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ABB ACS1000 User Manual

ABB ACS1000
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01 ABOUT THIS MANUAL
3BHS213401 E01 REV H ACS1000 AIR-COOLED USER MANUAL 8/184
1.6 Related documentation
Table 1-1: Maintenance
Table 1-2: Technical data
Table 1-3: Schematics
Table 1-4: Specifications and guidelines
Table 1-5: Serial communication interfaces
Table 1-6: Encoder
Reference
number
Document Document number
[1] ACS1000 preventive maintenance schedule 3BHS855276 E01
Reference
number
Document Document number
[2] Technical data from DriveSmart
(1)
(configuration software for medium
voltage drives)
(1) Configuration software for 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] Main transformer specification 3BHS356582 E01
[7] Induction motor specification 3BHS260163 E01
[8] Power cable specification 3BHS189994 E01
[9] Power cables engineering guideline 3BHS542290 E01
[10] Auxiliary power and control cables guideline 3BHS813742 E01
Reference
number
Document Document number
[11] Ethernet - NETA-21 remote monitoring tool user manual 3AUA0000096939
[12] Modbus - NMBA-01 installation and start-up guide 3AFY58919772
[13] Profibus - NPBA-12 installation and start-up guide 3BFE64341588
[14] DeviceNet - NDNA-02 installation and start-up guide 3AFY58919829
Reference
number
Document Document number
[15] Installation and Start-up Guide for the Pulse Encoder Module NTAC-0x 3AFY58919730

Table of Contents

Questions and Answers:

ABB ACS1000 Specifications

General IconGeneral
TypeMedium Voltage AC Drive
Power Range315 kW to 5000 kW
EfficiencyUp to 98%
Output Voltage0 to Input Voltage
CoolingAir or water-cooled
EnclosureIP54
Communication ProtocolsModbus, Profibus, Ethernet/IP

Summary

About this manual

Copyright Notice

The information in this manual is subject to change without notice.

Equipment Covered

This manual covers a standard drive and provides generic information on the drive.

User Documentation Structure

The complete set of user documentation of a standard drive consists of this manual and supplementary documentation.

Terms and Abbreviations

Lists terms and abbreviations to be familiar with when using this user manual.

Trademarks

Names believed to be trademarks of other companies and organizations.

Related Documentation

Lists related documents such as maintenance schedules and technical data sheets.

Target Groups and Qualifications

Defines target audience and required qualifications for handling the drive.

User Responsibilities

Ensures personnel are trained and understand manual instructions and safety.

Intended Use of Equipment

Specifies that the drive must be used only as specified and under stipulated conditions.

Cyber Security Disclaimer

Customer's responsibility to ensure secure network connection and data protection.

Quality Certificates and Standards

Lists available ISO, EC conformity, and compliance standards for the drive.

Items Covered by Delivery

Lists typical items included in the drive delivery package.

Identifying the Delivery

Explains identification of drive and accessories via type code on the rating label.

Important Safety Information

Overview

Read this material before working on or around the equipment.

Safety Messages

Provides hazard level indicators (DANGER, WARNING, CAUTION) for injury prevention.

Damage Prevention

Uses NOTICE for practices not related to physical injury but causing equipment damage.

Product Safety Labels

Describes safety labels affixed to components to alert personnel of potential hazards.

General Safety Instructions

Provides instructions on minimizing hazards, before energizing, working on, and simultaneously working.

7 Steps to Save Lives

Series of actions for safe working on electrical installations, including risk assessment and isolation.

Possible Residual Risks

Identifies risks like electromagnetic fields, unintentional movement, touch voltages, and emissions.

Main Circuit Breaker Note

Details the MCB's role as a protection device and its critical function in drive safety.

Power Electronics and Cabinet Features

Overview

Describes the ACS1000 as a general-purpose frequency converter for induction motors.

Drive Topology Overview

Explains the block diagrams of ACS1000 with 12-pulse and 24-pulse rectifiers.

Power Supply Configurations

Details the two independent power supplies required for drive operation.

Drive System Components

Introduces main components of the drive system like MCB, Transformer, Drive, and Motor.

Cooling System

Covers fan configurations, types, and operational principles for cooling the drive.

Cabinet Design

Describes the riveted and folded cabinet construction for strength and EMC protection.

Door Locking System

Ensures safety by making all doors lockable, with electro-mechanical security for medium voltage compartments.

Arc Resistant Design (Optional)

Provides optional arc fault protection in accordance with IEC 62477-2.

Space Heaters

Optional heaters protect the cabinet from condensation by switching on when cooling is off.

Control System

Overview

Details hardware in the control compartment for control, monitoring, and protection functions.

Main Components

Provides an overview of main hardware components of the control system and their interconnection.

I/O Interfaces

Explains how analog and binary I/O signals connect to the control system via IOEC modules.

Serial Communication Interface (Fieldbus)

Identifies serial communication interfaces for data transfer to higher-level control systems.

Pulse Encoder Interface NTAC (Option)

Part of the control system for pulse encoder feedback used to control the motor.

Transportation, Storage and Disposal

Safety

The drive must only be handled by skilled and experienced personnel in unpacking and transporting.

Transport Conditions

Based on IEC 60721-3-2 classification for environmental conditions during transport.

Unpacking and Inspection

Steps for removing packaging, checking for damages, and comparing delivery with purchase order.

Lifting and Transportation

Provides information on lifting and transporting the cabinet, referencing mechanical drawings.

Storage

Details minimum requirements for storage conditions, including conditions and storage time.

Disposal of Packaging Materials and Components

Instructs to dispose of materials and components according to local regulations.

Mechanical Installation

Safety

All installation work must be carried out by qualified personnel according to site and local regulations.

Overview of Installation Work

Lists the steps involved in the installation process.

General Notes on Installation

Provides notices on preventing component damage from foreign matter and dust.

Preparing the Floor

Specifies floor conditions: support weight, evenness, non-flammable, smooth, non-abrasive.

Fixing the Cabinet to the Floor

Details drilling holes, checking alignment, and using anchor bolts for floor fixing.

Assembling and Installing the Air Exhaust Hood

Provides instructions for assembling and installing the air exhaust hood for drives with internal fans.

Installing the Redundant Fan Unit

Guides the installation of the redundant fan unit, including removing lifting rails and covers.

Electrical Installation

Safety

Warns about hazardous voltage and emphasizes qualified personnel and proper procedures.

Overview of Installation Work

Includes wire and cable connections for power, ground, auxiliary, control, and serial communication cables.

Cable Requirements

Refers to specifications and guidelines for power, ground, auxiliary, and control cables.

Cable Entries

Describes options for cable entry through roof or floor using EMC plates, sealing modules, or glands.

Power Cables, Ground Cables and Equipotential Bonding Conductor

Details preparing cable entry, determining cable length, and splitting multi-core cables.

Auxiliary Power, Control and Serial Communication Cables

Explains preparing cable entry and connecting these types of cables.

Power Supply Cable for Redundant Fan Unit

Guides routing and connecting the power supply cable for the optional redundant fan.

Final Checks

Ensures entry plates are fastened and grommets fit tightly to prevent water entry.

Commissioning

Overview

Provides an overview of the commissioning process for the drive.

Required Qualification

States that commissioning must be done by ABB-certified personnel only.

Commissioning Procedure

Information on commissioning procedure and start conditions can be obtained from ABB.

Commissioning Checklist

A checklist to prepare the drive and associated equipment for commissioning.

Customer Assistance

Requests qualified personnel for assistance during commissioning.

Customer Acceptance

Describes signing the commissioning report and receiving settings as acceptance.

Mechanical Installation Checklist

Checklist for verifying mechanical installation requirements before commissioning.

Electrical Installation Checklist

Checklist for verifying electrical installation requirements before commissioning.

Main Circuit Breaker (MCB) Checklist

Checks for MCB selection, connections, relay settings, and safety devices.

Input Transformer Checklist

Checks for ground connection, transformer auxiliaries, and safety devices.

Motor Checklist

Checks for motor installation, alignment, ground connection, auxiliaries, and signals.

Insulation Tests Checklist

Ensures power cables are tested for insulation resistance within required limits.

Power Supply Checklist

Verifies availability of medium voltage and low voltage auxiliary power for start-up.

Miscellaneous Checklist

Checks spare parts availability, drive room air conditioning, and optional equipment.

Operation

Safety

Drive must be operated only by qualified and authorized personnel familiar with hazards.

Overview

Outlines the local operation of the drive, excluding remote control via PLC.

Operating Conditions

Specifies operating conditions according to IEC 60721-3-3 for stationary use.

Sound Pressure Level

Provides sound pressure levels for single and redundant fans.

Overview of Local Operator Panel

Describes the operator panel functions for controlling the drive locally.

Status Messages

Lists messages for drive states like operation, stop, and fault conditions.

Start Sequence of the Drive

Details the sequence of events from NotReadyOn to Operation state.

Stop Sequence of the Drive

Describes the sequence from Operation to NotReadyOn state upon receiving a stop command.

Emergency-Off Sequence of the Drive

Outlines the sequence when an emergency-off command is initiated.

Starting the Drive

Recommends documents and provides a checklist for starting the drive locally.

Stopping the Drive

Instructs to press the STOP key on the CDP control panel to stop the motor.

Emergency-Off

Explains the hard-wired emergency-off circuit and its operation.

Starting the Drive After an Emergency-Off

Steps to unlatch the pushbutton and reset the safety relay to restart the drive.

CDP Control Panel

Overview

Explains that panel messages and settings are typical examples for illustrating instructions.

CDP Control Panel Functions

Lists tasks performable with the panel: data entry, control, display, parameter adjustment.

CDP Control Panel Modes

Introduces modes like Identification, Actual Signals, Parameters, and Functions.

Identification Mode

Informs about panel version and drive ID number when power is switched on.

Actual Signals Mode

Allows monitoring the drive by displaying three selectable actual values.

Parameters Mode

Allows entering parameter settings for drive configuration, organized in groups.

Functions Mode

Used to set the display contrast by adjusting the contrast value.

Local and Remote Control

Enables selecting control location (local or remote) via the LOC-REM key.

Operational Commands

Covers starting, stopping, and setting direction of rotation from the CDP control panel.

Preventive and Corrective Maintenance

General Information

Specifies that maintenance during warranty must be by ABB personnel.

Identifying Electrical Equipment

Describes identification of devices, cables, and wires using labels and diagrams.

Alarm / Fault Indications

Explains how the CDP panel displays alarms and faults, and the meaning of error levels.

Standard Troubleshooting Procedure

Steps to follow when a fault occurs, including saving data and contacting ABB service.

Removing the CDP Control Panel

Provides instructions for removing the control panel, with safety precautions during operation.

LEDs and Switches on Circuit Boards

Explains the meaning of LEDs and switches on AMC circuit board and IOEC modules.

Corrective Maintenance

Overview of maintenance tasks like visual checks, cleaning, and replacing components.

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