ABB ACS1000i air-cooled User Manual Download Page 57

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Summary of Contents for ACS1000i air-cooled

Page 1: ... MEDIUM VOLTAGE AC DRIVES ACS1000i air cooled User manual ...

Page 2: ... reliability you expect Document name ACS1000i air cooled user manual Document owner ABB Switzerland Ltd Medium voltage AC drives Document number 3BHS206977 E01 Rev H Number of pages 174 Release date 2020 03 18 new abb com drives medium voltage ac drives ...

Page 3: ...Contents ACS1000i air cooled User manual ...

Page 4: ... electronics and cabinet features 29 04 Control system 57 05 Transportation storage and disposal 71 06 Mechanical installation 79 07 Electrical installation 89 08 Commissioning 105 09 Operation 111 10 CDP control panel 125 11 Preventive and corrective maintenance 149 ...

Page 5: ... 01 About this manual 01 5 16 ...

Page 6: ...arget groups and required qualification 10 1 7 1 Handling 11 1 7 2 Mechanical installation 11 1 7 3 Electrical installation 11 1 7 4 Operation 11 1 7 5 Maintenance 11 1 8 User s responsibilities 11 1 9 Intended use of equipment 12 1 10 Cyber security disclaimer 12 1 11 Quality certificates and applicable standards 13 1 12 Items covered by delivery 14 1 13 Identifying the delivery 15 ...

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

Page 9: ...fer via optical fibers between AMC circuit board and INTerface circuit boards RTD Resistance temperature detector or device The RTD is a temperature sensor where the change in electrical resistance is used to measure the temperature Safeline ABB synonym for uninterruptable power supply Supervisory signal Indicates the operating condition of a circuit or device SW Software TC Short form for termina...

Page 10: ... medium voltage drives Reference number Document Document number 3 Layout drawing Project specific Reference number Document Document number 4 Retrofit guideline 3BHS301179 E01 5 Input circuit breaker engineering guideline 3BHS104785 E01 6 Induction motor specification 3BHS260163 E01 7 Power cable specification 3BHS189994 E01 8 Power cables engineering guideline 3BHS542290 E01 9 Auxiliary power an...

Page 11: ... include all persons who operate the drive from the local operator panel of the drive The personnel must know the functions of the operator panel be adequately trained for the drive and know the driven process Special knowledge of frequency converter technology is not required 1 7 5 Maintenance The personnel include all persons who Are qualified to carry out preventive and corrective maintenance o...

Page 12: ...s product is designed to be connected to and to communicate information and data via a network interface It is the customer s sole responsibility to provide and continuously ensure a secure connection between the product and Customer network or any other network as the case may be Customer shall establish and maintain any appropriate measures such as but not limited to the installation of firewall...

Page 13: ...afety signs Registered safety sign 20 EN 50110 European standard code for electrical work safety 21 ISO 13849 1 Safety of machinery Safety related parts of control systems Part 1 General principles for design section 6 2 6 Category 3 22 IEC 60204 1 Safety of machinery Electrical equipment of machines Part 1 General requirements 23 IEC 60721 3 1 Classification of environmental conditions Classifica...

Page 14: ...he user manual and related documents Strain relief rails Air exhaust hood Redundant fan unit option Set of bolts nuts and washers Figure 1 1 Delivered items Note For a complete list of the items in the delivery see the shipping note 1 Drive shipped in sea freight or air freight packaging 2 Cable entry box 3 Fans shipped in a separate container The number of fans depends on the cooling configuratio...

Page 15: ...NUAL 15 174 1 13 Identifying the delivery The drive and accessories are identified by the type code printed on the rating label The label provides information on the type of drive the rated voltage the frequency and the current of the main and the auxiliary power supply ...

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Page 17: ... 02 Important safety information 02 17 28 ...

Page 18: ... 4 Product safety labels 20 2 5 General safety instructions 21 2 6 The 7 steps that save lives 22 2 7 Possible residual risks 24 2 8 Important note main circuit breaker 25 2 8 1 Safety and protection requirements 26 2 8 2 Minimum requirements for MCB and MCB control 26 2 8 3 Maintenance recommendation 27 ...

Page 19: ...ety colours and safety signs Registered safety sign 19 EN 50110 European standard code for electrical work safety 20 2 2 Safety messages The following safety messages are provided to help prevent personal injury and damage to the equipment The indicated hazard level is based on the ANSI Z535 6 standard DANGER WARNING CAUTION 2 3 Damage prevention information NOTICE DANGER Indicates a hazardous 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: ...fety 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 sourc...

Page 22: ...ans 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 barricadin...

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 ...

Page 24: ...led 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 equipme...

Page 25: ...y on an open or trip command from the drive to prevent hazard to the personnel and further damage to the equipment The MCB is located on the primary side of the converter transformer Figure 2 2 Drive system overview An MCB is a switching device that disconnects the power supply when required by the process or when a fault occurs Typical MCBs are Vacuum circuit breakers SF6 circuit breakers Fused c...

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 serv...

Page 27: ...ge Upstream 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 comm...

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Page 29: ... 03 Power electronics and cabinet features03 29 56 ...

Page 30: ...s 35 3 4 Drive topology 36 3 4 1 Overview 36 3 4 2 Terminal compartment 38 3 4 3 Control compartment and terminal compartment 39 3 4 4 Transformer and rectifier compartment 40 3 4 5 Rectifier 40 3 4 6 Grounding switch 41 3 4 7 Trapped key interlock option 43 3 4 8 Protection IGCTs 43 3 4 9 Inverter 44 3 4 10 Filter 44 3 4 11 Cooling system 45 3 4 12 Optional Braking Chopper 49 ...

Page 31: ...5 2 Additional cabinets 52 3 6 Door locking system 54 3 6 1 Additional cabinets 54 3 7 Arc resistant design optional 55 3 7 1 Internal arc classification 55 3 7 2 Power compartment doors 55 3 7 3 Associated protection requirement 56 3 8 Space heaters 56 ...

Page 32: ...d induction motors The 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 ACS1000i air cooled For information on the power and voltage range of the drive see the technical...

Page 33: ...uired motor voltage The protection for the transformer is always included Drive For more information see 3 4 Drive topology on page 36 Motor For more information see the induction motor specification 1 Main circuit breaker necessary when fused input contactor 3 is not installed 2 Combined input disconnector and grounding switch option 3 Fused input contactor option 4 Converter transformer 5 Diode ...

Page 34: ...ronic components Auxiliary power supply for the control and cooling system Figure 3 3 Drive overview with power supplies 1 Auxiliary power supply 2 ACS1000i 3 Control and cooling system 4 Auxiliary power distribution 5 Cooling system 6 Control system 7 Main power supply 8 Switchgear 9 Converter transformer 10 Power electronic components 11 Diode rectifier 12 DC link 13 Inverter 14 Motor 1 2 3 4 5 ...

Page 35: ...power supply is interrupted drive internal batteries provide a backup for the control system thus enabling 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...

Page 36: ...mponents of a typical drive 3 4 1 Overview 3 4 1 1 Drive with combined input disconnector and grounding switch Figure 3 4 ACS1000i air cooled with combined input disconnector and grounding switch 1 Terminal compartment with combined input disconnector and grounding switch terminals for feeder and motor cables 2 Transformer and rectifier compartment 3 Control compartment 4 DC link and inverter comp...

Page 37: ...ED USER MANUAL 37 174 3 4 1 2 Drive with grounding switch Figure 3 5 ACS1000i air cooled with grounding switch 1 Terminal compartment with terminals for feeder and motor cables 2 Transformer and rectifier compartment 3 Control compartment 4 DC link and inverter compartment 1 2 3 4 ...

Page 38: ...r the feeder and motor cables The terminals are located behind a bolted cover Figure 3 6 Terminal compartment with input disconnector A and without input disconnector B 1 Input disconnector with feeder cable terminals 2 Feeder cable terminals 3 Motor cable terminals For more information on cable entry and connection see 07 Electrical installation on page 89 1 2 3 3 A B ...

Page 39: ...e 04 Control system on page 57 Terminal compartment 2 in Fig 3 7 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 Electrical installation on page 89 Figure 3 7 Contro...

Page 40: ...nsformer and rectifier compartment with combined input disconnector A and with grounding switch B 3 4 5 Rectifier The 24 pulse diode rectifier converts the AC voltage of the main power supply and connects its output to the minus neutral point and plus side of the DC link 1 Grounding switch 2 24 pulse rectifier 3 Transformer 4 Protection IGCTs 1 1 2 2 3 3 4 A B ...

Page 41: ...ombined input disconnector and grounding switch 2 in Fig 3 9 The input disconnector and the grounding switch are mechanically coupled and operated with a single lever Figure 3 9 Switchgear of the drive The switch is electro mechanically interlocked with a discharge monitoring circuit that prevents turning of the switch while the DC link capacitors are still charged When the drive is grounded the D...

Page 42: ...ded 3 in Fig 3 10 and reverse Combined input disconnector and grounding switch with one switching operation the input disconnector first separates the drive from the main power supply and the grounding switch then connects the DC link of the drive to the PE ground busbar Figure 3 10 Grounding the drive 1 Lamp Grounding switch unlocked 2 Grounding switch in not grounded position 3 Grounding switch ...

Page 43: ...predefined and safe sequence The key interlocks are not supplied If the option is ordered the drive is prepared for the installation Figure 3 11 Trapped key interlocking system 1 3 4 8 Protection IGCTs The drive features a fuseless protection design The IGCTs are placed between the rectifier and the DC link If a severe fault occurs the IGCTs directly isolate the inverter from the main power supply...

Page 44: ... control the output voltage 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 63 Figure 3 12 Three level voltage source inverter principle 3 4 10 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 fil...

Page 45: ...and two fans for the inverter This configuration ensures that the operation of the drive is not interrupted if any single fan fails Figure 3 14 Fan configurations and air flow 3 4 11 2 Type of fan The drive is equipped with one of the following 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 fa...

Page 46: ...n the type of fan used there are the following group options Figure 3 15 Fan groups AC and EC fans Figure 3 16 Fan groups EC fans only 1 Group 1 fan 1 of inverter 2 Group 1 fan 1 of transformer 3 Group 2 fan 2 of inverter if redundant 4 Group 2 fan 2 of transformer if redundant 1 Group 1 fan 1 of inverter 2 Group 1 fan 2 of inverter if redundant 3 Group 2 fan 1 of transformer 4 Group 2 fan 2 of tr...

Page 47: ... 5 minutes 3 4 11 5 AC redundant fans operating principles Default settings Cycle time during which AC fan 1 and AC fan 2 run alternately 10 h Operating time of AC fan 1 6 h Operating time of AC fan 2 4 h Figure 3 17 Operating times of the AC fan units during continuous drive operation A and Intermittent drive operation B 1 Cycle time 2 Group 1 3 Group 2 4 10 hours default cycle time during which ...

Page 48: ... second EC fan will speed up to ensure the required cooling Figure 3 18 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 Minimum fan speed For more information on parameter settings f...

Page 49: ...ing down time eg for conveyor belts fans and pumps Emergency stops The braking 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 19 ACS1000i with braking chopper 1 The braking chopper is controlled and monitored by the ACS1000 Figure 3 20 Principle diagram 1 Rectifier 2 Braking ch...

Page 50: ...ct 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 12 2 2 Thermal protection The braking chopper and the braking resistors are monitored for over temperature by the ACS1000 In addition an e...

Page 51: ...r 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...

Page 52: ...tween 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 ordered optionally with the whole of the outside painted EMC performance is further enhanced by the use of metal...

Page 53: ...ICS AND CABINET FEATURES 3BHS206977 E01 REV H ACS1000I AIR COOLED USER MANUAL 53 174 Figure 3 22 ACS1000i with additional cabinet 1 For more information see Appendix A Additional manuals Appendix C Mechanical drawings 1 ...

Page 54: ... by personnel authorized to do so Figure 3 23 Door locks 3 6 1 Additional cabinets The door of an additional cabinet which contains medium voltage eg braking chopper output disconnector is secured by a door monitoring switch The switch releases the door when the DC link of the drive has discharged and the drive has been grounded 1 Cover of terminal compartment bolted 2 Door of transformer and rect...

Page 55: ...the drive the doors of the power compartments must be secured with bolts and washers which are in a bag Fig 3 25 in the loose parts box The drive frame has captive nuts for the bolts Figure 3 25 Door bolts For information on the arc resistant design class of your drive see the project specific Converter Data Sheet Appendix B of the ACS1000i user manual ABB class Description Class I Protection base...

Page 56: ... circuit breaker and for ABB Class III protection external fuses on the drive input side 3 8 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 26 Optional space heaters For more information MCB overview 2 8 Important note main circuit breaker on page 25 MCB requirements Input circu...

Page 57: ... 04 Control system 04 57 70 ...

Page 58: ... 2 Main components 60 4 2 1 Local control panel 61 4 2 2 AMC circuit board 61 4 3 I O interfaces 66 4 3 1 IOEC I O modules 66 4 3 2 Serial communication interface fieldbus 70 4 3 3 Pulse encoder interface NTAC option 70 ...

Page 59: ...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 60: ...p transmitter 8 Motor starters and circuit breakers 9 Fused terminal block for internal aux power 10 Terminal blocks internal cooling fans external 11 Batteries option 12 AC auxiliary supply 13 AMC circuit board and INT circuit board 14 CDP control panel 15 Transformer protection 16 Control pushbuttons and indication lights 17 Emergency off pushbutton For information on the devices present in the ...

Page 61: ...nication channels are used for high speed data transfer via the INT circuit board to the inverter Figure 4 3 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 ...

Page 62: ... The default parameter values 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 t...

Page 63: ...llers 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 ...

Page 64: ...de 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 65: ...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 66: ... 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 6 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 67: ... 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 ...

Page 68: ... 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 69: ...an be seen in Fig 4 8 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 70: ...r more information on the device consult the relevant manual Modbus TCP Ethernet NETA 21 remote monitoring tool user manual 12 Modbus RTU Modbus NMBA 01 installation and start up guide 13 Profibus Profibus NPBA 12 installation and start up guide 14 DeviceNet DeviceNet NDNA 02 installation and start up guide 15 For more information on the device see Installation and Start up Guide for the Pulse Enc...

Page 71: ... 05 Transportation storage and disposal05 71 78 ...

Page 72: ...ting and transportation 73 5 4 1 General notes on transportation 73 5 4 2 Using a crane 74 5 4 3 Using rollers 75 5 5 Storage 76 5 5 1 Storage conditions 76 5 5 2 Storing the drive 76 5 5 3 Storage and handling of spare parts 77 5 6 Disposal of packaging materials and components 77 ...

Page 73: ... 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 ...

Page 74: ...the hole To attach a sling use appropriate safety hooks or shackles 2 in Fig 5 1 Maximum slope angle is 30 3 in Fig 5 1 Protect the edges of the cabinet 4 in Fig 5 1 Figure 5 1 Transporting the cabinet by crane lift spreader example To prevent people stumbling it is recommended to remove the lifting lugs after the drive has been installed at its final location Lift the cabinet slowly and steadily ...

Page 75: ...imum length of 1 2 m Place at least 5 rollers underneath the transformer Space the rollers evenly Figure 5 2 Moving the drive with rollers To move the drive backwards or forwards Fig 5 3 use rollers with a minimum length of 1 m Place at least 4 rollers in the area directly underneath the lifting rings Figure 5 3 Moving the drive backwards or forwards 1 Minimum 5 rollers 2 Minimum 1 2 m 1 Minimum 1...

Page 76: ... a longer time proceed as follows 1 Remove the batteries if applicable 2 Cover all cable inlets and ventilation slots with an impermeable plastic or aluminum foil and a wooden panel 3 Add 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...

Page 77: ...nd 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 79: ... 06 Mechanical installation 06 79 88 ...

Page 80: ...tes on installation 81 6 3 1 Dimensions and clearances 81 6 3 2 Cabinet roof 81 6 3 3 Fire protection 81 6 3 4 Cable duct material 81 6 4 Preparing the floor 82 6 5 Fixing the cabinet to the floor 82 6 6 Installing the fans 84 6 6 1 Additional cabinet compartments 87 ...

Page 81: ...ith 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 failure and damage when the drive is energized Ensure t...

Page 82: ...rall incline across 5 m must not exceed 5 mm Even Non flammable smooth and non abrasive Protected against humidity diffusion 6 5 Fixing the cabinet to the floor 1 Drill fixing holes into the floor as indicated on the layout drawing Figure 6 1 Position of mounting holes Important If the doors of medium voltage compartments cannot be opened contact the ABB service organization ...

Page 83: ...g plates at the appropriate points arrows in Fig 6 2 Recommended size 80 x 300 x 0 5 mm Figure 6 2 Leveling the drive ACS1000 air cooled shown 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 Insert the screws from the ends of the cabinet base or via the holes inside the cabinet Figure 6 3 Fixing the cabin...

Page 84: ...touts on the right are only for small fans Figure 6 4 Cutouts in drive roof back A and front B Drives without fan redundancy have two fans Fig 6 5 either two large fans or one large and one small fan Figure 6 5 Standard fan installation Drives with redundancy have one of the following fan configurations 1 Cutouts for large or small fans 2 Cutouts for small fans 3 Shock absorbers for fan unit 4 Ope...

Page 85: ...emove the cover from the cutout in the roof 2 Attach the lifting gear to the eye bolts on top of the fan unit Figure 6 6 Location of the eye bolts 3 Before you lower the fan onto the cabinet roof feed the fan motor cable into the cabinet 4 in Fig 6 4 4 Align the holes in front of the cutout on the drive Fig 6 4 with the shock absorbers under the front of the fan unit and align the shock absorbers ...

Page 86: ...6 8 the shock absorbers and holes are in the plate Figure 6 8 Small fan installation over a roof cutout for a large fan 5 Lower the fan unit into place 6 Secure the fan or the plate underneath the small fan that is being installed over one of the large roof cutouts For the front use two M8x12 bolts and for inside the cabinet use two M8 locking washers 1 2 2 1 1 ...

Page 87: ...e back of a fan unit 7 Attach the fan cover 8 Connect the fan motor cable according to the wiring diagram 6 6 1 Additional cabinet compartments If optional additional cabinet compartments are delivered as separate units they must be joined to the drive on site according to the supplied specific mounting instructions 1 2 x M8x10 2 2 x M8 locking and sealing rings 3 Shock absorbers are pre installed...

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Page 89: ... 07 Electrical installation07 89 104 ...

Page 90: ...fety 93 7 5 2 Determining the cable length 93 7 5 3 MV cable entry from top 94 7 5 4 MV cable entry from bottom 97 7 5 5 Connecting the cables 99 7 6 Auxiliary power control and serial communication cables 102 7 6 1 Preparing the cable entry and the cables 102 7 6 2 Preparing cables for cable entries with cable glands 103 7 6 3 Connecting the cables 104 7 6 4 Connecting additional cabinets 104 7 7...

Page 91: ...h 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 measures to prevent main and auxiliary power supply b...

Page 92: ...01 REV H ACS1000I AIR COOLED USER MANUAL 92 174 Figure 7 1 Grounding the drive system 1 Drive with integrated transformer 2 Motor 3 Earth electrode 4 Ground cable 5 Equipotential bonding conductor U1 U2 V2 W2 U V W M PE PE V1 W1 1 2 3 4 4 5 ...

Page 93: ...ct 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 flashover If the drive is supplied with an input voltage higher than 6 9 kV there is a risk of flashover between a conductor and the cabinet To prevent...

Page 94: ...01 REV H ACS1000I AIR COOLED USER MANUAL 94 174 7 5 3 MV cable entry from top Figure 7 2 Top cable entry installation material 1 Cable entry box 2 Insulating barrier 3 Brackets 4 6x M6x16 5 6x M6 6 6x M6 7 2x M6x12 self tapping 1 2 3 4 5 6 7 ...

Page 95: ...ble entry box at the places indicated by 1 in Fig 7 3 and 2 in Fig 7 3 Input voltage of the drive is greater than 6 9 kV fasten the cable entry box at the places indicated by 1 in Fig 7 3 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 Note If the input voltage of the drive is higher than 6 9 kV continue with the follow...

Page 96: ...the insulating barrier for top cable entry 1 Fasten a bracket at the places indicated 2 Remove the protective film from the insulating barrier 3 Fasten the insulating barrier at the places indicated Figure 7 4 Insulating barrier placement for top cable entry 1 Insulating barrier 2 2x M6x12 self tapping 1 2 ...

Page 97: ...oof Figure 7 5 Bottom cable entry Installation material 1 Remove the transport cover from the cabinet roof 2 Remove the galvanized steel plate from the top of the cable entry box and fasten the plate to the roof of the terminal compartment Input voltage of the drive is less than or equal to 6 9 kV fasten the cable entry box at the places indicated by 1 in Fig 7 6 and 2 in Fig 7 6 Input voltage of ...

Page 98: ...steps ie 7 5 4 1 Installing the insulating barrier for bottom cable entry on page 98 7 5 4 1 Installing the insulating barrier for bottom cable entry 1 Remove the protective film from the insulating barrier 2 Fasten three brackets to the insulating barrier in the locations indicated in Fig 7 7 Figure 7 7 Bracket location on insulating barrier 1 Bolt location 2 Bolt location 3 Galvanized steel plat...

Page 99: ...ure 7 8 Insulating barrier placement for bottom cable entry 7 5 5 Connecting the cables 7 5 5 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 2 ...

Page 100: ...voltages will be present in the terminal compartment High voltages can cause flashover between conductors with different electric potential and between a conductor and earth Maintain the following required minimum clearances Transformer primary cables For minimum clearances see the applicable standard Motor cables 20 mm between conductors 40 mm between a conductor and earth 1 Terminals for transfo...

Page 101: ...ide of the busbar 3 in Fig 7 10 Note Other washers can be used provided they maintain the required contact pressure Figure 7 10 Bolted busbar connections Use cable lugs suitable for M12 bolts If two conductors are used per phase install the second conductor on the opposite side of the busbar 7 5 5 3 3 Lubrication If stainless steel bolts and nuts are used lubricate the thread and head contact surf...

Page 102: ...he connection point inside the cabinet 2 Cut the cable to the required length before connection Figure 7 11 Cable entry from top A from bottom B Note ABB recommends sealing the bottom cable entry with polyurethane foam 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 diag...

Page 103: ...power and control cables 2 Drill holes into the cover adequate for the diameter of the cable glands 3 Prepare the cables with an outer cable screen for EMC bonding with the metal enclosure of the cabinet as illustrated in Fig 7 13 Figure 7 13 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...

Page 104: ... as short as possible not longer than 50 mm 7 6 3 3 Cable shields Connect the shield of serial communications cables to the fieldbus adapter Remove a portion of the cable insulation and use grounding clamps to fix the exposed shield to the grounding rail 1 in Fig 7 14 Figure 7 14 Shield grounding point for encoder cable 7 6 4 Connecting additional cabinets When additional cabinets are delivered se...

Page 105: ... 08 Commissioning 08 105 110 ...

Page 106: ...sistance 107 8 1 5 Customer acceptance 107 8 2 Commissioning checklist 108 8 2 1 Mechanical installation checklist 108 8 2 2 Electrical installation checklist 108 8 2 3 Main circuit breaker MCB checklist 109 8 2 4 Motor checklist 109 8 2 5 Insulation tests checklist 109 8 2 6 Power supply checklist 109 8 2 7 Miscellaneous checklist 109 ...

Page 107: ...ipment are ready for commissioning Reviewing and completing the items in the 8 2 Commissioning checklist on page 108 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 108: ...and 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 the power cable specification 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 3BHS206977 E01...

Page 109: ...xiliaries eg bearing lubrication ready 5 Control and monitoring signals connected 1 All power cables to converter transformer between drive and motor measured and measured values within the required limits 2 Test report of the Megger insulation resistance test available Important If the test is carried out by the commissioning engineer of the drive an additional day per drive motor combination nee...

Page 110: ......

Page 111: ... 09 Operation 09 111 124 ...

Page 112: ...9 5 2 Stop sequence of the drive 117 9 5 3 Emergency off sequence of the drive 118 9 6 Starting the drive 119 9 6 1 Checks before starting the drive 119 9 6 2 Starting the drive remotely 119 9 6 3 Starting the drive locally 119 9 7 Stopping the drive 122 9 8 Emergency off 123 9 8 1 Initiating an emergency off 123 9 8 2 Starting the drive after an emergency off 124 ...

Page 113: ...ssification of groups of environmental parameters and their severities Section 3 Stationary use at weather protected location 25 Conditions 3K22 3B1 3S6 3M11 9 4 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 functions of the operator panel includ...

Page 114: ... breaker opens immediately and DC link discharges when pressed during operation of the drive 5 CDP control panel Starts and stops the motor Displays status messages Displays alarm and fault messages of the drive and monitored foreign equipment Resets alarm and fault messages 6 Main supply on Illuminated pushbutton Charges the DC link and closes the main circuit breaker 7 Emergency off reset button...

Page 115: ...at the 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 r...

Page 116: ...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 117: ...he 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 118: ...V H ACS1000I AIR COOLED USER MANUAL 118 174 9 5 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 119: ...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 125 for information on functions and features of the CDP control panel Hazardous voltages All covers...

Page 120: ...se 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 121: ...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 122: ...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 123: ...F pushbutton of the drive is part of the operator control panel Fig 9 1 and features a latching switch action CAUTION 9 8 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 124: ...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 125: ... 10 CDP control panel 10 125 148 ...

Page 126: ...tification mode 128 10 3 2 Actual signals mode 130 10 3 3 Parameters mode 137 10 3 4 Functions mode 142 10 4 Local and remote control 144 10 4 1 Local control 144 10 4 2 Remote control 145 10 5 Operational commands 146 10 5 1 Setting the direction of rotation 146 10 5 2 Entering a reference value 147 ...

Page 127: ...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 128: ...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 128 10 3 2 Actual signals mode on page 130 10 3 3 Parameters mode on page 137 10 3 4 Functions mode on page 142 10 3 1 Iden...

Page 129: ...the 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 130: ...mory 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 134 When the drive generates a fault or alarm the corresponding message displays immediately Changing ...

Page 131: ...tatus 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 ...

Page 132: ...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 133: ...ection 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 Ac...

Page 134: ...y 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 RE...

Page 135: ...he 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 MotorSp...

Page 136: ...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 137: ...nnot be changed while the drive is running If tried the following warning 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 G...

Page 138: ...ting 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 600 0 rpm 0 75 OPTION MODULES 01 IOEC3 OptionBoard YES...

Page 139: ...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 140: ...als 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 M...

Page 141: ...ser 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 New...

Page 142: ... 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 ENT...

Page 143: ...ntrast 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 CONTR...

Page 144: ...context remote control is not necessarily equivalent to higher level control For more information see 10 4 2 Remote control on page 145 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 r...

Page 145: ...START 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 146: ...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 147: ...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 148: ...1 REV H ACS1000I AIR COOLED USER MANUAL 148 174 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 149: ... 11 Preventive and corrective maintenance 11 149 172 ...

Page 150: ...on 153 11 2 2 Cables and wires 153 11 2 3 Understanding wiring diagrams 153 11 3 Alarm fault indications 154 11 3 1 Messages 154 11 3 2 Error message levels 154 11 3 3 Fault handling 154 11 3 4 Standard troubleshooting procedure 155 11 4 Removing the CDP control panel 156 11 5 LEDs and switches on circuit boards 157 11 5 1 AMC circuit board 157 11 5 2 IOEC I O modules 158 11 6 Corrective maintenan...

Page 151: ...eased 162 11 6 5 Checking the release conditions for the grounding switch 164 11 6 6 Visual checks on the drive 166 11 6 7 Cleaning the drive 166 11 6 8 Checking wire and cable connections 167 11 6 9 Cleaning and replacing filter mats 167 11 6 10 Inspecting and replacing batteries 169 11 6 11 Replacing a fan unit 171 ...

Page 152: ...to 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 a...

Page 153: ...o 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 refer...

Page 154: ... 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 con...

Page 155: ...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 125 3 Identify the fault and make a logbook entry 4 Save the ...

Page 156: ... PANEL 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 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 see Ap...

Page 157: ...the 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 Flas...

Page 158: ...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 159: ... 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 covers are securely fastened ...

Page 160: ... 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 161: ...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 162 If the yellow lamp is not on continue with 11 6 4 Grounding switch is not released on page 162 1 ...

Page 162: ...to 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 forc...

Page 163: ...VE MAINTENANCE 3BHS206977 E01 REV H ACS1000I AIR COOLED USER MANUAL 163 174 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 164: ...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 165: ... 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 presen...

Page 166: ...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 167: ...ushings 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 exceed 20 Nm Hazardous voltage When removing the filter mat while the drive is in operation observe the following Make sure that objects like wires or screwdrivers do not ent...

Page 168: ...particles μm ACS1x4x Ax xx xx xxxx xxxx xxxx xxx0 xxxxx xx ACS1x4x Ax xx xx xxxx xxxx xxxx xxxA xxxxx xx ACS1x4x Ax xx xx xxxx xxxx xxxx xxxB xxxxx xx ACS1x4x Ax xx xx xxxx xxxx xxxx xxxC xxxxx xx G3 10 18 ACS1x4x Ax xx xx xxxx xxxx xxxx xxxD xxxxx xx ACS1x4x Ax xx xx xxxx xxxx xxxx xxxE xxxxx xx ACS1x4x Ax xx xx xxxx xxxx xxxx xxxF xxxxx xx ACS1x4x Ax xx xx xxxx xxxx xxxx xxxG xxxxx xx G4 19 12 A...

Page 169: ...battery life is indicated as follows 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 u...

Page 170: ...r 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 2 in Fig 11 7 4 Remove the cable duct covers 3 in Fig 11 7 Figure 11 7 Control compartment replacing the batteries 5 Install the new battery in reverse order of removal 6 Record the date of battery replacement in the logbook 10 kg Each battery ...

Page 171: ...motor starter of the fan 3 Unplug the power supply cable of the fan 4 Unplug the supply cable of the fan inside of the drive 5 Remove the cover 6 Remove the fastening screws of the top plate 7 Attach lifting gear appropriate for the weight of the impeller and the motor and then lift off the top plate with the impeller attached to it 100 kg Heavy load The fan weighs approximately 50 kg For more inf...

Page 172: ... 3BHS206977 E01 REV H ACS1000I AIR COOLED USER MANUAL 172 174 8 Unscrew the top plate from the impeller motor 9 Attach the top plate to the replacement motor 10 Assemble and install the fan unit in reverse order of removal 2 x M8x13 17 19 mm ...

Page 173: ......

Page 174: ...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 3BHS206977 E01 Rev H 2020 03 18 174 ...

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