Page 1 — SYSTEM DRIVES ACS1000 air-cooled User manual OWNING ORGANIZATION DATE STATUS SECURITY LEVEL System Drives, ABB Switzerland Ltd. 2023-09-13 Approved Public DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE User manual 3BHS213401 E01 1/164 © Copyright 2011 ABB All rights reserved.
Page 2 This document contains information about one or more ABB products and may include a description of or a reference to one or more standards that are relevant to the ABB products. The presence of any such description of a standard or reference to a standard is not a representation that all of the ABB products referenced in this document include all the features of the described or referenced standard.
Page 3: Table Of Contents
CONTENTS — CONTENTS 1. About this manual......................... 12 1.1. Equipment covered by this manual ..................... 12 1.2. Structure of the user documentation ..................12 1.3. Terms and abbreviations........................ 13 1.4. Related documents ........................15 1.4.1. Maintenance ..........................15 1.4.2. Technical data ........................15 1.4.3.
Page 4 CONTENTS 3.4.5. Rectifier..........................36 3.4.6. Protection IGCTs........................36 3.4.7. Inverter ............................37 3.4.8. Filter............................37 3.4.9. Optional Braking Chopper ....................38 3.5. Cooling system..........................41 3.5.1. Fan configurations.......................41 3.5.2. Type of fan ..........................41 3.5.3. Starting, stopping the cooling system................41 3.5.4. AC redundant fans - operating principles..............42 3.5.5.
Page 5 CONTENTS 6.3.2. Cabinet roof........................... 71 6.3.3. Fire protection ........................71 6.3.4. Cable duct material ......................71 6.4. Preparing the floor...........................72 6.5. Fixing the cabinet to the floor ......................72 6.6. Assembling and installing the air exhaust hood ..............73 6.7. Installing the redundant fan unit....................74 7.
Page 6 CONTENTS 9.6.1. Start sequence of the drive .....................105 9.6.2. Stop sequence of the drive..................... 106 9.6.3. Emergency off sequence of the drive ................107 9.7. Starting the drive..........................107 9.7.1. Checks before starting the drive..................107 9.7.2. Starting the drive remotely....................107 9.7.3.
Page 7 CONTENTS 11.6.7. Cleaning the drive ......................149 11.6.8. Checking wire and cable connections ................. 150 11.6.9. Cleaning and replacing filter mats................150 11.6.10. Inspecting and replacing batteries ................153 11.6.11. Replacing the non-redundant fan ..................155 11.6.12. Replacing a redundant fan....................158 PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 8 Block diagrams of an ACS1000A with a (A) 12-pulse rectifier and a drive with a (B) 24-pulse rectifier ................ 30 Fig. 7. Drive overview with power supplies ..............31 Fig. 8. ACS1000 air-cooled topology ................33 Fig. 9. Control and terminal compartments ..............34 Fig. 10. Rectifier compartment ..................35 Fig.
Page 9 FIGURES Fig. 36. Top lifting rails with (1) recommended lifting points ........65 Fig. 37. Mounting bolts and washers for top rail ............66 Fig. 38. Sling configuration - standard case with top lifting rails ........ 68 Fig. 39. Leveling the drive ....................72 Fig.
Page 10 FIGURES Fig. 72. Location of I/O modules and fuses ..............147 Fig. 73. Filter panel (1) and filter mat (2) on rectifier and inverter compartment ......................152 Fig. 74. Control compartment – battery location ............153 Fig. 75. Control compartment - replacing the batteries ..........154 Fig.
Page 11 TABLES Table 1 Standards ............................18 Table 2 Braking ratings..........................40 Table 3 ABB arc resistant classes.......................47 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......................
Page 12: About This Manual
(eg, layout drawings, wiring diagrams, technical data, engineering notes). If information is required beyond the instructions in this manual, refer the matter to ABB. 1.2. Structure of the user documentation The documentation for a standard drive consists of this document and the following project- specific appendices.
Page 13: Terms And Abbreviations
1.3. Terms and abbreviations The following table lists terms and abbreviations you should be familiar with when using this user manual. Some of the terms and abbreviations used in this user manual are unique to ABB and might differ from the normal usage.
Page 14 ABOUT THIS MANUAL Term/Abbreviation Definition Molykote Brand name for lubricants Monitoring and diagnostics tool that allows access to the drive from any NETA-21 location in the world via a secure Internet connection. Printed circuit board Point of common coupling The PCC is the point in the electrical power supply system where the responsibility of the utility changes to the industrial customer.
Page 15: Related Documents
ABOUT THIS MANUAL 1.4. Related documents 1.4.1. Maintenance Title Document number ACS1000A preventive maintenance schedule 3BHS855276 E01 1.4.2. Technical data Title Document number Technical data from DriveSmart (configuration software for medium voltage drives) Configuration software for medium voltage drives 1.4.3. Schematics Title Document number Layout drawing...
Page 16: Target Groups And Required Qualification
IMPORTANT! Commissioning of the drive must only be performed by qualified and certified ABB personnel. 1.5.1. Handling The personnel must be skilled and experienced in unpacking and transporting heavy equipment.
Page 17: User's Responsibilities
ABB. Use of the drive outside the scope of the specifications is not permitted.
Page 18: Quality Certificates And Applicable Standards
1.8. Quality certificates and applicable standards The following certificates and conformity declarations are available with ABB: – ISO 9001 and ISO 14001 certificates stating that ABB Switzerland Ltd has implemented and maintains a management system which fulfills the requirements of the normative standards –...
Page 19: Items Covered By Delivery
ABOUT THIS MANUAL 1.9. Items covered by delivery Delivery typically comprises the following items: – Drive that is shipped in sea freight or airfreight packaging. – Optional components and cabinets – Set of door keys attached to lifting rail (1 in Fig. 1) –...
Page 20: Identifying The Delivery
ABOUT THIS MANUAL 1.10. 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. 1.11.
Page 21: Important Safety Information
IMPORTANT SAFETY INFORMATION 2. Important safety information Read this material carefully before working on or around the equipment. Failure to do so can result in serious Injury or DEATH! Keep for future reference. 2.1. Safety messages and safety signs in this document This document uses ANSI Z535.6 signal words, ISO 7010 safety signs, and ISO 3864-2 colors to highlight safety-related information.
Page 22: Product Safety Labels
IMPORTANT SAFETY INFORMATION 2.2. Product safety labels Product safety labels on the equipment alert you to the hazards that can occur when you work on or operate the equipment. – Always follow the instructions on the labels to avoid the hazard –...
Page 23: The Seven Steps That Save Lives
Only allow firefighters with the appropriate PPE to enter the drive room 2.3.2. The seven steps that save lives ABB’s seven steps that save lives concept is a series of actions that must take place prior to commencing work on or near electrical installations.
Page 24 IMPORTANT SAFETY INFORMATION • The Person in Charge of Work (PICW) must ensure that switching is performed in the proper manner by witnessing it from a safe distance if present on site or by engaging the person responsible for switching to identify all isolation points. •...
Page 25: Possible Residual Risks
IMPORTANT SAFETY INFORMATION 2.3.3. Possible residual risks Residual risks must be considered by the drive system integrator and/or plant owner when assessing the hazards of the equipment to personnel. The following risks can pose a hazard to drive system personnel –...
Page 26: Main Circuit Breaker Protection Device
IMPORTANT SAFETY INFORMATION 2.4. Main circuit breaker protection device The main circuit breaker (MCB) is a major protection device of the drive. If a serious fault occurs in the drive, the MCB must disconnect the main power supply to the drive immediately. The main power supply must be disconnected without delay on an open or trip command from the drive to prevent hazard to the personnel and further damage to the equipment.
Page 27: Safety And Protection Requirements
For safety and protection reasons, the MCB must meet the stipulated minimum requirements of the specifications of ABB MV Drives. It is the system integrator's responsibility to ensure that the minimum requirements are met. The minimum requirements for the MCB are stated in this note and in the respective MCB specifications, which are available for each medium voltage drive from ABB.
Page 28: Maintenance Recommendation
No hazard to personnel Maximum protection trip time Maximum safety trip time Fig. 4. MCB opening timing diagram In order to meet the stipulated safety requirements, ABB recommends one of the following: – MCB is equipped with 2 independent opening coils –...
Page 29: Power Electronics And Cabinet Features
POWER ELECTRONICS AND CABINET FEATURES 3. Power electronics and cabinet features 3.1. Overview The ACS1000 air-cooled drive is a general-purpose frequency converter for the control of standard induction motors. For information on the power and voltage range of the drive, see the Technical specifications and the rating plate of the drive.
Page 30: Drive Topology
POWER ELECTRONICS AND CABINET FEATURES 3.2. Drive topology Key: Medium voltage switchgear, including main circuit breaker and transformer protection Transformer Rectifier Protection IGCTs DC link Inverter Filter Motor Fig. 6. Block diagrams of an ACS1000A with a (A) 12-pulse rectifier and a drive with a (B) 24-pulse rectifier The drive system consists of the following main components: –...
Page 31: Power Supply Configurations
POWER ELECTRONICS AND CABINET FEATURES 3.3. Power supply configurations The drive requires 2 independent power supplies: – Main power supply for the power electronic components – Auxiliary power supply for the control and cooling system Key: Auxiliary power supply ACS1000A Control and cooling system Auxiliary power distribution Cooling system...
Page 32: Auxiliary Power Supply Configurations
POWER ELECTRONICS AND CABINET FEATURES 3.3.2. Auxiliary power supply configurations The total auxiliary power demand of the drive includes: – Auxiliary power for the cooling system – Auxiliary power for the control hardware and the gate units which are used to trigger the power semiconductors The total auxiliary power can be fed to the drive in the following ways: –...
Page 33: Drive Topology
Key: Control compartment and terminal compartment Rectifier and inverter compartment Fig. 8. ACS1000 air-cooled topology 3.4.2. Control compartment and terminal compartment The left compartment of the drive comprises: Control compartment at the front (1, Fig. 9): contains the hardware of the control system –...
Page 34: Fig. 9. Control And Terminal Compartments
POWER ELECTRONICS AND CABINET FEATURES 120° Key: Control compartment Terminal compartment Swing frame Fig. 9. Control and terminal compartments PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS1000A User manual 3BHS213401 E01 34/164...
Page 35: Rectifier And Inverter Compartment
POWER ELECTRONICS AND CABINET FEATURES 3.4.3. Rectifier and inverter compartment Key: Second 12-pulse rectifier 12-pulse rectifier with protection IGCTs Inverter phase U Inverter phase V Inverter phase W Grounding switch Common mode choke (option) Filter choke Filter capacitors (10) DC-link capacitors Fig.
Page 36: Grounding Switch
POWER ELECTRONICS AND CABINET FEATURES 3.4.4. Grounding switch The grounding switch is a safety device that enables safe access to the medium voltage compartments of the drive. When the switch is in position grounded, the DC link of the drive is connected to the PE ground busbar.
Page 37: Inverter
POWER ELECTRONICS AND CABINET FEATURES 3.4.7. Inverter The compartment contains the inverter and the DC-link capacitors and filter capacitors. The inverter converts the DC voltage to the required AC motor voltage and frequency. Each phase of the three-phase inverter consists of a combination of four IGCTs and two NP diodes for three-level switching operation.
Page 38: Optional Braking Chopper
POWER ELECTRONICS AND CABINET FEATURES 3.4.9. Optional Braking Chopper The optional braking chopper uses resistor braking to provide motor braking and shorter deceleration times, eg, for: – Reduction of coasting 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 ACS1000A and not part of the product scope.
Page 39: Fig. 16. Braking Chopper Design
POWER ELECTRONICS AND CABINET FEATURES 3.4.9.1. Control principle If the DC-link voltage rises above a preset limit, the control system of the ACS1000A automatically activates the braking chopper. A rise of the DC-link voltage can be caused by a machine, feeding into the DC link or by an increase of the voltage in the rectifier of the ACS1000A.
Page 40: Table 2 Braking Ratings
POWER ELECTRONICS AND CABINET FEATURES 3.4.9.3. External cooling for braking resistors A digital output and a digital input can be used to control and monitor an external cooling fan or pump for the braking resistors. 3.4.9.4. Braking chopper ratings The maximum braking power is limited to 60% of the nominal power of the ACS1000A and must not be greater than 2.5 MW (Table 2).
Page 41: Cooling System
POWER ELECTRONICS AND CABINET FEATURES 3.4.9.5. Cabinet dimensions and weight Length 644 mm Depth 902 mm Width 2002 (2070 including lifting eyes) Height 460 kg 3.4.9.6. Braking resistor cables Cable type Shielded Minimum cross sectional area 70 mm Voltage rating Half of maximum converter DC-link voltage If a multi-core cable is used, the full DC-link voltage must be taken into consideration.
Page 42: Ac Redundant Fans - Operating Principles
POWER ELECTRONICS AND CABINET FEATURES 3.5.4. 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 Key: Cycle time...
Page 43: Ec Redundant Fans - Operating Principles
POWER ELECTRONICS AND CABINET FEATURES 3.5.5. EC redundant fans – operating principles When no EC fan failure exists, all EC fans are turned on and are running at a lower speed (typically the minimum speed). When one EC fan fails, the second EC fan will speed up to ensure the required cooling.
Page 44: Air Flow Overview (Ac And Ec Fans)
POWER ELECTRONICS AND CABINET FEATURES 3.5.6. Air flow overview (AC and EC fans) Fig. 19. Air flow: (1) non-redundant fan configuration Key: Fan 1 Fan 2 Fig. 20. Air flow: redundant fan configuration PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS1000A User manual...
Page 45: Monitoring The Air Pressure
POWER ELECTRONICS AND CABINET FEATURES 3.5.7. Monitoring the air pressure 3.5.7.1. Air pressure in the drive (AC fans only) This type of supervision is only required for AC fans, which are used for UL or cUL certified drives. For EC fans, the supervision is integrated in the EC fan electronic board. A pressure switch (1, Fig.
Page 46: Cabinet Design
POWER ELECTRONICS AND CABINET FEATURES 3.6. Cabinet design The riveted and folded cabinet construction of the drive ensures a strong, flexible and self- supporting framework. The construction avoids the need for additional skeletal support and provides effective protection against electromagnetic emissions. EMC has been achieved by applying a cabinet design consisting of folded, galvanized sheet metal plates (approximately 2 mm thick) and minimizing the space between the rivets.
Page 47: Optional Cabinets
The optional “Arc Resistant Design” provides the drive with arc fault protection in accordance with IEC 62477-2. The ABB arc resistant classes in Table 3 indicate the type of arc proofing that a drive uses. Depending on the drive configuration, classes I and II are available for an ACS1000A.
Page 48: Space Heaters
POWER ELECTRONICS AND CABINET FEATURES 3.9. Space heaters The optional space heaters protect the cabinet from condensation. The drive switches on the space heaters when the cooling system is switched off. Fig. 24. Space heaters PRODUCT DOCUMENT KIND DOCUMENT ID. REV.
Page 49: Control System
Depending on the control concept of the drive system, the remote control devices include a higher-level control system and / or remote operator stations. Key: ABB Ability PC tools Cloud connectivity (10) AMC circuit board...
Page 50: Main Components
CONTROL SYSTEM 4.2. Main components This section provides an overview of the main hardware components of the control system and their interconnection. Key: Control power supply NETA-21 AMC circuit board and INT circuit board Motor starters and circuit breakers Pulse encoder (option) Control power supply Fieldbus interface (option) Local control panel...
Page 51: Local Control Panel
CONTROL SYSTEM Key: IOEC2 module (standard) IOEC4 module (option) Auxiliary voltage terminals IOEC3 module (option) Fig. 27. Control compartment – I/O devices For more information on the devices present in the control compartment, see “Appendix D - Wiring diagrams”. 4.2.1. Local control panel The local control panel on the door of the control compartment serves as the basic user interface for monitoring, control, operation of the drive, and setting of parameters.
Page 52: Amc Circuit Board
CONTROL SYSTEM 4.2.2. AMC circuit board The AMC circuit board is the major component of the drive’s control system and performs general drive control, motor control, and closed loop functions. The main internal control devices and the peripheral input and output interfaces to the customer communicate with the AMC circuit board via optical fibers.
Page 53: Fig. 29. Direct Torque Control
CONTROL SYSTEM 4.2.2.2. Parameters The control system is configured, customized, and tuned with a set of application parameters. The application parameters are organized in functional groups and have factory-set default values. 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.
Page 54 PC-based service tools comprising: • DriveWare® software tools, commissioning and maintenance tools, ie, DriveWindow and DriveDebug, and DriveOPC for data transfer between ABB drives and Windows®-based applications. • NETA-21 for monitoring and diagnostics tool that allows access to the drive from any location in the world via a secure Internet connection.
Page 55: Fig. 30. Pid Control Mode
CONTROL SYSTEM Key: Reference value Level transducer Actual value Pump Fig. 30. PID control mode Application examples – Booster pumps of municipal water supply systems – Automatic level control of water reservoirs – Booster pumps of district heating systems – Speed control of different types of material handling systems where the material flow has to be regulated.
Page 56: I/O Interfaces
CONTROL SYSTEM 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.
Page 57: Table 4 Ioec Module Configuration - Analog Inputs
CONTROL SYSTEM 4.3.1.1. IOEC module configuration Each IOEC module is configured with both analog and digital inputs and outputs as shown in the following tables. TABLE 4 IOEC module configuration - analog inputs No. of I/O Resolution 10 bit Signal interface Floating, galvanically isolated 0 - 20 mA, 4 - 20 mA, 0 - 10 V, 2 - 10 V Signal level...
Page 58: Table 8 24 V Internal Voltage Supply
CONTROL SYSTEM TABLE 7 IOEC module configuration - digital inputs No. of I/O Signal level Maximum: 120 V (DC) or 250 V (AC) Isolation level 4000 V (AC) Voltage Switching current Steady state current Switching capacity 24 V (DC) 24 V (AC) 48 V (DC) 48 V (AC) 120 V (DC)
Page 59: Fig. 32. Ioec Module
CONTROL SYSTEM 4.3.1.3. Module terminals The IOEC module has terminal blocks for internal wiring and indicator LEDs for diagnostic and I/O status. A3411 A3411 X21-1 X21-2 X21-3 X22-1 X22-2 24V DC X22-3 X6-1 X23-1 X6-2 X6-3 X23-2 X6-4 X23-3 X24-1 X24-2 POWER X24-3...
Page 60: Fig. 33. Ioec Module Identification
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 the ABB documentation. The designation for each IOEC module is shown in Table 9 .
Page 61: Serial Communication Interface (Fieldbus)
CONTROL SYSTEM 4.3.2. Serial communication interface (fieldbus) To identify the serial communication interface in the drive, see “Appendix D - Wiring diagrams”. For more information on the device, consult the relevant manual: – Modbus TCP - “Ethernet - NETA-21 remote monitoring tool user manual”, 3AUA0000096939 –...
Page 62: Transportation, Storage And Disposal
2. Check the drive and accompanying equipment for damages. 3. Compare the complete delivery with the purchase order and the packing list. 4. If parts are missing or damaged, immediately inform the shipping company and the ABB service organization (include photographs of the damaged parts).
Page 63: Lifting And Transportation
→ Before use, always check the lifting attachments for damage, eg, corrosion and cracks; DO NOT attempt to lift equipment with a damaged lifting attachment; contact ABB for a replacement before you proceed → Always transport the load in an upright position →...
Page 64: Lifting Attachment Types
TRANSPORTATION, STORAGE AND DISPOSAL 5.4.1. Lifting attachment types IMPORTANT! The lifting attachments, which are included with the delivery, are intended exclusively for use with ACS1000A equipment. Any use beyond this is strictly prohibited. Only use the original lifting attachments to transport the equipment. Explanation Key: For lifting a standard drive...
Page 65: Lifting With The Top Lifting Rails
If you need to remove the top lifting rails (special case only – ABB recommends that the rails remain on the roof): 4.
Page 66: Fig. 37. Mounting Bolts And Washers For Top Rail
TRANSPORTATION, STORAGE AND DISPOSAL Key: Mounting bolt (min. A2-70) Ripp-Lock washer Top rail Fig. 37. Mounting bolts and washers for top rail PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS1000A User manual 3BHS213401 E01 66/164...
Page 67: Lifting With Rotating Eyebolts (Redundant Fan Unit)
Table 10. TABLE 10 Lifting attachment specifications Type Mounting bolt and washer Torque ABB ID (Nm) 4 × M16×40 (A2-70) NB 312350P0464 Top lifting rail for standard drive Washer Ripp lock...
Page 68: Sling Configuration For Top Lifting Rails
The drive can be stored for up to one year in the original packaging as long as it is not damaged or opened. NOTE – For information on longer storage periods, contact the ABB service organization. 5.5.2. Storing the drive If the drive is taken out of service for a longer time proceed as follows: 1.
Page 69 TRANSPORTATION, STORAGE AND DISPOSAL 3. Add a desiccant of the appropriate quality: • 1 unit desiccant (30 g) absorbs 6 g water vapor. The following quantity is required when using a polyethylene foil: • 10 units/m foil 4. Close and lock the doors of the cabinet. 5.
Page 70: Storage And Handling Of Spare Parts
→ Apply ESD handling precautions before handling these devices. 5.5.3.1. Warranty information IMPORTANT! Check the spare parts immediately after receipt for damages and report any damage to the shipping company and the ABB service organization. – Keep spare parts in their original packaging –...
Page 71: Mechanical Installation
MECHANICAL INSTALLATION 6. Mechanical installation 6.1. Safety All installation work must be carried out by qualified personnel according to the site and equipment requirements and in compliance with local regulations. 6.2. Overview of installation work The installation includes the following work: –...
Page 72: Preparing The Floor
3. Recommended size: 80 x 300 x 0.5 mm Fig. 39. Leveling the drive 4. Fix the cabinet to the floor. NOTE – Floor fixings are not supplied. ABB recommends anchor bolts (Fig. 40) or M16 screws and nuts. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 73: Assembling And Installing The Air Exhaust Hood
MECHANICAL INSTALLATION 5. Insert the screws from the ends of the cabinet base or via the holes inside the cabinet. Fig. 40. Fixing the cabinet to the floor 6.6. Assembling and installing the air exhaust hood This section applies to drives with an internal fan. –...
Page 74: Installing The Redundant Fan Unit
MECHANICAL INSTALLATION 6.7. Installing the redundant fan unit This section applies to drives with a redundant fan unit. – Included in delivery: mounting screws IMPORTANT! Move the drive to its final location before you install the redundant fan unit. 1. Remove the top lifting rails (1, Fig. 42) and then remove the cabinet access cover for the fan unit (2, Fig.
Page 75: Fig. 43. Redundant Fan Unit - Installation
MECHANICAL INSTALLATION 3. Attach the lifting gear to the rotating eye bolts (3, Fig. 43) of the redundant fan unit (1, Fig. 43). CAUTION! The redundant fan weighs approximately 300 kg. 4. Orientate the redundant fan unit with the cable pointing to the left (2, Fig. 43). 5.
Page 76: Fig. 44. Recommended Sequence For Attaching The Sound Absorbing Panels On The Right Side Of The Fan Unit
MECHANICAL INSTALLATION 7. Fasten the redundant fan unit on both sides to the cabinet roof. 8. Attach the sound absorbing panels on the right side of the redundant fan unit. Recommended sequence: 1, 2, and 3. Fig. 44. Recommended sequence for attaching the sound absorbing panels on the right side of the fan unit PRODUCT DOCUMENT KIND...
Page 77: Fig. 45. Recommended Sequence For Attaching The Sound Absorbing Panels On The Left Side Of The Fan Unit
MECHANICAL INSTALLATION 9. Route the power supply cable of the redundant fan unit with the transformer and motor cables into the cabinet, 10. Attach the sound absorbing panels on the left side of the redundant fan unit. Recommended sequence: 1, 2, and 3. Fig.
Page 78: Electrical Installation
→ 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 79: Cable Entries
ELECTRICAL INSTALLATION 7.4. Cable entries The cables can be entered through the roof or the floor of the cabinet. The cabinet is equipped with one of the following cable entries: – Cable entry with EMC plates – Cable entry with sealing modules, type 1 –...
Page 80: Cable Entry With Type 1 Sealing Modules
ELECTRICAL INSTALLATION 7.4.2. Cable entry with type 1 sealing modules Usage: power cables, ground cables and bonding conductors – – Included in delivery: cable entry frame (1, Fig. 48) Not included in delivery: sealing modules (2, Fig. 48), accessories and tools –...
Page 81: Cable Entry With Cable Glands
ELECTRICAL INSTALLATION 7.4.4. Cable entry with cable glands Usage: – • Power cables, ground cables and bonding conductors • Auxiliary power cables and control cables – Included in delivery: undrilled plate for cable glands – Not included in delivery: cable glands, tools and accessories Fig.
Page 82: Fig. 51. Cable Termination Bar (A) Top And (B) Bottom Cable Entry; Busbar Thickness Is 5 Mm
ELECTRICAL INSTALLATION 7.5.1.1. Maximum number of cables per phase The maximum number of cables that can be used per phase depends on the type of the drive and its nominal voltage. TABLE 11 Maximum number of cables per phase ACS1000A type 2.3 kV nominal 3.3 kV nominal 4.0 kV nominal...
Page 83 ELECTRICAL INSTALLATION 7.5.1.3. Determining the cable length 1. Determine the required length of a cable between the point of entry and the connection point inside the cabinet. 2. Cut the cable to the required length before connection. 7.5.1.4. Splitting multi-core cables This section applies to drives without an additional cabinet.
Page 84 ELECTRICAL INSTALLATION 7.5.1.5. Preparing cables for EMC plates As a standard, the cabinet is delivered for cable entry through the roof of the terminal compartment. If cables are entered through the floor, swap entry plate and cover plate. The orientation of the EMC plates is the same for cable entry through the roof and through the floor, ie, the sealing grommets face upwards.
Page 85: Fig. 52. Preparing Cables For Emc Plates: (A) Cables With An Outer Screen Or Shield, (B) Cables Without An Outer Screen Or Shield
ELECTRICAL INSTALLATION 4. Prepare the cables as illustrated. A in Fig. 52 illustrates how cables with an outer cable screen or shield are prepared for • EMC bonding with the metal enclosure of the cabinet. B in Fig. 52 illustrates how cables without an outer screen or shield are prepared. •...
Page 86: Fig. 53. Preparing Power Cables For Sealing Modules
ELECTRICAL INSTALLATION 7.5.1.6. Preparing cables for cable entries with sealing modules As a standard, the cabinet is delivered for cable entry through the roof of the terminal compartment. If cables are entered through the floor, swap entry plate and cover plate. –...
Page 87: Fig. 54. Preparing Power Cables For Cable Glands
ELECTRICAL INSTALLATION 7.5.1.7. Preparing cables for cable entries with cable glands Prepare cables with an outer cable screen or shield for EMC bonding with the metal enclosure of the cabinet as illustrated in Fig. 54. Key: Outer cable sheath Cable gland Conductor insulation removed to expose cable shield Plate Screen extension to be connected to PE ground busbar...
Page 88: Connecting The Cables
ELECTRICAL INSTALLATION 7.5.2. Connecting the cables 7.5.2.1. Checking the cable insulation – Check the insulation of each cable before connection and verify that the results are within the specification of the cable manufacturer. – Leave the cable conductors unconnected at both ends until the commissioning engineer has given permission.
Page 89: Fig. 55. Power Cable Terminals In (A And C) 12-Pulse Acs1000A And (B And D) 24-Pulse Acs1000A
ELECTRICAL INSTALLATION Key: PE ground busbar Strain relief Feeder cable busbars Top cable entry Motor cable busbars Bottom cable entry Fig. 55. Power cable terminals in (A and C) 12-pulse ACS1000A and (B and D) 24-pulse ACS1000A PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 90: Minimum Creepage Distance Between Cable And Busbar
ELECTRICAL INSTALLATION ACS1000 Key: Input transformer Ground cable Drive Cable screen Motor Equipotential bonding conductor Earth electrode Motor Fig. 56. Grounding the drive system 7.5.3. Minimum creepage distance between cable and busbar If spacers are used to connect a cable to a busbar, observe the minimum creepage distance.
Page 91: Bolted Connections
ELECTRICAL INSTALLATION 7.5.4. Bolted connections 7.5.4.1. Material requirements Use stainless steel bolts and nuts with the appropriate steel grade and property class for the connection (recommended: A2-70; designation according to ISO 3506). NOTE – Nuts with bonded coating can be used as an alternative to uncoated stainless steel nuts.
Page 92: Auxiliary Power, Control And Serial Communication Cables
ELECTRICAL INSTALLATION 7.6. Auxiliary power, control and serial communication cables See the layout drawings in “Appendix C - Mechanical drawings” for information on: – Project-specific cable entry – Dimensions between point of cable entry and terminals See “Appendix D - Wiring diagrams” for information on: –...
Page 93 ELECTRICAL INSTALLATION 7.6.1.2. Preparing cables for EMC plates 1. Remove the grommets. 2. To ensure proper sealing, cut along the marking that corresponds to the cable diameter and slide the grommet onto the cable. IMPORTANT! The grommet must fit tightly to prevent water entering the cabinet. The grommets can be discarded if cables are entered through the floor 3.
Page 94: Fig. 59. Frame With Sealing Modules
ELECTRICAL INSTALLATION 6. Pull the cables through the EMC cushions. 7. Push the cushions together so they fit tightly around the bare screen and tighten the screws. 7.6.1.3. Preparing cables for cable entries with sealing modules 1. Unscrew the frame and remove the sealing modules. For information on removing and installing the sealing modules and using the compression wedge (1), see “Appendix A - Additional manuals”.
Page 95: Fig. 60. Preparing Control Cables For Sealing Modules
ELECTRICAL INSTALLATION 2. Prepare the cables with an outer cable screen for EMC bonding with the metal enclosure of the cabinet as illustrated in Fig. 60. Key: Sealing module Conductive foil Cable sheath removed to expose cable shield Conductor screen extension to be connected to PE terminal Fig.
Page 96: Connecting The Cables
ELECTRICAL INSTALLATION 7.6.2. Connecting the cables 7.6.2.1. IOEC modules – Connect the cables for digital and analog input and output signals to the distribution terminals. 7.6.2.2. Conductors – If a twisted pair cable is used, leave the unshielded cable ends twisted until they reach the terminals.
Page 97: Power Supply Cable For Redundant Fan Unit
ELECTRICAL INSTALLATION 7.7. Power supply cable for redundant fan unit This section applies to drives that are equipped with the optional redundant fan. For information on the cable connection, see “Appendix D - Wiring diagrams”. 1. Enter the pre-fabricated multi-core cable into the cabinet as close as possible to the redundant fan unit and according to the type of control cable entry used.
Page 98: Final Checks
ELECTRICAL INSTALLATION 7.8. Final checks – Check that the entry plates are properly secured. – If you used EMC entry plates check that the grommets fit tightly (arrows) to prevent water entering the cabinet. – If required, seal gaps with silicone. PRODUCT DOCUMENT KIND DOCUMENT ID.
Page 99: Commissioning
The following sections provide an overview of the commissioning process for your drive. 8.1.1. Required qualification Commissioning, parameter adjustments and functional tests must be carried out only by qualified commissioning personnel that have been certified by ABB. 8.1.2. Commissioning procedure Information on the commissioning procedure and the start conditions for commissioning can be obtained from ABB.
Page 100: Commissioning Checklists
(Megger test) before connection) 8.2.3. Main circuit breaker (MCB) checklist   1) Type of MCB selected as per the MCB specification from ABB  2) High-voltage power connections completed  3) MCB ready to be tested with drive ...
Page 101: Input Transformer Checklist
COMMISSIONING 8.2.4. Input transformer checklist   1) Grounding is completed  2) Transformer auxiliaries (eg, dehydrating breathers, cooling, protection devices) are ready.  3) Safety devices (eg, door locks) are tested and in operation. 8.2.5. Motor checklist   1) Motor is installed, aligned and alignment protocol available.
Page 102: Operation
The operating conditions for the drive are according to IEC 60721-3-3. Conditions: 3K22 / 3B1 / 3S6 / 3M11 – If the operating conditions are not within the specifications, contact ABB. 9.4. Sound pressure level Single fan: < 75 dB (A) –...
Page 103: Local Operator Panel
OPERATION 9.5. Local operator panel Under normal operating conditions, the local operator panel allows you to operate the drive without restrictions. For example, you can use the panel to perform the following actions: – Connect and disconnect the main power supply –...
Page 104: Status Messages
OPERATION 9.6. Status messages This section lists the messages of the main operating states the drive passes through, when it is put into operation, when it is stopped, or when a fault condition has occurred. The messages are sent to the higher-level control system and are displayed on the CDP control panel of the drive.
Page 105: Start Sequence Of The Drive
OPERATION 9.6.1. Start sequence of the drive 1) NotReadyOn ReadyOn conditions: • Doors closed and locked • Drive not grounded • No emergency off • No fault 2) ReadyForMCBOn 3) On command 4) Charging • MCB closes • DC link charges •...
Page 106: Stop Sequence Of The Drive
OPERATION 9.6.2. Stop sequence of the drive 1) Operation 2) Running 3) Stop command 4) Stopping • Speed ramps down • Inverter stops modulating 5) Ready To Strt 6) Off command 7) Discharging • MCB opens • DC link discharges •...
Page 107: Emergency Off Sequence Of The Drive
OPERATION 9.6.3. Emergency off sequence of the drive 1) Operation 2) Running 3) Emergency off command • MCB opens • Inverter stops modulating • Speed coasts down 4) Not ready on 9.7. Starting the drive DANGER Hazardous voltages! Unintentional contact with energized components can cause serious injuries or DEATH.
Page 108: Starting The Drive Locally
OPERATION 9.7.3. Starting the drive locally 1. Enable the local control mode of the drive. 2. Check that no alarm or fault messages are displayed on the CDP control panel. • If a fault message is displayed on the CDP control panel, reset the fault. •...
Page 109: Stopping The Drive
OPERATION 1 L -> [600.0 rpm] 0 Status Rdy to Strt MotorSpeed 0.0 rpm Power 0.0 % 5. Start the motor. 1 L -> [600.0 rpm] 0 Status Magnetizing MotorSpeed 0.00 rpm Power 0.0 % After the motor has been magnetized, the motor speed ramps up to the reference value. While the motor is accelerating, the run status indication on the display blinks.
Page 110 OPERATION 1 L -> 600.0 rpm I Status Stopping MotorSpeed 300.0 rpm Power 20.0 % NOTE – 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.
Page 111: Emergency-Off
OPERATION 9.9. Emergency-off The drive is equipped with a hard-wired emergency off circuit. When an emergency situation occurs during operation, this safety feature ensures that the drive can be disconnected without delay from the main power supply. If the EMERGENCY-OFF push button has been pressed while the drive is at standstill, the main power supply cannot be connected to the drive, hence the drive cannot be started up.
Page 112: Starting The Drive After An Emergency-Off
OPERATION 9.9.2. Starting the drive after an emergency-off 1. To start the drive after an emergency-off, unlatch the EMERGENCY-OFF push button. The EMERGENCY-OFF push button returns to its initial position when turned into the direction indicated by the arrows on the push button. 2.
Page 113: Cdp Control Panel
CDP CONTROL PANEL 10. CDP control panel 10.1. Overview The panel messages and parameter settings used in this chapter are typical examples to illustrate the related instructions and display functions and can therefore differ from the actual messages and parameter settings in the drive. 1 L ->...
Page 114: Cdp Control Panel Functions
CDP CONTROL PANEL 10.2. CDP control panel functions The CDP control panel serves as the basic user interface for operating and monitoring the drive when the local operating mode has been selected. The CDP control panel can be attached to or detached from the drive without having to switch off the auxiliary power supply first.
Page 115: Actual Signals Mode
CDP CONTROL PANEL After 2 to 3 seconds, information on the drive (1, and 2) and the drive identification (3) is displayed. ACS1000 xxxx <Device Name> ID-NUMBER 1 After another few seconds: 1 L -> 0.0 rpm Status InitSeq..MotorSpeed 0.00 rpm Power 0.0 %...
Page 116 CDP CONTROL PANEL 10.3.2.2. Actual values The actual values are organized in groups. Group Description Group 01 Measured or calculated motor values Group 02 Measured or calculated drive values Group 03 Speed and torque reference values Group 04 I/O values Group 05 Data values Group 06...
Page 117: Fig. 66. Control Panel - Actual Signals Mode
CDP CONTROL PANEL Control panel overview 1 L -> 1 L -> 600.0 rpm 600.0 rpm Status Status RdyForMCBon RdyForMCBon MotorSpeed 0.00 rpm MotorSpeed 0.00 rpm Power Power 0.0 % 0.0 % FUNC FUNC DRIVE DRIVE Key: Status line Actual signal names and values Selection key for actual signals mode Fast navigation key for selecting the actual signals display or the fault memory display Slow navigation key for selecting signals or fault messages...
Page 118 CDP CONTROL PANEL 10.3.2.4. Opening the actual signals display To open the actual signals display, press the ACT key. – 1 L -> 600.0 rpm 0 Status RdyForMCBon MotorSpeed 0.00 rpm Power 0.0 % Toggle between actual signals display and fault history –...
Page 119 CDP CONTROL PANEL Selecting actual signals 1. To select the actual signals display, press the ACT key. 1 L -> 600.0 rpm I Status Running Motor Speed 600.0 rpm Power 75.0 % To select a line where the actual signal is to be displayed, press the corresponding slow navigation key.
Page 120 CDP CONTROL PANEL 4. To select an actual signal, press a slow navigation key. 1 L -> 600.0 rpm 0 2 Actual Signals 02 DC Voltage Udc1 1000.0 V 5. To confirm the selection and to return to the actual signals mode, press the ENTER key. 1 L ->...
Page 121 CDP CONTROL PANEL 2. To change to the fault memory display, press a fast navigation key. 1 L -> 600.0 rpm 0 1 LAST FAULT + Panel Lost 0707730 12:30:02 3256 3. To display a specific fault, press the slow navigation keys. The UP key selects the previous, the down key the next fault.
Page 122: Parameters Mode
Displaying and resetting an active fault 1. To display an active fault, press the ACT key. 1 L -> 600.0 rpm 0 ACS1000 *** FAULT *** MCB CloseControl 2. To reset the fault, press the RESET key. 1 L ->...
Page 123 CDP CONTROL PANEL TABLE 13 Parameter groups (continued) Group Description Group 13 Basic analog inputs Group 14 Basic digital outputs Group 15 Basic analog outputs Group 16 System control inputs Group 17 Utilities Group 18 Process speed Group 19 Data storage Group 20 Limits Group 21...
Page 124: Fig. 67. Control Panel - Parameters Mode
CDP CONTROL PANEL Control panel overview 1 L -> 1 L -> 600.0 rpm 600.0 rpm 75 OPTION MODULES 75 OPTION MODULES 01 IOEC3 OptionBoard 01 IOEC3 OptionBoard Y ES FUNC FUNC DRIVE DRIVE Key: Status line Group number and name Parameter number and name Parameter value Selection key for parameters mode...
Page 125 CDP CONTROL PANEL 10.3.3.2. Selecting and changing parameters 1. To enter the parameters mode, press the PAR key. 1 L -> 600.0 rpm 0 12 REFERENCE SELECT 01 KeypadRefSelect 2. To select a different group, press the corresponding fast navigation key. 1 L ->...
Page 126 CDP CONTROL PANEL 5. To change the parameter value, press the: • Slow navigation key for numbers and text • Corresponding fast navigation key for numbers only 1 L -> 600.0 rpm 0 75 OPTION MODULES 02 IOEC4 OptionBoard [YES] 6.
Page 127 Setting the master pass code ABB recommends that you set a master pass code to lock the control panel to protect the parameter values. 1. To activate the user lock for the first time, enter the default pass code, ie, 358, in 16.03 Passcode You can now edit parameters 16.06…16.07 .
Page 128: Functions Mode
CDP CONTROL PANEL 10.3.4. Functions mode The functions mode is used to set the display contrast. 1 L -> 0.0 rpm UPLOAD <= <= DOWNLOAD => => CONTRAST FUNC FUNC DRIVE DRIVE Key: Status line Selectable functions Selection key for functions mode Slow navigation key for selecting a line (and adjusting the contrast) Enter key for confirming the selection Fig.
Page 129 CDP CONTROL PANEL 10.3.4.1. Adjusting the display contrast 1. To enter the functions mode, press the FUNC key: FUNC 1 L -> 0.0 rpm 0 UPLOAD <= <= DOWNLOAD => => CONTRAST 2. To select the contrast adjustment function, press the slow navigation keys until the cursor reaches the CONTRAST line.
Page 130 CDP CONTROL PANEL 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 => => CONTRAST 6. To cancel the setting and keep the original setting, press any of the mode selection keys. The selected keypad mode is entered.
Page 131: Local And Remote Control
CDP CONTROL PANEL 10.4. Local and remote control The local-remote feature of the CDP control panel allows selecting the control location of the drive. Possible are: – Local control – Remote control In this context, remote control is not necessarily equivalent to higher-level control. For more information, see Section 10.4.2, “Remote control”, page 132.
Page 132: Remote Control
CDP CONTROL PANEL 10.4.2. Remote control In remote control mode, operational commands or reference values come from a higher-level control system via fieldbus or remote I/O. However, with the following parameter settings it is possible to start and stop the drive, to set the motor’s direction of rotation, and to enter reference values from the CDP control panel.
Page 133: Operational Commands
CDP CONTROL PANEL 10.5. Operational commands For instructions on how to start and stop the drive system from the CDP control panel, see Section 9.7, “Starting the drive”, page 107 and Section 9.8, “Stopping the drive”, page 109. 10.5.1. Setting the direction of rotation Setting the direction of rotation from the CDP control panel is possible in: –...
Page 134: Entering A Reference Value
CDP CONTROL PANEL 10.5.2. Entering a reference value Entering a reference value from the CDP control panel is possible in: – Local control mode – Remote control mode Procedure 1. Press a mode selection key. FUNC DRIVE 1 L -> 600.0 rpm Status Running...
Page 135 CDP CONTROL PANEL 4. To exit the reference value input mode, press any of the mode selection keys. FUNC DRIVE 1 L -> 550.0 rpm Status Running MotorSpeed 550.00 rpm Power 75.0 % PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS1000A User manual...
Page 136: Preventive And Corrective Maintenance
PREVENTIVE AND CORRECTIVE MAINTENANCE 11. Preventive and corrective maintenance 11.1. General information During the warranty period of the drive, all maintenance must be performed exclusively by ABB service personnel. After the warranty period, maintenance must only be performed by certified personnel.
Page 137: Identifying Electrical Equipment
PREVENTIVE AND CORRECTIVE MAINTENANCE 11.2. Identifying electrical equipment This section describes how to identify electrical devices, cables, and wires. 11.2.1. Device identification To facilitate the identification in wiring diagrams and parts lists, all devices are labeled in accordance with IEC 81346-1. Fig.
Page 138: Alarm / Fault Indications
CDP control panel displays a corresponding alarm or fault message. 1 L -> 600.0 rpm 0 ACS1000 *** FAULT *** MCB CloseControl The message can be saved and viewed in the fault history of the drive when a PC with the DriveWindow or DriveDebug is connected to the drive.
Page 139: Standard Troubleshooting Procedure
The data logger provides information (eg, waveforms of voltage, current, torque) for efficient troubleshooting. 5) Contact ABB service if a fault cannot be rectified. When calling ABB service, it is recommended to have the following data available at the time when the fault occurred: •...
Page 140: Removing The Cdp Control Panel
PREVENTIVE AND CORRECTIVE MAINTENANCE 11.4. Removing the CDP control panel IMPORTANT! If the CDP control panel is removed during operation, the drive can only be stopped by pressing the EMERGENCY OFF button. 1. If the panel is removed while the drive is in operation, check the setting of parameter 31.06 PANEL LOSS SUPERVISION first.
Page 141: Leds And Switches On Circuit Boards
PREVENTIVE AND CORRECTIVE MAINTENANCE 11.5. LEDs and switches on circuit boards The following section provides an overview on the meaning of LEDs and switches of the main circuit boards and I/O devices. The LEDs presented in the following section can be checked easily with the auxiliary voltage switched on and without having to remove covers first.
Page 142: Ioec I/O Modules
PREVENTIVE AND CORRECTIVE MAINTENANCE 11.5.2. IOEC I/O modules 11.5.2.1. LEDs Explanation Key: On when output is energized Status LED of digital outputs Link error light Only on when there is a problem with the optical fibers. Rotary switch Sets the address On when input is energized Status LEDs of digital inputs Status LED of the 24 V internal...
Page 143: Corrective Maintenance
PREVENTIVE AND CORRECTIVE MAINTENANCE 11.6. Corrective maintenance Overview on maintenance tasks: – Section 11.6.6, “Visual checks on the drive”, page 149 – Section 11.6.7, “Cleaning the drive”, page 149 – Section 11.6.8, “Checking wire and cable connections”, page 150 – Section 11.6.9, “Cleaning and replacing filter mats”, page 150 –...
Page 144 PREVENTIVE AND CORRECTIVE MAINTENANCE The IPXXB/IP20 rating of the low voltage compartment is not fulfilled by live parts with voltages > 50 V AC. If the compartment door is open during drive operation, contact with these accessible live parts can result in DEATH or serious injury! →...
Page 145: Energizing The Drive Locally
PREVENTIVE AND CORRECTIVE MAINTENANCE 11.6.2. De-energizing the drive locally The following section describes how to de-energize the drive using the local operator panel of the drive. If the drive is controlled from remote, follow the established shutdown procedures. 1. Enable the local control mode of the CDP control panel. For more information, see Chapter 10, “CDP control panel”, page 113 2.
Page 146: Grounding
PREVENTIVE AND CORRECTIVE MAINTENANCE 5. If the grounding switch is equipped 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. 7.
Page 147: Grounding Switch Is Not Released
PREVENTIVE AND CORRECTIVE MAINTENANCE 11.6.4. Grounding switch is not released CAUTION Hazardous voltage! Forcing the grounding switch can damage the switch and short-circuit the DC-link capacitors! → DO NOT force the grounding switch when the GROUNDING SWITCH UNLOCKED lamp is off. →...
Page 148: Checking The Release Conditions For The Grounding Switch
If a fault is present, follow the instructions in Section 11.3.4, “Standard troubleshooting procedure”, page 139, before you reset a fault. • If a fault cannot be rectified and reset, contact the ABB service organization.  – If the CDP control panel does not display a fault, check that digital output DO04 of I/O module -A5191 (-A1) is energized.
Page 149: Visual Checks On The Drive
IMPORTANT! When the checklist has been completed, carefully try to turn the grounding switch to the grounded position. If you cannot turn the grounding switch but doors of medium voltage compartments have to be opened, call the ABB service organization. 11.6.6. Visual checks on the drive...
Page 150: Checking Wire And Cable Connections
The filter mats are in the control as the inverter compartments. For information on inspection and replacement intervals, see the “ACS1000A preventive maintenance schedule”, 3BHS855276 E01. TABLE 14 Filter mat specifications Drive compartment ABB ID Dimensions Filter class Filter type (L × W)
Page 151 PREVENTIVE AND CORRECTIVE MAINTENANCE 11.6.9.1. Control compartment filter mat NOTICE Risk of component damage! Dust can damage components and cause failure when the drive is energized. → Always clean the filter mat at a safe distance from the open cabinet door. 1.
Page 152: Fig. 73. Filter Panel (1) And Filter Mat (2) On Rectifier And Inverter Compartment
PREVENTIVE AND CORRECTIVE MAINTENANCE Referring to Fig. 73: 1. Set parameter 41.47 FILTER MAT CHANGE FUNCTION to ENABLE. The monitoring of differential air pressure is disabled for the time that is defined in parameter 41.48 FILTER MAT CHANGE TIME (default 30 minutes). NOTICE The drive might trip if the filter mat is not replaced before the time 1228 mm...
Page 153: Inspecting And Replacing Batteries
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. 11.6.10.2. Replacing a battery CAUTION Heavy object.
Page 154: Fig. 75. Control Compartment - Replacing The Batteries
PREVENTIVE AND CORRECTIVE MAINTENANCE Fig. 75. Control compartment - replacing the batteries 1. When the drive is in operation, disable the battery monitoring function first. To do this, set parameter 31.05 DISABLE BATTERY TEST to ON. Parameter 31.05 is automatically set to OFF after 1 hour. 2.
Page 155: Replacing The Non-Redundant Fan
PREVENTIVE AND CORRECTIVE MAINTENANCE 11.6.11. Replacing the non-redundant fan CAUTION Heavy object. The fan weighs approximately 100 kg. 774 mm 868 mm 469 mm Fig. 76. Fan location, dimensions and weight Key: ¼” ~70 mm 10 mm and 13 mm Trolley Lift truck Fig.
Page 156: Fig. 78. Replacing The Non-Redundant Fan
PREVENTIVE AND CORRECTIVE MAINTENANCE 7. Place the lift truck or height-adjustable trolley in front of the fan and pull the fan onto the platform. 8. Unplug the optical fibers (V3001:A1, V3002:A1) from the protection IGCTs (3, Fig. 78) and stow the optical fibers in a position where they cannot be damaged when the fan is replaced.
Page 157: Fig. 79. Installing The Non-Redundant Fan
PREVENTIVE AND CORRECTIVE MAINTENANCE 11.6.11.1. Installing the non-redundant fan 1. Check the mounting supports (1, Fig. 79). 2. If they are damaged, replace them. 3. If they can be re-used, attach them to the new fan. 4. On both sides of the fan, orientate the groove of the mounting supports (2, Fig. 79) towards the back of the cabinet.
Page 158: Replacing A Redundant Fan
PREVENTIVE AND CORRECTIVE MAINTENANCE 11.6.12. Replacing a redundant fan For information on inspection and replacement intervals, see “ACS1000A preventive maintenance schedule”, 3BHS855276 E01. The estimated working time to replace a redundant fan is approximately 1 hour. CAUTION Heavy object. The fan weighs approximately 100 kg. 774 mm 868 mm 469 mm...
Page 159: Fig. 81. Redundant Fans - Tools And Devices
PREVENTIVE AND CORRECTIVE MAINTENANCE Key: ¼” ~70 mm 13 mm and 17 mm 13 mm T 30 Cordless drill 3 × M10×20 Height-adjustable platform Lift truck Fig. 81. Redundant fans - tools and devices Procedure 1. Disconnect all power supplies to the drive and ground the drive according to Section 11.6.2, “De-energizing the drive locally”, page 145.
Page 160: Fig. 82. Redundant Fan Unit - Removing The Panels
PREVENTIVE AND CORRECTIVE MAINTENANCE T 30 Fig. 82. Redundant fan unit – removing the panels 7. Unplug the power supply cable. Fig. 83. Redundant fan unit – Unplugging the power supply cable 8. Remove the fixing bolts. NOTE – If the bolt at the back (1, Fig. 84) is not accessible from the back of the cabinet, remove the cover (2, Fig.
Page 161: Cover (2)
PREVENTIVE AND CORRECTIVE MAINTENANCE Key: Bolt Cover Mounting support ¼” 13 mm 13 mm Cordless drill T 30 Fig. 84. Redundant fan unit – removing the fixing bolts PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE ACS1000A User manual 3BHS213401 E01 161/164...
Page 162: Fig. 85. Redundant Fan Unit - Using A Crane
PREVENTIVE AND CORRECTIVE MAINTENANCE 9. Remove the fan by one of the following methods: Crane: replace 3 of the fixing bolts with eye bolts, attach the lifting gear to the eye bolts • and then lift the fan off the cabinet. Key: ¼”...
Page 163 PREVENTIVE AND CORRECTIVE MAINTENANCE 11. If the new fan housing does not have screw holes for the mounting supports, drill holes into the underside of the fan housing. For information on the exact hole positions, see drawing number 3BHS128478 E01 in “Appendix C - Mechanical drawings”.
Page 164 — ABB Switzerland Ltd. Bruggerstrasse 66 CH-5400 Baden Switzerland new.abb.com/drives/medium-voltage-ac-drives — © Copyright 2011 ABB. All rights reserved. The information in this document is subject to change without notice.

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