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CHAPTER 2 – POWER ELECTRONICS AND CABINET FEATURES

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2.3.3 AFE - Active front end

The active front end of the drive consists of an rec-
tifier for four quadrant operation. The AFE features
the same electrical design as the INU of the drive.
The AFE rectifies the AC line voltage of the main
power supply and connects its output to the
minus, neutral point and plus side of the DC link.
The AFE maintains the DC-link voltage at the
required level and provides the desired input
power factor at the point of common coupling
(PCC). The input power factor is adjusted by the
AFE to near unity.

—
References

—
2-5 AFE - Active front end

—

IFU

AFE

DC link

INU

EMC filter

Transformer

Utility

Energy flow in driving mode

Energy flow in braking mode

Customer

PCC

M

1

2

3

4

Phase module 1

Phase module 2

Phase module 3

Extracted phase module

1

2

3

4

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Summary of Contents for ACS2000 AFE 1MVA

Page 1: ...LTAGE DRIVES ACS2000 AFE 1MVA User Manual High reliability due to proven design and low parts count Fuseless design Air cooled Application tailored design Softstarter Arc resistant design Direct torque control Power range from 250 to 800 kW ...

Page 2: ... ABB Sp z o o System Drives Placydowska 27 95 070 Aleksandrow Lodzki Poland Document name ACS2000 AFE 1MVA User Manual Document number 3BHS297030 ZAB E01 Rev J Issue date 2020 07 ...

Page 3: ... note on main circuit breaker 24 Safety 30 Power electronics and cabinet features 48 Control system 68 Transportation storage and disposal 78 Mechanical installation 86 Electrical installation 110 Commissioning 114 Commissioning check list 118 Operation 132 CDP control panel 150 Preventive and corrective maintenance ...

Page 4: ...front end 37 Phase module 38 DC link 39 Grounding switch 39 Grounding circuit 40 Grounding the drive 41 INU Inverter unit 41 EMC filter 42 Terminal compartment 44 Door locks 45 Fan unit types 46 Example of fan group 1 46 Example for the operating time of the fan units 47 Air flow inside the drive 47 Air pressure switches 49 Block diagram of control system 50 Control compartment 51 Control compartm...

Page 5: ...n 98 Preparing power cables for EMC plates 99 Preparing power cables for sealing modules 101 Power cable entry 102 Bolted busbar connection 103 Control cable entry 104 Preparing control cables for EMC plates 105 Preparing control cables for sealing modules 105 Preparing control cables for cable glands 106 Shield grounding point for encoder cable 123 Local operator panel 133 CDP control panel 152 D...

Page 6: ...170 Replacing filter mats 171 Phase modules location 171 Phase module Dimensions and weight ...

Page 7: ...gnal allocation 61 3 9 Standard analog output signal allocation 62 3 10 Optional digital output signal allocation 62 3 11 Optional digital input signal allocation 63 3 12 Optional analog input signal allocatio 63 3 13 Optional analog output signal allocation 70 4 1 Transport Conditions 74 4 2 Storage conditions 91 6 1 Auxiliary power terminal sizes 91 6 2 I O module terminal sizes 119 8 1 Operatin...

Page 8: ...Terms trademarks related documentation ...

Page 9: ...taining ABB drives equipped with optical communication links DriveMonitor DriveMonitor is a monitoring and diagnostics system that allows secure access to the drive via the internet from a remote location DriveMonitor provides long term monitoring functions that allow to infer equipment status and improve equipment performance Equipment Frequency converter and related equipment EMC Electromagnetic...

Page 10: ...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 uninterruptible power supply Supervisory signal Indicates the operating condition of a circuit or device SW Software TC Short form for terminal compartment of the drive Zero speed threshold Used ...

Page 11: ... registrations and trademarks are used in this man ual Term Abbreviation Meaning Windows Registered trademark of Microsoft Corporation Industrial ITTM Trademark of ABB DriveWare Registered trademark of ABB Advant Registered trademark of ABB Advant FieldbusTM Trademark of ABB Ethernet Registered trademark of Xerox Corporation Profibus Registered trademark of Profibus International P I Modbus Regist...

Page 12: ...formance Motor Spec 3BHS824805 ZAB E01 ABB MVD ACS High Speed Motor Spec 3BHS824806 ZAB E01 ACS2000 power cable specification 3BHS189994 ZAB E01 Power cables engineering guideline 3BHS542290 ZAB E01 Maintenance Preventive maintenance schedule 4MFB005215 ZP3 E01 Drive monitoring DriveMonitor user manual 3BHS268039 ZAB E01 Serial communications interfaces AF 100 fieldbus NAFA 01 installation and sta...

Page 13: ...13 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV J ...

Page 14: ...General information on manual and drive ...

Page 15: ...o Placydowska 27 95 070 Aleksandrow Lodzki Poland Phone 1 479 648 5912 E Mail drivessupport abb com Web http www abb com drives Equipment covered by the manual This manual covers a standard drive and provides generic information on the drive The manual does not claim to cover all variations and details of the drive nor to consider all eventualities that may arise during installation commissioning ...

Page 16: ...ns who operate the drive from the local operating panel of the drive The personnel must know the functions of the operating panel be adequately trained for the drive and know the driven process Special knowl edge of frequency converter technology is not required Maintenance The personnel include all persons who are qualified to carry out preventive and correc tive maintenance on drive as described...

Page 17: ...ormative standards EC Conformity Declaration List of the standards the drive complies with Items covered by delivery Delivery comprises the following items see figure below Drive 1 shipped either in seafreight or air freight packaging Transformer can be integrated or non inte grated 2 Fan unit s 3 shipped separately Phase module kit 4 if selected as additional option Set of door keys 5 T handle sc...

Page 18: ...essories are identified by the type code printed on the rating label 7 The rating label is located on the front of the con trol compartment door 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 19: ...19 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV J ...

Page 20: ...Important note on main circuit breaker ...

Page 21: ...ut transformer 0 1 shows the conceptual single line diagram of a typical drive system including main power supply MCB input transformer drive and electrical motor The MCB is defined as a switching device to dis connect the power supply whenever required by the process or when a fault occurs Typical devices used as MCBs are Vacuum circuit breakers SF6 circuit breakers Fused contactors or motor cont...

Page 22: ...ice position the drive must have exclusive control of closing the MCB Local closing of the MCB is not permitted The maximum opening time of the MCB must never exceed the product or project specific maximum time defined in the MCB specifica tions Typical maximum values for the drive are defined as follows Maximum protection trip time 75 ms The maximum protection trip time is the maximum allowed bre...

Page 23: ...23 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV J Maintenance recommendation The MCB trip circuits should be checked once yearly ...

Page 24: ...Chapter 1 Safety 25 Meaning of safety instructions 26 General safety information 27 Possible residual risks 28 Safety labels 29 Cyber Security Requirements ...

Page 25: ...afety colors and safety signs Part 2 Design principles for product safety labels ANSI Z535 6 American National Standard for Product Safety Information in Product Manuals Instructions and Other Collateral Materials DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a hazardous situation which if not avoided could resul...

Page 26: ...ground connections are in place appropriate personal protective equipment is provided and used when required everyone involved is informed When working near the running drive wear pro tective earmuffs Before work is carried out simultaneously on the drive and on other drive system equipment make sure that the relevant safety codes and standards are observed all energy sources of the equipment are ...

Page 27: ...ip ment 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 caused by for exam ple Operation of the equipment outside the scope of the specifications External influence on or damage of the equipment Induced voltages by external equipment Condensation on ...

Page 28: ...are attached to the cabinet to alert personnel of potential hazards when working on the equipment The instructions on the safety labels must always be followed and the labels must be kept in a perfectly legible condition References 1 1 Safety labels 1 1 ...

Page 29: ...aches unauthorized access interference intrusion leakage and or theft of data or informa tion ABB and its affiliates are not liable for damages and or losses related to such security breaches any unauthorized access interference intrusion leakage and or theft of data or information 1 5 2 User Lock For better cyber security it is highly recommended that you set a master pass code to prevent e g the...

Page 30: ...Chapter 2 Power electronics and cabinet features 31 Overview 32 Power supply configurations 34 Drive topology 42 Terminal compartment 43 Cabinet design 44 Door locking system 45 Cooling system ...

Page 31: ...former ACS2000 for connection to an integrated trans former 1 ACS2000 for direct to line connection DTL The following sections provide an overview of the available main and auxiliary power configu rations the power electronic components of the drive the cooling system cabinet features such as the grounding switch and the electro mechanical door interlock For information on the power and voltage ra...

Page 32: ...ft side of the drive The length of the cabinet depends on drive power For the integrated configuration a dry type transformer is used Non integrated The transformer is external to the drive The transformer can either be an oil immersed or dry type device The distance between drive and transformer is determined by the maximum possible cable length for the transformer sec ondary cables Drives with a...

Page 33: ...pped for one three phase power supply that provides the total auxiliary power Optional power supplies To accommodate requirements for safe opera tion if the auxiliary power fails the drive can be furnished with one three phase power supply and one single phase power supply Independent of the power supply scheme the drive provides an internal back up supply for 100 ms This safety feature enables th...

Page 34: ...ical ACS2000 References 2 3 Drive overview with input transformer 2 3 IFU input filter unit DTL compartment not pres ent in drives for connection to an input transformer Terminal compartment for feeder and motor cables EMC filter behind control compartment Control compartment with local operator panel AFE active front end DC link INU inverter unit 1 2 3 4 5 6 7 8 4 3 2 1 1 7 5 8 6 ...

Page 35: ...ges injected to the supply network 2 3 2 DTL compartment The DTL compartment 2 3 2 is present in drives configured for direct to line connection The func tions of the compartment are twofold It smooths the current harmonics in the power supply It decouples the common mode voltages of the drive from the network References 2 4 IFU Input filter unit 2 4 AFE DC link DC NP DC U1 V1 W1 to NP IFU to INU ...

Page 36: ...its output to the minus neutral point and plus side of the DC link The AFE maintains the DC link voltage at the required level and provides the desired input power factor at the point of common coupling PCC The input power factor is adjusted by the AFE to near unity References 2 5 AFE Active front end 2 5 IFU AFE DC link INU EMC filter Transformer Utility Energy flow in driving mode Energy flow in...

Page 37: ...rd of the AFE The high voltage IGBT is a power semiconductor switching device specially developed for medium voltage drives The device is based on well estab lished transistor technology and combines high speed switching capabilities with high blocking voltage and low conduction losses as known from GTOs References 2 6 Phase module 2 6 Phase capacitor Phase INT circuit board Gate drivers Connector...

Page 38: ...n ished the charging unit is disconnected from the medium voltage circuit the MCB is closed and the DC link reaches its nominal level Stand by mode Once the DC link is charged it is possible to keep the drive in this state to facilitate a more rapid start up procedure The losses during stand by mode are approx 1 of the nominal power and are caused from small losses from the AFE the INU and the aux...

Page 39: ...in position grounded input fil ter 2 9 1 AFE 2 9 2 DC link 2 9 3 INU 2 9 4 and output filter 2 9 5 of the drive are connected to the PE ground bus 2 9 6 The switch is electromechanically interlocked with a discharge monitoring circuit that prevents clos ing of the switch while the DC link capacitor is still charged References 2 8 Grounding switch 2 9 Grounding circuit 2 8 2 9 1 2 3 4 5 6 ...

Page 40: ...press the pushbutton Grounding Switch Unlocked 2 10 1 located on the control compart ment door the pushbutton lights up and at the same time turn the grounding switch to the posi tion grounded 2 10 2 When the grounding switch is in position grounded the door safety switch of the AFE INU compartment will be released and the door can be opened References 2 10 Grounding the drive 2 10 Grounding switc...

Page 41: ...rd motors The INU is composed of three identical phase mod ules see Phase module The phase modules can be extracted from the cabinet to facilitate mainte nance and service on the INU 2 3 6 EMC filter The INU includes a three phase du dt filter con nected to its AC output The filter chokes 2 12 1 resistors 2 10 2 and capacitors 2 10 3 protect the motor against excessive voltage slopes du dt is limi...

Page 42: ...s for the termination of the ground cable and the cable screens The cable entry is prepared in the factory for to the cable entry configuration ordered Top or bottom cable entry Type of entry plate For information on the type of cable entry in the drive see Appendix C Mechanical drawings For further information see 6 8 Cable entries References 2 13 Terminal compartment 2 3 ...

Page 43: ...plying a cabinet design consisting of folded galvanized sheet metal plates approximately 2 mm thick and mini mizing the space between the rivets The inside walls of the cabinet are not painted because paint tends to reduce the effectiveness of metallic bond ing which is important for successful EMC Accordingly only the front of the cabinet is painted while all other walls are galvanized However th...

Page 44: ... 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 The covers of the integrated transformer are bolted References 2 14 Door locks 2 14 Cover of DTL compartment bolted Cover of terminal compartment bolted Door of control compartment lockab...

Page 45: ...d with fan units Optionally the drive and the integrated transformer can have a redundant fan configuration ensuring full operation in the event of fan failure The drive can be equipped with fan units of the fol lowing types References 2 15 Fan unit types 2 15 ACS2000 DTL ACS2000 with integrated transformer 1 1 1 1 2 2 Fan unit type 1 Fan unit type 2 1 2 ...

Page 46: ...ging of the DC link is initiated When the drive is stopped the fan group continues to run for a preset time after the main power has been switched off and the DC link voltage has decreased below a preset value Operating intervals Parameter setting allows to run one of the two fans continuously or to run the fans alternately in adjustable intervals The intervals are set with parameters References 2...

Page 47: ... cabinets When the filter mats are clogged and the pressure drop reaches the specified final pressure loss the message Conv1CoolAirFilter is displayed on the CDP control panel and the alarm fault lamp lights up on the control compartment door When a fan of the drive or a fan of the integrated transformer fails the control system of the drive switches on the stand by fan automatically The failure o...

Page 48: ...Chapter 3 Control system 49 Overview 50 Main components 54 I O interfaces ...

Page 49: ...control system and or remote operator stations References 3 1 Block diagram of control system 3 1 ACS2000 IOEC I O modules INT circuit board INU Phase module Phase module Phase module INU External devices Pulse encoder DriveWare DriveMonitor RS485 PPCS DDCS PPCS PPCS PPCS option DDCS CDP control panel Fieldbus adapter AMC circuit board AFE AMC circuit board INU INT circuit board AFE Phase module P...

Page 50: ...provides a short functional overview of the main hardware components of the control system and their interconnection References 3 2 Control compartment 3 2 Shown is the ACS2000 for connection to an input transformer Control compartment Local control panel 1 2 1 2 ...

Page 51: ...ion and Chapter 9 CDP control panel For information on the devices present in the control compartment of the drive see Appendix D Wiring diagrams For 24 V circuits the ATO style blade fuses rated 3 A 32 V are used References 3 3 Control compartment details 3 3 AMC circuit boards IOEC modules with analog and digital intputs and outputs Circuit breakers auxiliary relays and contactors Power supply u...

Page 52: ...of the drive The AMC circuit board of the INU processes drive and status information performs the speed and torque control tasks and monitors the operation of the drive The AMC circuit board continuously monitors all relevant drive variables eg speed torque current voltage Pre programmed protection functions ensure that these variables remain within certain limits in order to maintain safe operati...

Page 53: ... microseconds Motor torque and flux comparators compare the actual values to reference values which are produced by the torque and flux refer ence controllers Depending on the outputs from the hysteresis con trollers the switching logic directly determines the optimum switch positions every 50 microseconds and initiates switching whenever required Peripheral I O devices The peripheral input and ou...

Page 54: ...or most applications The drive can include optional expansion I O that includes an external module IOEC 4 and an inter nal module IOEC 3 These expansion modules pro vide extra inputs and outputs for control and supervision as may be required by ABB or the cus tomer to support various control options References 3 6 IOEC modules overview 3 7 IOEC modules location 3 6 IOEC 4 IOEC 1 IOEC 2 IOEC 3 AMC ...

Page 55: ...r voltage input Common mode voltage Maximum 48 V Isolation level 350 V AC Analog outputs No of I O 2 Signal range 0 20 mA load impedance max 250 Resolution 12 bit Isolation level 350 V AC Digital inputs No of I O 14 Signal level 22 80 V DC 22 120 V DC with IOEC Adapter 3BHE040914R0101 22 250 V AC Logical thresholds 13 V AC or DC 0 16 V AC or DC 1 Input current 13 mA steady state 14 mA max inrush a...

Page 56: ...8 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 AI2 20mA AI2 10V AI3 20mA AI3 10V AI4 20mA AI4 10V AO1 AO2 X6 1 X6 2 X6 3 X6 4 2 DDCS TX DDCS RX MCB OFF IN 4V DC IOEC I O INTERFAC...

Page 57: ...epresents the kind of part an assembly the next three digits are the page num ber the part is located on page 340 and the last digit 1 means that the 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 Table 3 3 Table 3 3 IOEC module identificati...

Page 58: ...X32 3 X31 4 AI3 AI3 Freely programmable 72 X32 4 X31 5 AI4 AI4 Freely programmable 72 X32 5 Table 3 5 Standard digital output signal allocation Terminal Channel Default setting Parameter group X21 1 DO01 Ready on drive is ready for operation X21 2 X21 3 X22 1 DO02 Ready ref drive is running X22 2 X22 3 X23 1 DO03 Alarm fault alarm fault is present X23 2 X23 3 X24 1 DO04 Tripped drive has shut down...

Page 59: ...mmon X11 9 DI05 Freely programmable 72 X11 10 Common X12 1 DI06 Freely programmable 72 X12 2 Common X12 3 DI07 Freely programmable 72 X12 4 Common X12 5 DI08 Freely programmable 72 X12 6 Common X12 7 DI09 MV switchgear open X12 8 Common X12 9 DI10 MV switchgear closed X12 10 Common X13 1 DI11 MV switchgear available not tripped X13 2 Common X13 3 DI12 Freely programmable 72 X13 4 Common X13 5 DI13...

Page 60: ...mmon X12 1 DI06 Constant speed select 24 25 X12 2 Common X12 3 DI07 External ON request start DC link charge 72 02 72 03 X12 4 Common X12 5 DI08 Process stop stops drive 72 43 72 44 X12 6 Common X12 7 DI09 MV switchgear open X12 8 Common X12 9 DI10 MV switchgear closed X12 10 Common X13 1 DI11 MV switchgear available not tripped X13 2 Common X13 3 DI12 Remote reset 72 33 72 34 X13 4 Common X13 5 D...

Page 61: ...nce X32 3 X31 4 AI3 AI3 Motor winding V temperature X32 4 X31 5 AI4 AI4 Motor winding W temperature X32 5 Remote speed supply output specifications Output voltage 10 V Available output current 5mA X31 1 X32 4 X32 1 X31 2 X32 2 X31 3 X32 3 X31 4 X31 5 X32 5 10 V 0 V AI1 Wiring example remote speed Internal supply voltage Remote speed control Table 3 9 Standard analog output signal allocation Termin...

Page 62: ... NO NC NO Table 3 11 Optional digital input signal allocation Terminal Channel Default setting Parameter group X11 1 DI01 Freely programmable X11 2 Common X11 3 DI02 Freely programmable X11 4 Common X11 5 DI03 Freely programmable X11 6 Common X11 7 DI04 Freely programmable X11 8 Common X11 9 DI05 Freely programmable X11 10 Common X12 1 DI06 Freely programmable X12 2 Common X12 3 DI07 Freely progra...

Page 63: ...Optional analog input signal allocatio Terminal Channel Default setting Parameter group X31 1 10 V 0 V Internal supply voltage X32 1 X31 2 AI1 AI1 Motor winding U1 temperature X32 2 X31 3 AI2 AI2 Motor winding V1 temperature X32 3 X31 4 AI3 AI3 Motor winding W1 temperature X32 4 X31 5 AI4 AI4 Freely programmable X32 5 Table 3 13 Optional analog output signal allocation Terminal Channel Default set...

Page 64: ...2 D N Data negative X2 3 DG Data ground X2 4 SHF Shield AC ground via RC filter X2 5 SH Shield ground direct X2 6 0 V Power supply 24 V DC 10 X2 7 24 V X2 8 PE Ground NPBA 12 terminal assignment X1 1 A Data negative conductor 2 in twisted pair Customer connections X1 2 B Data positive conductor 1in twisted pair X1 3 A Data negative conductor 2 in twisted pair X1 4 B Data positive conductor 1in twi...

Page 65: ...r is DIN rail mounted inside the control compartment 3 10 1 The indicated mounting position may vary depend ing on the number of optional devices present on the swing frame To identify the adapter type installed in the drive see the applicable Wiring dia grams INU AMC circuit board Higher level control system Fieldbus adapter DDCS References 3 10 Location of fieldbus and pulse encoder interface 3 ...

Page 66: ...ce is DIN rail mounted inside the control compartment 3 10 2 The indicated mounting position may vary depend ing on the number of optional devices present on the swing frame 3 3 7 Motor temperature supervision Motor temperature supervision is accomplished via optional PT100 input modules These modules are suitable for connection of PT100 resistance thermometers in accordance with IEC60751 in 2 3 o...

Page 67: ...67 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV J ...

Page 68: ...tation storage and disposal 69 Safety 70 Transport conditions 71 Unpacking and inspection 72 Lifting and transportation 74 Storage 75 Storage and handling of spare parts 76 Disposal of packaging materials and components ...

Page 69: ...69 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV J 4 1 Safety The drive must only be handled by personnel who are skilled and experienced in unpacking and transporting heavy equipment ...

Page 70: ... temperature 45 C High air temperature Unventilated enclosures 70 C Ventilated enclosures outdoor 40 C Relative humidity 100 Absolute humidity 60 2B1 Biological conditions Flora No Fauna No 2M4 Mechanical conditions Stationary vibration random Acceleration spectral density 10 m2 s3 2 3 Hz 1 m2 s3 10 20 Hz 0 5 m2 s3 50 2000 Hz Non stationary vibration including shock Shock response spectrum 100 m s...

Page 71: ... 2 Check the drive and accompanying equipment for damages 3 Compare the complete delivery with the pur chase order and the packing list 4 If parts are missing or damaged immediately inform the shipping company and the ABB ser vice organization It is recommended to photograph the damages and send the photographs to ABB ...

Page 72: ...he outer holes of the rails arrows The rails can be removed after the cabinet has been installed at its final location Do not pass a sling through the hole To attach a sling use appropriate safety hooks or shackles Verify that the slope angle 1 is appropriate to the weight of the cabinet Observe the center of gravity Lift the cabinet slowly and steadily to the required clearance height maintaining...

Page 73: ...binet 4 3 This is the cabinet side where the heaviest drive compo nents are located Use forks of sufficient length to ensure stable transportation and to prevent tipping The arrow in 4 3 indicates the minimum fork length if the forklift is positioned on the right If the forklift is positioned on the left of the cabinet the forks must be as long as the cabi net Insert the forks fully to transport t...

Page 74: ... aluminum foil and a wooden panel 2 Add a desiccant of the appropriate quality 1 unit desiccant 30g absorbs 6 g water vapor The following quantity is needed when using a polyethylene foil 10 units m2 foil 3 Close and lock the doors of the cabinet 4 Use polyethylene or equivalent for packaging 0 3g m2 24h water vapor diffusion 5 Attach humidity indicators to the packaging The storage conditions and...

Page 75: ...good condition and to keep the warranty valid during the warranty period observe the following Check the spare parts immediately after receipt for damages Report any damage to the ship ping company and the ABB service organiza tion Keep spare parts in their original packaging Store printed circuit boards in antistatic bags or boxes Ground yourself with a wrist strap before touching a component Hol...

Page 76: ...ANSPORTATION STORAGE AND DISPOSAL 76 4 7 Disposal of packaging materials and components Dispose of the packaging materials and the com ponents at the end of the life time of the drive according to local regulations ...

Page 77: ...77 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV J ...

Page 78: ...Chapter 5 Mechanical installation 79 Safety 80 Overview on installation work 81 General notes on installation 82 Fixing the cabinet to the floor 84 Installing fan units ...

Page 79: ...2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV J 5 1 Safety All installation work must be carried out by qualified personnel according to the site and equipment requirements and in compliance with local regulations ...

Page 80: ...CHAPTER 5 MECHANICAL INSTALLATION 80 5 2 Overview on installation work The installation includes the following work Preparing the floor Fixing the cabinet to the floor Installing fan units ...

Page 81: ...its should be protected to prevent dust humidity and animals entering into the drive 5 3 5 Preparing the floor Condition of the floor Must support the weight of the cabinet Overall incline across 5 m must not exceed 5 mm Even Non flammable smooth and non abrasive Protected against humidity diffusion NOTICE Foreign matter and particularly metallic dust can cause failure and damage when the drive is...

Page 82: ...loor fixings Insert the screws from the ends of the cabinet base 5 1 A or via the holes inside the cabinet 5 1 B D Hole number 5 1 4 cannot be accessed from inside the cabinet Floor fixings are not supplied Anchor bolts as illus trated 5 1 E or screws and nuts of size M20 are recommended References 5 1 Fixing the cabinet to the floor ...

Page 83: ...83 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV J 5 1 3 2 1 4 A B C E D ...

Page 84: ...configurations require prior instal lation of the appropriate redundancy adaptor box on the cabinet roof For information on the number of fan units to be installed and their location on the cabinet roof see the applicable Mechanical drawings 94 kg 17 kg Additional fan unit supplied with DTL direct to line drives For information on the electrical installa tion see 6 11 Control and power supply cabl...

Page 85: ...85 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV J ...

Page 86: ...es 91 Terminal sizes 92 Ground cable connection and cable shield connections 94 Cables between integrated transformer and drive 96 Cable entries 97 Power cables ground cables equipotential bonding conductor 103 Auxiliary power control and serial communication cables 107 Control and power supply cables for fan units 109 Final checks ...

Page 87: ... 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 being switched on during installation ...

Page 88: ...ctrical installation includes the following wire and cable connections Cables between integrated transformer and drive Power cables ground cables equipotential bonding conductor Auxiliary power control and serial communica tion cables Control and power supply cables for fan units ...

Page 89: ...he requirements for power cables ground cable and equipo tential bonding conductor see ACS2000 power cable specification Power cables engineering guideline For information on the requirements for the auxiliary power cable and the control cables see Auxiliary power and control cables guideline ...

Page 90: ...g of power cables Independent of the distance between the non integrated transformer and the drive and the drive and the motor one single core cable per each phase must be used The current carrying capacity must not be increased by laying cables in parallel ...

Page 91: ...PE Optional single phase UPS Terminal Wire cross section mm2 X1 11 1 5 to 25 X1 12 PE Optional auxiliary power supply for converter space heater Terminal Wire cross section mm2 X1 15 1 5 to 25 X1 16 PE Table 6 2 I O module terminal sizes Wire cross section mm2 Digital inputs 0 5 to 2 5 Digital outputs Analog inputs Analog outputs For information on the auxiliary supply voltage see the rating label...

Page 92: ...ields of the cables and for the connection of the ground cable To identify the ground busbar see the applicable Mechanical drawings References 6 1 Grounding the drive system and integrated transformer 6 1 1 2 3 1 2 3 PE PE U V W U2 V2 W2 U1 V1 W1 M Input transformer Drive Motor Earth electrode Ground cable Cable screen Cable shield Equipotential bonding conductor 1 2 3 4 5 6 7 8 1 2 3 4 6 5 7 8 ...

Page 93: ... drive system and non integrated transformer 6 2 1 2 3 1 2 3 PE PE U1 V1 W1 U V W U2 V2 W2 1 2 3 1 2 3 PE PE U2 V2 W2 U1 V1 W1 M Input transformer Drive Motor Earth electrode Ground cable Cable screen Cable shield Equipotential bonding conductor 1 2 3 4 5 6 7 8 1 2 3 8 7 6 5 4 ...

Page 94: ...ly for primary cur rent measurement The cables are identified by their specific number and are labeled with the designation of the termi nal where they are connected to The cables are prepared for connection Power cables are rolled up in the transformer cabinet control cables in the drive cabinet 6 7 1 Heating cable optional This section applies to drives that are delivered in several transport un...

Page 95: ... Connect the power supply of the heating cable 2 Connect the heating cables of two adjoining transport units with each other 3 Fasten the connectors with cable ties For further information on power supply connections see the applicable Wiring diagrams ...

Page 96: ...g grommets 2 EMC cushions 1 on the underside of the EMC plate if the cable entry is used for control cables 6 8 2 Cable entry with sealing modules type 1 Usage Power cables ground cables bonding conductors Included in delivery Cable entry frame 1 Not included in delivery Sealing modules 2 accessories tools 6 8 3 Cable entry with sealing modules type 2 Usage Auxiliary power cables control cables In...

Page 97: ...ded if cables are entered through the cabinet floor 4 If necessary remove the entry plate and push the cable through the entry holes 5 Prepare the cables as illustrated 6 5 A illustrates how cables with an outer cable screen or shield are prepared for EMC bonding with the metal enclosure of the cab inet 6 5 B illustrates how cables without an outer screen or shield are prepared See the applicable ...

Page 98: ...er cables for EMC plates 6 5 Outer cable sheath Grommet Entry plate EMC sleeve Conductor insulation removed to expose cable shield Cable tie Conductor screen extension to be connected to PE ground busbar Heat shrinkable termination 1 2 3 4 5 6 7 8 A 1 2 3 4 5 6 7 8 B ...

Page 99: ...the sealing module supplier References 6 6 Preparing power cables for sealing modules 6 6 Outer cable sheath Sealing module Frame Conductive foil of sealing module Cable sheath removed to expose cable shield Cable clamp Shrinkable sheath seal Shield extension to be connected to PG busbar Conductor screen extension to be connected to the PG busbar Heat shrinkable termination Cable lug as specified ...

Page 100: ...e cable conductors unconnected at both ends until the commissioning engineer has given permission NOTICE 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 a conductor and earth Therefore maintain a minimum clearance of 55 mm between a conductor and the terminals of any other...

Page 101: ...busbars U1 V1 W1 the motor cables to busbars U2 V2 W2 the screen ends of all conductors and the shields of all cables to the PE ground bus the ground cable to the PE ground bus 6 7 1 the equipotential bonding conductor to the PE ground bus 6 7 1 References 6 7 Power cable entry 6 7 U2 V2 W2 U1 V1 W1 1 1 A B Entry from top Entry from bottom A B ...

Page 102: ...r 6 8 1 and flat washer 6 8 2 on each side of the busbar 6 8 3 Other washers can be used provided they maintain the required contact pressure Cable lugs suitable for M12 bolts Lubrication If stainless steel bolts and nuts are used lubri cate the thread and head contact surface of the bolt using recommended pastes eg Molykote D paste If a coated nut eg with bonded molybdenum disulfide MoS2 coating ...

Page 103: ...ection point inside the cabinet 2 Cut the cable to the required length before con nection Routing the cables Top and bottom entry To facilitate cable routing remove the cover above the cable transit 6 9 1 and the cover of the cable duct 6 9 2 Rout the cables as illustrated to the customer terminals in the control compartment See Appendix C Mechanical drawings for information on Project specific ca...

Page 104: ... through the entry holes 5 Loosen the screws of the EMC cushion brackets and push the cushions apart 6 Remove the cable insulation at the point of entry 6 10 1 If the outer cable screen is non conductive cut open the cable screen in the middle of the stripped area 6 10 1 To turn the conductive side inside out pull the cable screen ends over the cable insulation 6 10 2 Connect the screens ends with...

Page 105: ...ng with the metal enclosure of the cabinet as illustrated For information on removing and install ing the sealing modules see Appendix A Additonal manuals References 6 11 Preparing control cables for sealing modules 6 12 Preparing control cables for cable glands 6 11 Sealing module Conductive foil Cable sheath removed to expose cable shield Conductor screen extension to be connected to PE terminal...

Page 106: ...tor ends as short as possible not longer than 50 mm 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 6 13 3 Do not con nect the shields directly to the encoder adapter 6 13 1 To accommodate encoder cables of different diameters ground clamps 6 ...

Page 107: ...picture below Standard fan units 1 Pull the control and power supply cables through the rear cable entry located in the floor of the fan unit see picture below 2 Route the cables through the fan cable entry on the cabinet roof and connect them to the appropriate terminals inside the cabinet Note The control and power supply cables are already prepared in the factory for connection For information ...

Page 108: ...CHAPTER 6 ELECTRICAL INSTALLATION 108 6 11 1 3 4 2 5 6 1 2 7 7 DTL fan unit Standard fan unit Power supply cable Terminal box Front cable entry Rear cable entry Cable entry on cabinet roof 1 2 3 4 5 6 7 ...

Page 109: ...E01 REV J 6 12 Final checks Check that the entry plates are properly fas tened If EMC entry plates with grommets are used check that the grommets fit tightly arrows to prevent water entering the cabinet If neces sary seal gaps with silicone ...

Page 110: ...Chapter 7 Commissioning 111 Required qualification 111 Commissioning procedure 111 Commissioning check list 112 Customer assistance 112 Customer acceptance ...

Page 111: ...ommissioning procedure and the start conditions for commissioning can be obtained from ABB To contact the ABB service organization see Con tact information 7 3 Commissioning check list In order to ensure uncomplicated and speedy commissioning it is important that drive and associated equipment are ready for commissioning Reviewing and completing the items in the Commissioning check list before the...

Page 112: ...process authorized to operate associated medium and low voltage equipment eg main circuit breaker other low and medium voltage switch gear authorized to operate the driven process for functional tests 7 5 Customer acceptance When commissioning has been completed the commissioning report is signed by the responsible commissioning personnel and by the customer as a sign of acceptance A copy of the r...

Page 113: ...113 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV J ...

Page 114: ...Commissioning check list ...

Page 115: ...ed according to the power cable specification 3 Pulse encoder cable screens connected to screen grounding point and not connected directly to the pulse encoder interface only applicable for drives with pulse encoder interface 4 Cable entry prepared according to the instructions in the user manual 5 All control cable screens and conductors are connected according to the instructions of the user man...

Page 116: ...e of MCB selected as per MCB specification 2 High voltage connections completed 3 MCB ready to be tested with drive 4 MCB protection relay settings tested 5 Safety devices eg door locks tested and in operation 1 Ground connection completed 2 Transformer auxiliaries eg dehydrating breathers cooling protection devices ready 3 Safety devices eg door locks tested and in operation ...

Page 117: ... measured values within the required limits 2 Report of the megger test available If the test is carried out by the commissioning engineer of the drive an additional day per drive motor combination needs to be reserved After the test the feeder cables can be connected except at the drive end The test must comply with the specification 1 Medium voltage available for start up of drive 2 Low voltage ...

Page 118: ...Chapter 8 Operation 119 Operating conditions 120 Safety 121 Overview 122 Overview of local operator panel 124 Status messages 128 Starting the drive 130 Stopping the drive 131 Emergency off ...

Page 119: ...ive substances Sea salt and road salts Salt mist Mean value Max value Sulphur dioxide 0 3 mg m3 1 0 mg m3 Hydrogen sulfide 0 1 mg m3 0 5 mg m3 Chlorine 0 1 mg m3 0 3 mg m3 Hydrogen chloride 0 1 mg m3 0 5 mg m3 Hydrogen fluoride 0 01 mg m3 0 03 mg m3 Ammonia 1 mg m3 3 mg m3 Ozone 0 05 mg m3 0 1 mg m3 Nitrogen oxides 0 5 mg m3 1 0 mg m3 3S2 Mechanically active substances Sand 30 mg m3 Dust suspensio...

Page 120: ...CHAPTER 8 OPERATION 120 8 2 Safety The drive must only be operated by qualified and authorized personnel ie personnel who are familiar with the operation of the drive and the hazards involved ...

Page 121: ...l con trol system is not described in this chapter If the drive is controlled from remote see the appropri ate manuals for information The panel messages and parameter settings used in this chapter are typical examples to illustrate the related instructions and display functions and may therefore differ from the actual messages and parameter settings in the drive ...

Page 122: ...ements for normal operation are met The functions of the operator panel include Connecting disconnecting the main power supply Setting the reference value Starting stopping the drive Displaying Actual values Status messages Alarm and fault messages Viewing setting parameters Resetting alarm and fault messages Activating the emergency off circuit Testing lights and illuminated pushbuttons ...

Page 123: ...and turns the main power supply off the main circuit breaker opens and the DC link discharges 4 Alarm Fault lamp Fault permanent light Alarm flashing light 5 Grounding Switch Unlocked Illuminated pushbutton It lights up if the grounding switch can be released by pushing the Grounding Switch Unlocked pushbutton Keep this pushbutton pressed to turn the grounding switch to the grounded or ungrounded ...

Page 124: ...rol com partment door The status message ReadyOn changes to Charging when the DC link capacitors of the drive are being charged The status message ReadyRun tells the operator that 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 modu late When the drive is in ReadyRef state it is running and operating according...

Page 125: ...y on Ready on Ready run Ready ref On command AFE Ready on DC link charges MCB closes INU starts to modulate Start command Operation AFE Ready ref Ready on conditions Auxiliary power supply on AFE INU door closed and locked Drive not grounded No emergency off No fault Charging Fan switches on ...

Page 126: ...n Ready on Ready ref Off command MCB opens Operation AFE Ready on Stop command Speed ramps down INU stops to modulate Stop command to AFE Actions Auxiliary supply is off AFE INU door released for opening Drive is grounded Stopping DC link discharges Fan switches off after a delay ...

Page 127: ... 4 Emergency off sequence of the drive For the sake of simplicity the flow diagrams of the AFE are omitted in the above diagrams Not ready on Ready ref Operation Emergency off command MCB opens INU stops to modulate Stop command to AFE Speed coasts down ...

Page 128: ...th without inter rupting the operation of the drive However to stop the drive the CDP control panel must be connected to the INU Switching the CDP control panel from the INU to the AFE and back is done with the drive selection mode For further information see 9 8 Drive selection mode 1 Check that the CDP control panel is connected to the INU 2 Enable the local control mode of the CDP con trol pane...

Page 129: ...shed the AFE starts to modulate If the CDP control panel was switched to the AFE you would first see the message Modu lating and then after a short instant the message ReadyRef in the status line of the display When the AFE is in ReadyRef state the state of the INU changes to ReadyRun and the motor can be started 6 Enter the reference value For further information see 9 10 2 Entering a reference v...

Page 130: ...gress the drive can always be restarted by pressing the START key on the CDP control panel Just before the motor comes to a standstill the CDP control panel displays shortly the message Stopping When the drive has stopped modulating the CDP control panel displays ReadyRun As long as the MCB has not been opened the motor can be started again 1 L 600 0 rpm StateINU ReadyRef MOTOR SP 300 00 rpm POWER...

Page 131: ...cuit When an emergency off is initiated during drive operation the following takes place The MCB opens The drive coasts down The DC link of the drive discharges The status line of the CDP control panel alter nates between the message EmergencyOff NotReadyOn The EMERGENCY RESET pushbutton flashes The SUPPLY OFF pushbutton flashes 8 8 3 Starting the drive after an emergency off 1 To start the drive ...

Page 132: ...Overview 134 CDP control panel functions 135 CDP control panel modes 136 Identification mode 137 Actual signals mode 140 Parameters mode 143 Functions mode 145 Drive selection mode 147 Local and remote control 148 Operational commands ...

Page 133: ...ings in the drive 9 1 1 Display and keypad References 9 1 CDP control panel 9 1 Display Keypad Mode selection keys Fast navigation keys select and or change a value fast Slow navigation keys select and or change a value slowly Enter key terminates a procedure Local remote selection key Reset key Reference key Start key Forward key Reverse key Stop key 1 2 3 4 5 6 7 8 9 10 11 12 13 1242 0 rpm 1 L S...

Page 134: ...ol panel can be attached to or detached from the drive without having to switch off the auxiliary power supply first Using the CDP control panel it is possible to enter start up data to control the drive with a reference value and start stop and direction commands to display actual values three values can be read simultaneously to display and adjust parameters to display information on the most re...

Page 135: ...00 AFE 1MVA UM 3BHS297030 ZAB E01 REV J 9 3 CDP control panel modes The CDP control panel provides the following modes Identification mode Actual signals mode Parameters mode Functions mode Drive selection mode ...

Page 136: ...nitialized as described before the display changes as follows After 2 3 seconds information on the drive 1 2 the application software in use 3 and the drive identification 4 is displayed After another few seconds After another few seconds the display changes to the actual signals mode The status line of the dis play alternates between DCGnd NOpen NotReadyOn CDP312 PANEL V5 30 ACS2000 xxxx Device N...

Page 137: ...isplay and reset the fault memory see 9 5 7 Displaying and resetting an active fault When the drive generates a fault or alarm the cor responding message displays immediately Changing from the fault memory mode to other modes is possible without resetting the fault first When no keys is actuated the fault or warning text is displayed as long as the fault is active Control panel overview Status lin...

Page 138: ... function press the ENTER key 4 To select a parameter group press a fast navi gation key 5 To select an actual signal press a slow naviga tion key 6 To confirm the selection and to return to the actual signals mode press the ENTER key 7 To cancel the selection and keep the original selection press any of the mode selection keys The selected CDP control panel mode is entered 1 L 600 0 rpm StateINU ...

Page 139: ...ey 5 To return to the actual signals display press a fast navigation key 9 5 7 Displaying and resetting an active fault 1 To display an active fault press the ACT key 2 To reset the fault press the RESET key 1 L 600 0 rpm StateINU MOTOR SP POWER ReadyOn 0 00 rpm 0 0 kW 1 L 600 0 rpm 1 LAST FAULT PANEL LOST 0707730 12 30 02 3256 1 L 600 0 rpm 2 LAST FAULT AMC Fault Class 1 9 H 38 MIN 48 S 1 L 600 0...

Page 140: ...ta 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 07 Control words 21 01 Start function Group 08 Status words 21 02 Start function Group 09 Fault and alarm words 21 03 Off1 stop mode Group...

Page 141: ...eter value press a slow navigation key for numbers and text a fast navigation key for numbers only 6 To confirm the setting and to return to the actual signals mode 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 77 SYSTEM CONFIG 01 INU IdentifySel INU1 MASTER 2 3 4 1 5 6 7 8 1 2 3 4 ...

Page 142: ...OCK and 16 03 PASSCODE and belong to parameter group 16 SYSTEM CTRL INPUTS Enabling the parameter lock 1 Select parameter 16 02 2 Set parameter 16 02 to 1 LOCKED 3 Confirm the setting and exit the parameters mode Unlocking the parameter lock 1 Select parameter 16 03 2 Set the correct pass code 3 Confirm the setting and exit the parameters mode For further information see Appendix G Signal and para...

Page 143: ...press the FUNC key 2 To select the contrast adjustment function press the slow navigation keys until the blinking cursor reaches the CONTRAST line 3 To enter the contrast setting function press the ENTER key 4 To change the contrast value press a slow navi gation key 5 To confirm the selection and to return to the actual signals display press the ENTER key 1 L 0 0 rpm UPLOAD DOWNLOAD 4 CONTRAST 1 ...

Page 144: ...ng and keep the original set ting press any of the mode selection keys The selected keypad mode is entered 9 7 3 Upload and Download functions The Upload and download functions of the CDP are not supported in ACS2000 1 L 0 0 rpm UPLOAD DOWNLOAD 6 CONTRAST ...

Page 145: ... to the INU 1 To enter the drive mode press the DRIVE key 2 To select the ID number of the AFE and to con nect the CDP control panel to the AFE press any of the slow navigation keys If none of the keys is pressed the display automat ically returns to the actual signals display after a while If the ID number of the AFE or INU is changed by accident eg to 3 and the ENTER key has been pressed the new...

Page 146: ...ressing the LOC REM key arrow when the CDP control panel is con nected to the AFE If the drive is in operation the AFE stops modulat ing and the drive shuts down If the drive is stopped and the CDP control panel is set to LOCAL the drive cannot be started up ...

Page 147: ...RT 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 letter R 9 9 3 Disabling enabling local lock function Accidental switching from remote control to local co...

Page 148: ...ramps down to zero speed and re accelerates in the opposite direction to the preset speed The arrow changes at zero speed 9 10 2 Entering a reference value Entering a reference value from the CDP control panel is possible in Local control mode L Remote control mode R 1 Press a mode selection key 2 To enter the reference value input mode press the REF key 3 To change the reference value press the c...

Page 149: ...149 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV J ...

Page 150: ...ctive maintenance 151 General information 152 Identifying electrical equipment 153 Alarm fault indications 155 Removing the CDP control panel 156 LEDs and switches on printed circuit boards and I O devices 163 Corrective maintenance ...

Page 151: ... with the ABB service organization To contact the ABB service organization see Con tact information 10 1 2 Maintenance schedule Carry out all maintenance tasks according to the maintenance schedule on time and at the stated intervals in the ACS2000 Preventive maintenance schedule 10 1 3 Logbook It is recommended to record all troubleshooting and maintenance work in a logbook including Date and tim...

Page 152: ...l devices are labeled in accor dance with IEC 81346 1 10 2 2 Cables and wires Cables and wires in the drive are equipped with marker sleeves that carry the same identification number as in the wiring diagrams 10 2 3 Understanding wiring diagrams For information on item designation and cross reference conventions see the applicable Wiring diagrams References 10 1 Device identification 10 1 ...

Page 153: ... the drive Alarm An alarm does not shut down the drive If the con dition causing the alarm is not corrected a persist ing alarm can often lead to a fault An alarm cannot be reset manually The alarm message is deleted from the display as soon as the alarm condition has been corrected Fault A fault shuts down the drive The type of shutdown depends on the origin of the fault Depending on the type of ...

Page 154: ... Fault PPCS Communication represents a subsequent fault that occurred 2 min 22 sec later than the first fault 1 Fault AMC Fault Class 2 classifies the fault 10 3 4 Troubleshooting procedure If a fault shuts down the drive proceed as follows 1 Do not switch off the auxiliary power supply or try to reset a fault message before all informa tion at the time of the occurrence of the fault has been save...

Page 155: ... been removed during operation the drive can only be stopped by pressing the emergency off but ton 2 To remove the panel proceed as illustrated Meaning of the LEDs The green LED 4 signals that the control voltage has been switched on Communication with AMC circuit board The CDP control panel 1 is connected to the AMC circuit board of the INU 2 and the AFE 3 via an RS485 Interface For information o...

Page 156: ...atus of the devices and can be used for diagnostic purposes 10 5 1 AMC circuit board References 10 3 AMC34 circuit board 10 3 R P S1 F M T1 S3 S2 T2 S0 LED Color Meaning Status when SW loaded Status when SW 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 O...

Page 157: ...on the module 10 4 3 The factory set value must not be changed For information on IOEC switch settings see Appendix D Wiring diagrams References 10 4 IOEC module 10 4 LED Meaning 1 Status LEDs of digital outputs On when output is energized 2 Link error light On only when there is a problem with the optical fibers 4 Status LEDs of digital inputs On when input is energized 5 Status LED of the 24 V i...

Page 158: ... tool user s manual Modbus RTU NMBA 01 installation and start up guide Profibus NPBA 12 installation and start up guide References 10 5 AF 100 interface 10 5 Table 10 1 AF 100 LED description LED Meaning F Fault Red Module fault Also lights up during module start up Turns off when the self test is successful R Run Green In operation P Power OK Green Internal power OK T1 Traffic 1 Yellow Data traff...

Page 159: ... connector providing an interface for a panel bus that can be used for communication with certain drive types 9 Reset button 1 7 8 8 9 6 5 4 3 2 Table 10 2 NETA 21 LED description LED Color Meaning USB Off No USB mass storage devices attached Green USB mass storage device attached and mounted Blinking green Device attached initialization in progress Yellow Device can be removed Red Unidentified er...

Page 160: ...nterface Blinking yellow Factory level access operation Firmware update in progress Note System status STAT LED blinks during the firmware update PWR Off Power off Green Power on Yellow Timed power off or standby NETA 21 can go to the standby mode as a protective measure eg if the environmental temperature is too high To wake up the NETA 21 press the SD RJ45 button STAT Green System in operation O...

Page 161: ...y error or if the received command has a CRC error or if the received command is not supported by the interface or if the interface has detected an error Table 10 3 Modbus RTU LED description LED Error indication Meaning XMIT REC ERROR On ROM checksum test failed REC ERROR On RAM test failed ERROR On DDCS ASIC register access test failed 1 Bus cable terminals 2 Fiber optic connectors for communica...

Page 162: ...en Off Green Communication established Green Flashing green then green Green Operation Green Green Green Table 10 4 Profibus LED description LED Cause Master MSG DDCS Red Red Off RAM test failure Off Red Red ROM test failure Last valid state Last valid state red DDCS link failure Green Flashing red Flashing green Communication failure Flashing red Red Flashing green Link failure 1 Fiber optic conn...

Page 163: ...are removed from the drive all internal and external covers are securely fastened and all doors are closed locked and or bolted the manual release of the safety switches are in the locked position DANGER Hazardous voltages When a phase module is removed from the cabinet the grounding path between grounding switch and PE ground busbar is interrupted For this reason connect grounding equipment at th...

Page 164: ... on continue with Grounding If the yellow lamp is not on continue with 10 6 4 Grounding switch is not released Grounding 7 If the yellow lamp GROUNDING SWITCH UNLOCKED is on turn the grounding switch to the grounded position When the grounding switch is in the grounded position the CDP control panel shows the fol lowing 8 If necessary open the doors of medium voltage compartments To open the AFE I...

Page 165: ...rcuit breaker open is present at digital input DI09 of I O module A3411 4 Check if the LED of digital output DO03 I O module A3401 is lit If the LED is lit the grounding switch is released 5 Check the discharging level of the DC link If the value of parameter 2 01 DC VOLTAGE is below 50 V the DC link is discharged If the DC link is discharged the message ReadyOn is displayed on the CDP control pan...

Page 166: ... 2 Use the telescopic insulating pole to connect the busbar ground clamps 10 9 3 to the ground ball studs of the busbars and to tighten each connection Connect the inner most busbar first 10 10 3 then the middle busbar 10 10 4 and then the outer busbar 10 10 5 References 10 9 Four way grounding set 10 9 1 Telescopic insulating pole 2 Enclosure ground clamp 3 Busbar ground clamps 3 3 3 2 1 ...

Page 167: ...167 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV J The drive is now dead and safe access is possible 10 10 1 2 5 4 3 References 10 10 Connecting a grounding set ...

Page 168: ...cked If the auxiliary voltage is switched off and the door is locked and cannot be opened check the position of the release dial of the door safety switch If the release dial is in the locked position unlock the safety switch as described in the following section Safety switch settings 1 Release dial 2 Unlocked position The unlocked position enables opening the AFE INU compartment door whether the...

Page 169: ...n circuit boards with special care To pre vent the components being damaged use anti static 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 and busbars with water and oil absorbing microfibers such as 3M Scotch Brite Use a nylon ...

Page 170: ... a vacuum cleaner Perform this operation away from the drive to prevent dust from entering NOTICE Capaci torbushi ngs ar e dam aged w hen excessi ve f or ce i s appl i ed Do notexceed the m axi m um ti ghteni ng tor que The ti ghteni ng tor que val ue i s pri nted on a l abel w hi ch i s attached to the capaci tor I fnotspeci fi ed the m axi m um ti ghteni ng tor que m ustnotexceed 20 Nm For infor...

Page 171: ...he module tray can be order as a standard option The rest of the tools are not included in the scope of supply 10 13 INU phase module 1 INU phase module 2 INU phase module 3 AFE phase module 1 AFE phase module 2 AFE phase module 3 10 14 W width L length H height Weight 490 mm 650 mm 250 mm 35 kg L H W References 10 13 Phase modules location 10 14 Phase module Dimensions and weight 10 13 mm 225 mm ...

Page 172: ...e 4 Slide the module rails under the phase module 5 Holding the phase module at the handles pull it out carefully DANGER Hazardous voltages When a phase module is removed from the cabinet the grounding path between grounding switch and PE ground busbar is interrupted For this reason connect grounding equipment at the appropriate locations The grounding equipment ensures that hazardous voltages can...

Page 173: ...ase module 1 2 Pull down the end of the chain a little 3 and then pull it into the direction of the arrow 4 to disengage the chain from the mounting bracket 8 Lift the phase module off the rails Attention Due to the weight it is recom mended that two persons one on each side lift the phase module off the rails Furthermore make appropriate arrangements for removing one of the upper phase modules 9 ...

Page 174: ...ct all power supplies to the drive and ground the drive For further information see 10 6 3 De energiz ing the drive locally To isolate the fan unit from the auxiliary power supply switch off the motor starter of the fan unit 2 Continue with Standard fan units or DTL fan units as applicable Standard fan units 3 Remove the cover from the fan housing 4 Disconnect the control and power supply cables o...

Page 175: ...1 Lift off the cover and the fan attached to it 12 Disconnect the cable at the exit of the terminal box unscrew the locknut of the cable gland unscrew the cover from the fan 13 Replace the fan and re assemble in reverse order of removal Disconnect here ...

Page 176: ......

Page 177: ...hird parties nor used for any unauthorized purpose without written permission from ABB Sp z o o Medium Voltage Drives The hardware and software described in this manual is provided under a license and may be used copied or disclosed only in accordance with the terms of such license ABB Sp z o o Placydowska 27 95 070 Aleksandrow Lodzki Poland Phone 1 479 648 5912 E Mail drivessupport abb com www ab...

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