Abb ACS1000 Manuals

Table of Contents

3

About this Manual

12

Equipment Covered by this Manual

12

Structure of the User Documentation

12

Terms and Abbreviations

13

Related Documents

15

Maintenance

15

Technical Data

15

Schematics

15

Specifications and Guidelines

15

Serial Communication Interfaces

15

Encoder

15

Target Groups and Required Qualification

16

Handling

16

Mechanical Installation

16

Electrical Installation

16

Operation

16

Maintenance

16

User's Responsibilities

17

Intended Use of Equipment

17

Quality Certificates and Applicable Standards

18

Table 1 Standards

18

Items Covered by Delivery

19

Fig. 1. Delivered Items

19

Identifying the Delivery

20

Document Conventions

20

Important Safety Information

21

Safety Messages and Safety Signs in this Document

21

Safety Messages

21

Safety Signs

21

Product Safety Labels

22

Electrical Safety

22

General Safety Instructions

22

Fig. 2. Product Warning Label Examples (Label Placement Depends on the Drive)

22

The Seven Steps that Save Lives

23

Possible Residual Risks

25

Main Circuit Breaker Protection Device

26

Fig. 3. Drive System Overview

26

Safety and Protection Requirements

27

Minimum Requirements for MCB and MCB Control

27

Maintenance Recommendation

28

Fig. 4. MCB Opening Timing Diagram

28

Power Electronics and Cabinet Features

29

Overview

29

Fig. 5. ACS1000 Air-Cooled

29

Drive Topology

30

Fig. 6. Block Diagrams of an ACS1000A with a (A) 12-Pulse Rectifier and a Drive with a (B) 24-Pulse Rectifier

30

Power Supply Configurations

31

Main Power Supply Configurations

31

Fig. 7. Drive Overview with Power Supplies

31

Auxiliary Power Supply Configurations

32

Drive Topology

33

Overview

33

Control Compartment and Terminal Compartment

33

Fig. 8. ACS1000 Air-Cooled Topology

33

Fig. 9. Control and Terminal Compartments

34

Rectifier and Inverter Compartment

35

Fig. 10. Rectifier Compartment

35

Grounding Switch

36

Rectifier

36

Protection Igcts

36

Fig. 11. Grounding Switch

36

Inverter

37

Filter

37

Fig. 12. Three-Level Voltage Source Inverter Principle

37

Fig. 13. Voltage and Current Waveforms at Drive Output

37

Optional Braking Chopper

38

Fig. 14. ACS1000A with Braking Chopper (1)

38

Fig. 15. Principle Diagram

38

Fig. 16. Braking Chopper Design

39

Table 2 Braking Ratings

40

Cooling System

41

Fan Configurations

41

Type of Fan

41

Starting, Stopping the Cooling System

41

AC Redundant Fans - Operating Principles

42

Fig. 17. Operating Times of the AC Fan Units During Continuous (A) Drive Operation and (B) Intermittent Drive Operation

42

EC Redundant Fans - Operating Principles

43

Fig. 18. Operating Principles of Redundant EC Fans

43

Air Flow Overview (AC and EC Fans)

44

Fig. 19. Air Flow: (1) Non-Redundant Fan Configuration

44

Fig. 20. Air Flow: Redundant Fan Configuration

44

Monitoring the Air Pressure

45

Adjustable Parameters

45

Fig. 21. Air Pressure Switches

45

Cabinet Design

46

Door Locking System

46

Fig. 22. Door Locks

46

Optional Cabinets

47

Arc Resistant Design (Optional)

47

Internal Arc Classification (IAC)

47

Associated Protection Requirement

47

Fig. 23. IAC Label Example

47

Table 3 ABB Arc Resistant Classes

47

Space Heaters

48

Fig. 24. Space Heaters

48

Control System

49

Overview

49

Fig. 25. Block Diagram of Control System with (A) Customer Interface, (B) Control System, and (C) Power Electronics

49

Main Components

50

Fig. 26. Control Compartment

50

Local Control Panel

51

Fig. 27. Control Compartment - I/O Devices

51

AMC Circuit Board

52

Fig. 28. AMC Circuit Board

52

Fig. 29. Direct Torque Control

53

Fig. 30. PID Control Mode

55

I/O Interfaces

56

IOEC I/O Modules

56

Fig. 31. IOEC Interfaces Overview

56

Table 4 IOEC Module Configuration - Analog Inputs

57

Table 5 IOEC Module Configuration - Analog Outputs

57

Table 6 IOEC Module Configuration - Digital Inputs

57

Table 8 24 V Internal Voltage Supply

58

Table 7 IOEC Module Configuration - Digital Inputs

58

Fig. 32. IOEC Module

59

Fig. 33. IOEC Module Identification

60

Table 9 IOEC Module Identification

60

Serial Communication Interface (Fieldbus)

61

Pulse Encoder Interface NTAC (Option)

61

Fig. 34. NTAC-02 Pulse Encoder Interface

61

Transportation, Storage and Disposal

62

Safety

62

Transport Conditions

62

Unpacking and Inspection

62

Lifting and Transportation

63

Lifting Attachment Types

64

Fig. 35. Lifting Attachment Types

64

Lifting with the Top Lifting Rails

65

Fig. 36. Top Lifting Rails with (1) Recommended Lifting Points

65

Fig. 37. Mounting Bolts and Washers for Top Rail

66

Lifting with Rotating Eyebolts (Redundant Fan Unit)

67

Reinstalling Lifting Attachments

67

Table 10 Lifting Attachment Specifications

67

Sling Configuration for Top Lifting Rails

68

Storage

68

Storage Conditions

68

Storing the Drive

68

Fig. 38. Sling Configuration - Standard Case with Top Lifting Rails

68

Storage and Handling of Spare Parts

70

Disposal of Packaging Materials and Components

70

Mechanical Installation

71

Safety

71

Overview of Installation Work

71

General Notes on Installation

71

Dimensions and Clearances

71

Cabinet Roof

71

Fire Protection

71

Cable Duct Material

71

Preparing the Floor

72

Fixing the Cabinet to the Floor

72

Fig. 39. Leveling the Drive

72

Assembling and Installing the Air Exhaust Hood

73

Fig. 40. Fixing the Cabinet to the Floor

73

Fig. 41. Assembling and Installing the Air Exhaust Hood

73

Installing the Redundant Fan Unit

74

Fig. 42. Redundant Fan Unit - Removing Lifting Rails (1) and Fan Access

74

Fig. 43. Redundant Fan Unit - Installation

75

76

77

Electrical Installation

78

Safety

78

Overview of Installation Work

78

Cable Requirements

78

Additional Cable Requirements for a UL Certified Drive

78

Cable Entries

79

Cable Entry with EMC Plates

79

Fig. 46. EMC Plate Example

79

Fig. 47. EMC Cushion

79

Cable Entry with Type 1 Sealing Modules

80

Cable Entry with Type 2 Sealing Modules

80

Fig. 48. Type 1 Sealing Modules (Example)

80

Fig. 49. Type 2 Sealing Modules Example

80

Cable Entry with Cable Glands

81

Power Cables, Ground Cables and Equipotential Bonding Conductor

81

Preparing the Cable Entry and the Cables

81

Fig. 50. Cable Entry with Cable Glands

81

Fig. 51. Cable Termination Bar (A) Top and (B) Bottom Cable Entry; Busbar Thickness Is 5 MM

82

Table 11 Maximum Number of Cables Per Phase

82

Fig. 52. Preparing Cables for EMC Plates: (A) Cables with an Outer Screen or Shield, (B) Cables Without an Outer Screen or Shield

85

Fig. 53. Preparing Power Cables for Sealing Modules

86

Fig. 54. Preparing Power Cables for Cable Glands

87

Connecting the Cables

88

Fig. 55. Power Cable Terminals in (a and C) 12-Pulse ACS1000A and (B and D) 24-Pulse ACS1000A

89

Minimum Creepage Distance between Cable and Busbar

90

Fig. 56. Grounding the Drive System

90

Table 12 Minimum Creepage Distance between Cable and Busbar

90

Bolted Connections

91

Fig. 57. Bolted Busbar Connections

91

Auxiliary Power, Control and Serial Communication Cables

92

Preparing the Cable Entry and the Cables

92

Fig. 58. Cable Entry from (A) Top and from (B) Bottom

92

Fig. 59. Frame with Sealing Modules

94

Fig. 60. Preparing Control Cables for Sealing Modules

95

Fig. 61. Preparing Control Cables for Cable Glands

95

Connecting the Cables

96

Fig. 62. Shield Grounding Point for Encoder Cable

96

Power Supply Cable for Redundant Fan Unit

97

Fig. 63. Routing, Connecting the Cable of the Redundant Fan Unit

97

Final Checks

98

Commissioning

99

Overview

99

Required Qualification

99

Commissioning Procedure

99

Commissioning Checklist

99

Customer Assistance

99

Customer Acceptance

99

Commissioning Checklists

100

Mechanical Installation Checklist

100

Electrical Installation Checklist

100

Main Circuit Breaker (MCB) Checklist

100

Input Transformer Checklist

101

Motor Checklist

101

Insulation Tests Checklist

101

Power Supply Checklist

101

Miscellaneous Checklist

101

Operation

102

Safety

102

Overview

102

Operating Conditions

102

Sound Pressure Level

102

Local Operator Panel

103

Fig. 64. Local Operator Panel

103

Status Messages

104

Start Sequence of the Drive

105

Stop Sequence of the Drive

106

Emergency off Sequence of the Drive

107

Starting the Drive

107

Checks before Starting the Drive

107

Starting the Drive Remotely

107

Starting the Drive Locally

108

Stopping the Drive

109

Emergency-Off

111

Initiating an Emergency-Off

111

Starting the Drive after an Emergency-Off

112

CDP Control Panel

113

Overview

113

Fig. 65. CDP Control Panel

113

CDP Control Panel Functions

114

CDP Control Panel Modes

114

Identification Mode

114

Actual Signals Mode

115

Fig. 66. Control Panel - Actual Signals Mode

117

Parameters Mode

122

Table 13 Parameter Groups

122

Fig. 67. Control Panel - Parameters Mode

124

Functions Mode

128

Fig. 68. Control Panel - Functions Mode

128

Local and Remote Control

131

Local Control

131

Remote Control

132

Operational Commands

133

Setting the Direction of Rotation

133

Entering a Reference Value

134

Preventive and Corrective Maintenance

136

General Information

136

Required Qualification

136

Maintenance Schedule

136

Logbook

136

Spare Parts

136

Identifying Electrical Equipment

137

Device Identification

137

Cables and Wires

137

Understanding Wiring Diagrams

137

Fig. 69. Device Identification

137

Alarm / Fault Indications

138

Messages

138

Error Message Levels

138

Fault Handling

138

Standard Troubleshooting Procedure

139

Removing the CDP Control Panel

140

Leds and Switches on Circuit Boards

141

AMC Circuit Board

141

Fig. 70. AMC Circuit Board

141

IOEC I/O Modules

142

Fig. 71. IOEC Module

142

Corrective Maintenance

143

Safety

143

Energizing the Drive Locally

145

Grounding

146

Grounding Switch Is Not Released

147

Fig. 72. Location of I/O Modules and Fuses

147

Checking the Release Conditions for the Grounding Switch

148

Visual Checks on the Drive

149

Cleaning the Drive

149

Checking Wire and Cable Connections

150

Cleaning and Replacing Filter Mats

150

Table 14 Filter Mat Specifications

150

Fig. 73. Filter Panel (1) and Filter Mat (2) on Rectifier and Inverter Compartment

152

Inspecting and Replacing Batteries

153

Fig. 74. Control Compartment - Battery Location

153

Fig. 75. Control Compartment - Replacing the Batteries

154

Replacing the Non-Redundant Fan

155

Fig. 76. Fan Location, Dimensions and Weight

155

Fig. 77. Fan - Tools and Devices

155

Fig. 78. Replacing the Non-Redundant Fan

156

Fig. 79. Installing the Non-Redundant Fan

157

Replacing a Redundant Fan

158

Fig. 80. Redundant Fans - Location, Dimensions, and Weight

158

Fig. 81. Redundant Fans - Tools and Devices

159

Fig. 82. Redundant Fan Unit - Removing the Panels

160

Fig. 83. Redundant Fan Unit - Unplugging the Power Supply Cable

160

Cover (2)

161

Fig. 84. Redundant Fan Unit - Removing the Fixing Bolts

161

Fig. 85. Redundant Fan Unit - Using a Crane

162

Fig. 86. Redundant Fan Unit - Using a Platform

162

ABB ACS1000 Manuals

ABB ACS1000 User Manual (164 pages)

Table of Contents

ABB ACS1000 User Manual (166 pages)

Table of Contents

ABB ACS1000 User Manual (186 pages)

Table of Contents

02 Important Safety Information

03 Power Electronics and Cabinet Features

Overview

Drive Topology

Power Supply Configurations

Drive Topology

Cooling System

Cabinet Design

Door Locking System

Arc Resistant Design (Optional)

Space Heaters

04 Control System

Overview

Main Components

I/O Interfaces

05 Transportation, Storage and Disposal

Safety

Transport Conditions

Unpacking and Inspection

Lifting and Transportation

Storage

Disposal of Packaging Materials and Components

07 Electrical Installation

Cable Entries

Cable Requirements

Safety

Overview of Installation Work

Power Cables, Ground Cables and Equipotential Bonding Conductor

Auxiliary Power, Control and Serial Communication Cables

Power Supply Cable for Redundant Fan Unit

Final Checks

08 Commissioning

Overview

Commissioning Checklist

09 Operation

10 CDP Control Panel

Overview

CDP Control Panel Modes

CDP Control Panel Functions

Local and Remote Control

Operational Commands

11 Preventive and Corrective

General Information

Identifying Electrical Equipment

Alarm / Fault Indications

Removing the CDP Control Panel

Leds and Switches on Circuit Boards

Corrective Maintenance

Related Products

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