiated the motor is magnetized and the drive starts to modulate Magnetizing The status message Rdy to Strt changes to Magnetizing when the firing pulses of the inverter are released Running When the drive is in Running state it is running and operating according to the set speed or torque reference value When in remote...

Page 120: ...rt sequence of the drive ReadyOn conditions Doors closed and locked Drive not grounded No emergency off No fault ReadyForMCBOn On command Charging DC link charges Fan switches on MCB closes Rdy To Strt Start command Inverter starts to modulate Magnetizing Running Operation NotReadyOn ...

Page 121: ...e drive Operation Running Stop command Stopping Speed ramps down Inverter stops modulating Rdy To Strt Discharging MCB opens DC link discharges Fan switches off after a delay NotReadyOn Off command RdyForMCBOn Actions Drive is grounded Doors are released for opening Auxiliary supply is switched off ...

Page 122: ...EV H ACS1000 AIR COOLED USER MANUAL 120 184 9 6 3 Emergency off sequence of the drive Operation Running Stopping Speed ramps down Inverter stops modulating Emergency off command MCB opens Inverter stops modulating Speed coasts down ...

Page 123: ...t message is displayed on the CDP control panel reset the fault It is recommended to have the following documents at hand when starting the drive locally for the first time after commissioning Appendix D Wiring diagrams to identify the circuit breakers to be switched on 10 CDP control panel on page 127 for information on functions and features of the CDP control panel Hazardous voltages All covers...

Page 124: ...e the MCB and charge the DC link The pushbutton lights up The status line of the CDP control panel changes to Charging After charging has been finished the following takes place The protection IGCTs are closed The status line of the CDP control panel changes to Rdy to Strt and the motor can be started 4 Enter the reference value LOC RESET REF REM 1 L 0 0 rpm Status RdyForMCBon MotorSpeed 0 00 rpm ...

Page 125: ...tatus indication on the display blinks When the motor speed has reached the reference value the run status indication lights up permanently The display shows Running to indicate that the drive is operating 1 L 600 0 rpm 0 Status Ready to Strt MotorSpeed 0 00 rpm Power 0 0 LOC RESET REF REM 1 L 600 0 rpm 0 Status Magnetizing MotorSpeed 0 00 rpm Power 0 0 1 L 600 0 rpm I Status Running MotorSpeed 60...

Page 126: ...ing The run status message blinks during the stop sequence As long as the stop sequence is in progress the drive can always be restarted by pressing the START key on the CDP control panel When the drive has stopped modulating the CDP control panel displays Rdy to Strt Note As long as the MCB has not been opened the motor can be started again I 0 1 L 600 0 rpm I Status Stopping MotorSpeed 300 0 rpm...

Page 127: ...F pushbutton of the drive is part of the operator control panel Fig 9 1 and features a latching switch action CAUTION 9 9 1 Initiating an emergency off To initiate an emergency off press the EMERGENCY OFF pushbutton on the control compartment door or an external EMERGENCY OFF pushbutton if present linked to the emergency off circuit When an emergency off is initiated during drive operation the fol...

Page 128: ...rns to its initial position when turned into the direction indicated by the arrows on the pushbutton 2 To reset the emergency off safety relay of the drive press the RESET button on the control keypad After resetting the status message of the drive changes to RdyForMCBOn The main power supply can be connected to the drive and the drive can be started again LOC RESET REF REM 1 L 0 0 rpm Status Rdyf...

Page 129: ... 10 CDP control panel 10 127 150 ...

Page 130: ...tification mode 130 10 3 2 Actual signals mode 132 10 3 3 Parameters mode 139 10 3 4 Functions mode 144 10 4 Local and remote control 146 10 4 1 Local control 146 10 4 2 Remote control 147 10 5 Operational commands 148 10 5 1 Setting the direction of rotation 148 10 5 2 Entering a reference value 149 ...

Page 131: ...ive Figure 10 1 CDP control panel 1 Display 2 Status line 3 Actual signal names and values 4 Keypad 5 Mode selection keys 6 Fast navigation key for selecting the actual signals display or the fault memory display 7 Local remote selection key 8 Reset key 9 Forward key 10 Backward key 11 Slow navigation key for selecting signals or fault messages 12 Enter key terminates a procedure 13 Reference key ...

Page 132: ...sly Display and adjust parameters Display information on the most recent forty fault events Upload and download complete parameter sets from one drive to another 10 3 CDP control panel modes The CDP control panel provides the following modes 10 3 1 Identification mode on page 130 10 3 2 Actual signals mode on page 132 10 3 3 Parameters mode on page 139 10 3 4 Functions mode on page 144 10 3 1 Iden...

Page 133: ...he drive 1 2 and the drive identification 3 is displayed After another few seconds After another few seconds the display changes to the actual signals mode ACS1000 xxxx Device Name ID NUMBER 1 1 2 3 1 L 0 0 rpm Status InitSeq MotorSpeed 0 00 rpm Power 0 0 1 L 0 0 rpm Status ErthIsoClos MotorSpeed 0 00 rpm Power 0 0 ...

Page 134: ...ory The fault memory display provides information on the 64 most recent fault events that occurred in the drive It displays the name of the fault and the time it occurred For instructions on how to display and reset the fault memory see 10 3 2 5 Displaying and resetting the fault history on page 136 When the drive generates a fault or alarm the corresponding message displays immediately Changing f...

Page 135: ...atus line 2 Actual signal names and values 3 Selection key for actual signals mode 4 Fast navigation key for selecting the actual signals display or the fault memory display 5 Slow navigation key for selecting signals or fault messages 6 Enter key for confirming the selection 1 2 3 4 5 6 1 L 600 0 rpm Status RdyForMCBon MotorSpeed 0 00 rpm Power 0 0 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1...

Page 136: ...signals display release the ACT key 10 3 2 4 3 Selecting actual signals 1 To select the actual signals display press the ACT key 2 To select a line where the actual signal is to be displayed press the corresponding slow navigation key A blinking cursor indicates the selected line 1 L 600 0 rpm 0 1 LAST FAULT OverSpeed 070730 12 30 02 3256 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM ACT PAR FUNC...

Page 137: ...ction and to return to the actual signals mode press the ENTER key 1 L 600 0 rpm Status Running MotorSpeed 600 00 rpm P ower 75 0 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 1 Actual Signals 10 ShaftPower 0 0 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 0 2 Actual Signals 01 ControlMode SPEED CTRL ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 0 2 Act...

Page 138: ... 1 To enter the actual signals mode press the ACT key 2 To change to the fault memory display press a fast navigation key 1 L 600 0 rpm 0 Status Ready to Strt MotorSpeed 0 00 rpm DCVoltage Udc1 1000 0 V ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 0 Status Ready to Strt MotorSpeed 0 00 rpm Power 0 0 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM ACT PAR FUNC DRIVE LOC I 0 RESET REF...

Page 139: ...e actual signals display press a fast navigation key 1 L 600 0 rpm 0 1 LAST FAULT Panel Lost 0707730 12 30 02 3256 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 0 2 LAST FAULT Panel Lost 0707730 12 21 02 2452 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 0 1 LAST FAULT H MIN S ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 0 Status Ready to Strt MotorSpe...

Page 140: ...ing an active fault 1 To display an active fault press the ACT key 2 To reset the fault press the RESET key ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 0 ACS1000 FAULT MCB CloseControl 1 L 600 0 rpm 0 Status Ready to Strt MotorSpeed 0 00 rpm Power 0 0 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM ...

Page 141: ... selected parameter displays Running the drive system with incorrect data can result in improper operation reduction of control accuracy and damage to equipment Parameters must only be set by qualified personnel Do not change any parameter if the meaning of the parameter and the effects of the change are not fully understood Group Description Group 07 Control words Group 08 Status words Group 09 F...

Page 142: ...meters mode Warning Write Access Denied Parameter Setting Not Posssible 1 Status line 2 Group number and name 3 Parameter number and name 4 Parameter value 5 Selection key for parameters mode 6 Fast navigation key for selecting a parameter group and a parameter value 7 Slow navigation key for selecting a parameter and a parameter value 8 Enter key for confirming the selection 1 2 3 4 5 6 7 8 1 L 6...

Page 143: ...ow navigation key 4 To enter the parameter setting function press the ENTER key 1 L 600 0 rpm 0 12 REFERENCE SELECT 01 KeypadRefSelect 1 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 0 75 OPTION MODULES 01 IOEC3 OptionBoard YES ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 0 75 OPTION MODULES 02 IOEC4 OptionBoard NO ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 6...

Page 144: ...ls display press the ENTER key 7 To cancel the setting and keep the original selection press any of the mode selection keys The selected keypad mode is entered 1 L 600 0 rpm 0 75 OPTION MODULES 02 IOEC4 OptionBoard YES ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 0 75 OPTION MODULES 02 IOEC4 OptionBoard YES ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm 0 75 OPTION MO...

Page 145: ...er lock For better cyber security ABB recommends that you set a master pass code for the control panel to prevent the parameter values from being changed NOTICE To activate the user lock for the first time enter the default pass code 358 into 16 03 Passcode This will make parameters 16 06 16 07 changeable Then enter the old pass code to 16 06 OldUserPasscode and change user pass code in 16 07 NewU...

Page 146: ...4 1 Adjusting the display contrast 1 To enter the functions mode press the FUNC key 1 Status line 2 Selectable functions 3 Selection key for functions mode 4 Slow navigation key for selecting a line and adjusting the contrast 5 Enter key for confirming the selection 1 2 3 4 5 1 L 0 0 rpm 0 UPLOAD DOWNLOAD CONTRAST 4 1 L 0 0 rpm 0 UPLOAD DOWNLOAD CONTRAST 4 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTE...

Page 147: ...trast value press a slow navigation key 5 To confirm the selection and to return to the actual signals display press the ENTER key 1 L 0 0 rpm 0 UPLOAD DOWNLOAD C ONTRAST 4 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 0 0 rpm 0 CONTRAST 4 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 0 0 rpm 0 CONTRAST 6 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 0 0 rpm 0 UPLOAD DOWNLOAD CONTRA...

Page 148: ...ontext remote control is not necessarily equivalent to higher level control For more information see 10 4 2 Remote control on page 147 10 4 1 Local control In local control mode full operational control of the drive is enabled from the local operator panel Commands from remote have no effect To enter the local control mode press the LOC REM key Local control is indicated by the letter L 1 L 0 0 rp...

Page 149: ...TART STOP DIR 10 KEYPAD or 12 03 EXT REF1 SELECT 1 KEYPAD and 12 02 EXT1 EXT2 SELECT 1 EXT1 11 02 EXT2 START STOP DIR 10 KEYPAD or 12 06 EXT REF2 SELECT 1 KEYPAD and 12 02 EXT1 EXT2 SELECT 2 EXT2 To enter remote control press the LOC REM key Full remote control from a higher level control system is indicated by a blank space Partial remote control some commands enabled locally is indicated by the ...

Page 150: ...icates the direction of rotation When the motor is running the arrow indicates the actual direction When the motor is not running the arrow indicates the preselected direction To set the direction of rotation press the forward or backward key If you change the direction while the motor is running the motor automatically ramps down to zero speed and re accelerates in the opposite direction to the p...

Page 151: ...he reference value input mode press the REF key 3 To enter change the reference value press the corresponding fast or slow navigation key 1 L 600 0 rpm I Status Running MotorSpeed 600 00 rpm Power 75 0 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 600 0 rpm I Status Running MotorSpeed 600 00 rpm Power 75 0 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM 1 L 550 0 rpm I Status Running MotorSpee...

Page 152: ...1 REV H ACS1000 AIR COOLED USER MANUAL 150 184 4 To exit the reference value input mode press any of the mode selection keys 1 L 550 0 rpm I Status Running MotorSpeed 550 00 rpm Power 75 0 ACT PAR FUNC DRIVE LOC I 0 RESET REF ENTER REM ...

Page 153: ... 11 Preventive and corrective maintenance 11 151 182 ...

Page 154: ...on 155 11 2 2 Cables and wires 155 11 2 3 Understanding wiring diagrams 155 11 3 Alarm fault indications 156 11 3 1 Messages 156 11 3 2 Error message levels 156 11 3 3 Fault handling 156 11 3 4 Standard troubleshooting procedure 157 11 4 Removing the CDP control panel 158 11 5 LEDs and switches on circuit boards 159 11 5 1 AMC circuit board 159 11 5 2 IOEC I O modules 160 11 6 Corrective maintenan...

Page 155: ... the release conditions for the grounding switch 166 11 6 6 Visual checks on the drive 168 11 6 7 Cleaning the drive 168 11 6 8 Checking wire and cable connections 169 11 6 9 Cleaning and replacing filter mats 170 11 6 10 Inspecting and replacing batteries 172 11 6 11 Replacing the non redundant fan 174 11 6 12 Replacing a redundant fan 176 ...

Page 156: ...o the maintenance schedule and the applicable service instructions on time and at the intervals stated in the ACS1000 preventive maintenance schedule 1 11 1 3 Logbook ABB recommends that you keep track of all troubleshooting and maintenance work in a logbook including Date and time Detailed description 11 1 4 Spare parts To ensure safe and reliable operation use only spare parts recommended and ap...

Page 157: ... facilitate the identification in wiring diagrams and parts lists all devices are labeled in accordance with IEC 81346 1 Figure 11 1 Device identification 11 2 2 Cables and wires Cables and wires in the drive are equipped with marker sleeves which carry the same identification number as in the wiring diagrams 11 2 3 Understanding wiring diagrams For information on item designation and cross refere...

Page 158: ...condition has been corrected Note An exception is when an alarm of the cooling system eg FanDiffPres AirFiltSupv is not reset automatically To reset the alarm set parameter 41 04 FanAlarmReset to RESET Fault A fault shuts down the drive The type of shutdown depends on the origin of the fault Depending on the type of fault the drive opens the main circuit breaker MCB or keeps it closed A fault cond...

Page 159: ...gnal and parameter table 1 Do not switch off the auxiliary supply voltage or try to reset a fault message before all information at the time of the occurrence of the fault condition has been saved 2 Select the fault history display on the CDP control panel but do not clear the buffer For more information see 10 CDP control panel on page 127 3 Identify the fault and make a logbook entry 4 Save the ...

Page 160: ...L LOSS SUPERVISION first If the parameter is set to NOT USED the panel can be removed without interrupting drive operation 2 Proceed as illustrated Note The green LED 4 signals that the control voltage has been switched on Important When the CDP control panel has been removed during operation the drive can only be stopped by pressing the emergency off button For information on setting parameters s...

Page 161: ...he status of the devices and can be used for diagnostic purposes 11 5 1 AMC circuit board Figure 11 2 AMC circuit board LED Color Description Status when software has loaded Status when software has not loaded Booting ON Booting ON F Red Fault ON OFF ON ON R Green Run OFF OFF OFF OFF M Green ON OFF ON ON P Green Supply OK ON ON ON ON T1 Yellow Receiving data on DDCS channel 0 Flashing ON OFF Flash...

Page 162: ...The address is set with the rotary switch on the module 3 in Fig 11 3 The factory set value must not be changed LED Description 1 Status LEDs of digital outputs On when output is energized 2 Link error light Only on when there is a problem with the optical fibers 3 Rotary switch Sets the address 4 Status LEDs of digital inputs On when input is energized 5 Status LED of the 24 V internal voltage su...

Page 163: ... work on the drive make sure that Main and auxiliary power supply to the drive is switched off locked out and tagged out Drive is de energized Safety ground connections are in place Personal protective equipment is provided and used when required Everyone involved is informed Before energizing the drive again make sure that All foreign objects are removed from the drive All internal and external c...

Page 164: ... the MAIN SUPPLY OFF pushbutton to disconnect the drive from the main power supply The following takes place The MCB opens The DC link discharges for approximately five minutes While the DC link discharges the display shows the following When the DC link has discharged completely the status line displays RdyforMCBOn and the MAIN SUPPLY OFF pushbutton lights up For more information see 10 CDP contr...

Page 165: ...ipped with the optional lock 1 that secures the switch in the ungrounded position unlock the grounding switch 6 Wait until the yellow lamp GROUNDING SWITCH UNLOCKED lights up The lamp lights up when cooling stops after a delay time If the yellow lamp is on continue with 11 6 3 Grounding on page 164 If the yellow lamp is not on continue with 11 6 4 Grounding switch is not released on page 164 1 ...

Page 166: ...o have the auxiliary voltage switched on 3 If necessary connect a grounding set 11 6 4 Grounding switch is not released CAUTION To check why the grounding switch is not released complete the list Checking the release conditions for the grounding switch 1 L 0 0 rpm Status ErthIsoClos MotorSpeed 0 00 rpm Power 0 0 Hazardous voltage If the lamp GROUNDING SWITCH UNLOCKED does not light up do not force...

Page 167: ...IVE MAINTENANCE 3BHS213401 E01 REV H ACS1000 AIR COOLED USER MANUAL 165 184 Figure 11 4 Location of I O modules and fuses 1 IOEC1 A5191 standard 2 Fuses 3 IOEC2 A5201 standard 4 IOEC4 A5211 option 5 IOEC3 A5221 option 1 2 3 4 5 ...

Page 168: ...24 V blade type fuse X27_P2 14 is blown The fuse protects the control circuit of the pushbutton If the LED is not lit Check the control signal wiring between switchgear and drive as per applicable wiring diagram 3 Checking the discharge level of the DC link Check if the value of parameter 2 06 DC VOLTAGE is below 50 V When the value is below 50 V the DC link is regarded as discharged For informati...

Page 169: ...voltage is present at the supply terminals of the I O module X6 1 24 V DC X6 2 0 V d Check that LED V726 and LED V740 of the I O module A5191 are lit The LEDs monitor the control voltages of the I O module Fig 11 3 When the LEDs are lit the I O module functions properly LED V726 24 V DC LED V740 5 V DC e If digital output DO04 I O module A5191 is energized check that the control voltage is present...

Page 170: ...c discharge Therefore take electrostatic sensitive precautions and use suitable tools Clean circuit boards with special care To prevent the components being damaged use antistatic brushes and a vacuum cleaner with a soft nozzle Remove dust on assemblies and busbars inside the cabinet with a vacuum cleaner and lint free cleaning cloths Remove water oily or greasy deposits on assemblies components a...

Page 171: ...sional malfunction or equipment failure Check all power and control cable connections and tighten them if necessary Check that all plugs and connectors are tight Capacitor bushings are damaged when excessive force is applied Do not exceed the maximum tightening torque The tightening torque value is printed on a label which is attached to the capacitor If not specified the maximum torque must not e...

Page 172: ...the drive is in operation observe the following Make sure that objects like wires or screwdrivers do not enter into the air intake These objects can cause fatal short circuits To prevent foreign matter entering do not discontinue work for a longer period For information on inspection and replacement intervals see ACS1000 preventive maintenance schedule 1 1 Filter 2 Panel fasteners 3 Unfasten 4 Fas...

Page 173: ...ER MANUAL 171 184 Table 11 1 Filter information To remove a filter mat roll down the filter mat beginning at the top Clean the filter mat with compressed air or a vacuum cleaner away from the drive so that dust cannot enter the drive Filter class EN779 Thickness mm G3 6 8 G4 19 G4 22 ...

Page 174: ...ws CDP control panel displays an alarm message Alarm LED on the power supply unit for the battery lights up 3 in Fig 11 6 When the end of the battery life is indicated the drive continues to operate until the time set with parameter 145 26 Batt Alm Tim out has elapsed ABB recommends replacing all of the batteries when one battery is at end of life 1 Power supply unit for battery pack 1 2 Power sup...

Page 175: ...attery monitoring function first To do this set parameter 31 05 DISABLE BATTERY TEST to ON Note Parameter 31 05 is automatically set to OFF after 1 hour 2 Disconnect the wires 1 in Fig 11 7 3 Unscrew the battery at the front 2 in Fig 11 7 and at the back 3 in Fig 11 7 Install the new battery in reverse order of removal 4 Record the date of battery replacement in the logbook 10 kg Each battery weig...

Page 176: ... fan 3 Unplug the power supply cable 2 in Fig 10 10 1 of the fan 4 Remove the bolts 2 in Fig 10 10 Note Do not drop washers and bolts into the cabinet 5 Move the fan onto the lift truck by one of the following methods Place lift truck or trolley in front of the fan place the lift truck or height adjustable trolley in front of the fan and pull the fan onto the platform 100 kg Heavy load The fan wei...

Page 177: ...stow the optical fibers in a position where they cannot be damaged when the fan is replaced Figure 11 10 Replacing the non redundant fan Push the lift truck under the fan ensure that the lift truck does not catch cables and components and lift the fan a little and remove it from the cabinet while avoiding sudden movements 1 Power supply cable 2 Bolts 3 Optical fiber cables 4 1 4 5 70 mm 6 13 mm 1 ...

Page 178: ... orientate the groove of the mounting supports 2 in Fig 11 11 towards the back of the cabinet Figure 11 11 Installing the non redundant fan 3 Check that all screws are properly fastened 4 Install the new fan in reverse order of removal 11 6 12 Replacing a redundant fan The estimated working time to replace a redundant fan is approximately 1 hour 1 Mounting supports 2 Groove 3 1 4 4 10 mm 1 2 3 4 F...

Page 179: ...ure 11 12 Redundant fans location dimensions and weight Figure 11 13 Redundant fans tools and devices 100 kg Heavy load The fan weighs approximately 100 kg 1 1 4 2 70 mm 3 13 mm and 17 mm 4 13 mm 5 T 30 6 Cordless drill 7 3 x M10x20 8 Height adjustable platform 9 Lift truck 469 mm 774 mm 868 mm 1 2 3 4 5 6 7 8 9 ...

Page 180: ...itch off the motor starter of the fan 3 Remove the panels If the fan is removed towards the front of the cabinet the top panel can stay on the cabinet If the rear panel is not accessible remove the sound absorbing panels on the side where the fan is replaced Figure 11 14 Redundant fan unit removing the panels 4 Unplug the power supply cable For more information see 11 6 2 De energizing the drive l...

Page 181: ...4 Figure 11 15 Redundant fan unit Unplugging the power supply cable 5 Remove the fixing bolts Note If the bolt at the back 1 in Fig 11 16 is not accessible from the back of the cabinet remove the cover 2 in Fig 11 16 reach through the opening and unscrew the mounting support 3 in Fig 11 16 from below ...

Page 182: ... MAINTENANCE 3BHS213401 E01 REV H ACS1000 AIR COOLED USER MANUAL 180 184 Figure 11 16 Redundant fan unit removing the fixing bolts 1 Bolt 2 Cover 3 Mounting support 4 1 4 5 13 mm 6 13 mm 7 Cordless drill 8 T 30 1 2 3 4 5 4 5 6 7 8 ...

Page 183: ...undant fan unit using a crane Height adjustable platform place the platform as close as possible to the fan and then pull the fan onto the platform Figure 11 18 Redundant fan unit using a platform Note If the fan housing is in good condition no damages or bad corrosion only replace the fan motor and the impeller and re use the fan housing 7 Remove the mounting supports from the fan housing to be r...

Page 184: ...ousing does not have screw holes for the mounting supports drill holes into the underside of the fan housing 9 Check that all screws are properly fastened 10 Install the new fan in reverse order of removal For information on the exact hole positions see drawing number 3BHS128478 E01 in Appendix C Mechanical drawings 1 2 ...

Page 185: ......

Page 186: ...ABB All rights reserved The information in this document is subject to change without notice ABB Switzerland Ltd CH 5300 Turgi Switzerland new abb com drives medium voltage ac drives 3BHS213401 E01 Rev H 2020 03 18 18 ...

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