Abb ACS1000i air-cooled Voltage Drive Manuals

Table of Contents

3

About this Manual

13

Equipment Covered by this Manual

13

Structure of the User Documentation

13

Terms and Definitions

14

Table 1-1 Terms and Definitions

14

Related Documents

16

Table 1-2 Maintenance

16

Table 1-3 Technical Data

16

Table 1-4 Schematics

16

Table 1-5 Specifications and Guidelines

16

Table 1-6 Serial Communication Interfaces

16

Table 1-7 Encoder

16

Target Groups and Required Qualification

17

Handling

17

Mechanical Installation

17

Electrical Installation

17

Operation

17

Maintenance

18

User's Responsibilities

18

Intended Use of Equipment

18

Quality Certificates and Applicable Standards

19

Table 1-8 Standards

19

Items Covered by Delivery

20

Identifying the Delivery

20

Figure 1-1 Delivered Items

20

Important Safety Information

21

Safety Standards

21

Safety Messages

21

Product Safety Labels

22

Figure 2-1 Product Warning Label Examples (Label Placement Depends on the Drive)

22

General Safety Instructions

23

The 7 Steps that Save Lives

24

Possible Residual Risks

26

Main Circuit Breaker Protection Device

27

Figure 2-2 Drive System Overview

27

Safety and Protection Requirements

28

Minimum Requirements for MCB and MCB Control

28

Figure 2-3 MCB Opening Timing Diagram

29

Maintenance Recommendation

30

Power Electronics and Cabinet Features

31

Overview

31

Figure 3-1 Acs1000I Air-Cooled

31

Main Components of the Drive System

32

Figure 3-2 Block Diagrams of the Drive

32

Power Supply Configurations

33

Main Power Supply Configurations

33

Figure 3-3 Drive Overview with Power Supplies

33

Auxiliary Power Supply Configurations

34

Drive Topology

35

Overview

35

Figure 3-4 Acs1000I Air-Cooled with Combined Input Disconnector and Grounding Switch

35

Figure 3-5 Acs1000I Air-Cooled with Grounding Switch

36

Terminal Compartment

37

Figure 3-6 Terminal Compartment with Input Disconnector (A) and Without Input Disconnector (B)

37

Control Compartment and Terminal Compartment

38

Figure 3-7 Control Compartment with Open Door

38

Transformer and Rectifier Compartment

39

Rectifier

39

Figure 3-8 Transformer and Rectifier Compartment with Combined Input Disconnector (A) and with Grounding Switch (B)

39

Grounding Switch

40

Figure 3-9 Switchgear of the Drive

40

Figure 3-10 Grounding Switch Unlocked Lamp (1)

41

Figure 3-11 Grounding the Drive

41

Trapped Key Interlock (Option)

42

Protection Igcts

42

Figure 3-12 Trapped Key Interlocking System (1)

42

Inverter

43

Filter

43

Figure 3-13 Three-Level Voltage Source Inverter Principle

43

Figure 3-14 Voltage and Current Waveforms at Drive Output

43

Cooling System

44

Figure 3-15 Fan Configurations and Air Flow

44

Figure 3-16 Fan Groups - AC and EC Fans

45

Figure 3-17 Fan Groups - EC Fans Only

45

Figure 3-18 Operating Times of the AC Fan Units During Continuous Drive Operation (A) and Intermittent Drive Operation (B)

46

Figure 3-19 Operating Principles of Redundant EC Fans

47

Optional Braking Chopper

48

Figure 3-20 Acs1000I with Braking Chopper (1)

48

Figure 3-21 Principle Diagram

48

Figure 3-22 Braking Chopper Design

49

Table 3-1 Braking Ratings

50

Cabinet Design

51

Mechanical Design

51

Additional Cabinets

52

Figure 3-23 Acs1000I with an Additional Cabinet (1)

52

Door Locking System

53

Optional Cabinets

53

Figure 3-24 Door Locks

53

Arc Resistant Design (Optional)

54

Internal Arc Classification

54

Figure 3-25 IAC Label Example

54

Table 3-2 ABB Arc Resistant Classes

54

Power Compartment Doors

55

Associated Protection Requirement

55

Figure 3-26 Door Bolts

55

Space Heaters

56

Figure 3-27 Optional Space Heaters

56

Control System

57

Overview

57

Figure 4-1 Block Diagram of Control System with Customer Interface (A), Control System (B) and Power Electronics (C)

57

Main Components

58

Local Control Panel

58

Figure 4-2 Control Compartment

58

AMC Circuit Board

59

Figure 4-3 AMC Circuit Board

59

Figure 4-4 Direct Torque Control

60

Figure 4-5 PID Control Mode

62

I/O Interfaces

63

IOEC I/O Modules

63

Figure 4-6 IOEC Interfaces Overview

63

Table 4-1 IOEC Module Configuration - Analog Inputs

64

Table 4-2 IOEC Module Configuration - Analog Outputs

64

Table 4-3 IOEC Module Configuration - Digital Inputs

64

Table 4-5 24 V Internal Voltage Supply

65

Table 4-4 IOEC Module Configuration - Digital Inputs

65

Figure 4-7 IOEC Module

66

Figure 4-8 IOEC Module Identification

67

Table 4-6 IOEC Module Identification

67

Serial Communication Interface (Fieldbus)

68

Pulse Encoder Interface NTAC (Option)

68

Figure 4-9 NTAC-02 Pulse Encoder Interface

68

Transportation, Storage and Disposal

69

Safety

69

Transport Conditions

69

Unpacking and Inspection

69

Lifting and Transportation

69

General Notes on Transportation

70

Using a Crane

70

Figure 5-1 Transporting the Cabinet by Crane (Lift Spreader Example)

71

Using Rollers

72

Figure 5-2 Moving the Drive with Rollers

72

Figure 5-3 Moving the Drive Backwards or Forwards

72

Storage

73

Storage Conditions

73

Storing the Drive

73

Storage and Handling of Spare Parts

74

Disposal of Packaging Materials and Components

74

Mechanical Installation

75

Safety

75

Overview of Installation Work

75

General Notes on Installation

75

Dimensions and Clearances

75

Cabinet Roof

75

Fire Protection

75

Cable Duct Material

75

Preparing the Floor

76

Fixing the Cabinet to the Floor

76

Figure 6-1 Position of Mounting Holes

76

Figure 6-2 Leveling the Drive

76

Installing the Fans

77

Figure 6-3 Fixing the Cabinet to the Floor

77

Figure 6-4 Cutouts in Drive Roof - Back (A) and Front (B)

77

Figure 6-5 Standard Fan Installation

78

Table 6-1 Fan Configurations

78

Figure 6-6 Lifting Point Locations on Fan Unit

79

Figure 6-7 Large Fan Installation

80

Figure 6-8 Small Fan Installation over a Roof Cutout for a Large Fan

81

Figure 6-9 Fan Installation Material

81

Additional Cabinet Compartments

82

Figure 6-10 Bolt Location at the Back of a Fan Unit

82

Electrical Installation

83

Safety

83

Overview of Installation Work

83

Cable Requirements

83

Ground Cable Connection and Cable Shield Connections

84

Figure 7-1 Grounding the Drive System

84

Power Cables, Ground Cables and Equipotential Bonding Conductor

85

Safety

85

Determining the Cable Length

85

MV Cable Entry from Top

86

Figure 7-2 Top Cable Entry - Installation Material

86

Figure 7-3 Bolt Locations for Cable Entry Box on Terminal Compartment Roof (a Is the Back and B Is the Front of the Compartment)

87

Figure 7-4 Insulating Barrier Placement for Top Cable Entry

88

MV Cable Entry from Bottom

89

Figure 7-5 Bottom Cable Entry - Installation Material

89

Figure 7-6 Bolt Locations on Terminal Compartment Roof for the Galvanized Steel Plate

90

Figure 7-7 Bracket Location on Insulating Barrier

91

Figure 7-8 Insulating Barrier Placement for Bottom Cable Entry

91

Connecting the Cables

92

Figure 7-9 Power Cable Terminals in a Terminal Compartment Without an Input Disconnector (A) and a Terminal Compartment with an Input Disconnector (B)

92

Figure 7-10 Bolted Busbar Connections

93

Auxiliary Power, Control and Serial Communication Cables

94

Preparing the Cable Entry and the Cables

94

Figure 7-11 Cable Entry from Top (A), from Bottom (B)

94

Preparing Cables for Cable Entries with Cable Glands

95

Figure 7-12 Top Entry for Auxiliary Power and Control Cables

95

Figure 7-13 Preparing Control Cables for Cable Glands

95

Connecting Additional Cabinets

96

Final Checks

96

Figure 7-14 Shield Grounding Point for Encoder Cable

96

Commissioning

97

Overview

97

Required Qualification

97

Commissioning Procedure

97

Commissioning Checklist

97

Customer Assistance

97

Customer Acceptance

97

Commissioning Checklists

98

Mechanical Installation Checklist

98

Electrical Installation Checklist

98

Main Circuit Breaker (MCB) Checklist

99

Motor Checklist

99

Insulation Tests Checklist

99

Power Supply Checklist

99

Miscellaneous Checklist

100

Operation

101

Safety

101

Overview

101

Operating Conditions

101

Local Operator Panel

101

Figure 9-1 Local Operator Panel

102

Status Messages

103

Start Sequence of the Drive

104

Stop Sequence of the Drive

105

Emergency off Sequence of the Drive

106

Starting the Drive

106

Checks before Starting the Drive

106

Starting the Drive Remotely

107

Starting the Drive Locally

107

Stopping the Drive

109

Emergency-Off

109

Initiating an Emergency-Off

110

Starting the Drive after an Emergency-Off

110

CDP Control Panel

111

Overview

111

Figure 10-1 CDP Control Panel

111

CDP Control Panel Functions

112

CDP Control Panel Modes

112

Identification Mode

112

Actual Signals Mode

113

Figure 10-2 Control Panel - Actual Signals Mode

115

Parameters Mode

120

Table 10-1 Parameter Groups

120

Figure 10-3 Control Panel - Parameters Mode

122

Figure 10-4 Control Panel - Functions Mode

126

Local and Remote Control

128

Local Control

128

Remote Control

128

Operational Commands

129

Setting the Direction of Rotation

129

Entering a Reference Value

131

Preventive and Corrective Maintenance

133

General Information

133

Required Qualification

133

Maintenance Schedule

133

Logbook

133

Spare Parts

133

Identifying Electrical Equipment

134

Device Identification

134

Cables and Wires

134

Understanding Wiring Diagrams

134

Figure 11-1 Device Identification

134

Alarm / Fault Indications

135

Messages

135

Error Message Levels

135

Fault Handling

136

Standard Troubleshooting Procedure

137

Removing the CDP Control Panel

138

Leds and Switches on Circuit Boards

139

AMC Circuit Board

139

Figure 11-2 AMC Circuit Board

139

IOEC I/O Modules

140

Figure 11-3 IOEC Module

140

Corrective Maintenance

141

Safety

141

Energizing the Drive Locally

142

Grounding

143

Grounding Switch Is Not Released

144

Figure 11-4 Location of I/O Modules and Fuses

144

Checking the Release Conditions for the Grounding Switch

145

Visual Checks on the Drive

147

Cleaning the Drive

147

Checking Wire and Cable Connections

148

Cleaning and Replacing Filter Mats

148

Table 11-1 Filter Mat Specifications

148

Figure 11-5 Cleaning and Replacing Filter Mats N

149

Inspecting and Replacing Batteries

150

Figure 11-6 Control Compartment - Battery Location

150

Figure 11-7 Control Compartment - Replacing the Batteries

151

Replacing a Fan Unit

152

Figure 11-8 Lifting Point Locations on Fan Unit

153

ABB ACS1000i air-cooled Voltage Drive Manuals

ABB ACS1000i air-cooled User Manual (156 pages)

Table of Contents

ABB ACS1000i air-cooled User Manual (174 pages)

Table of Contents

01 About this Manual

02 Important Safety Information

03 Power Electronics and Cabinet Features

Overview

Main Components of the Drive System

Power Supply Configurations

Drive Topology

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

Unpacking and Inspection

Lifting and Transportation

Transport Conditions

Storage

Disposal of Packaging Materials and Components

07 Electrical Installation

Overview of Installation Work

Safety

Cable Requirements

Ground Cable Connection and Cable Shield Connections

Power Cables, Ground Cables and Equipotential Bonding Conductor

Auxiliary Power, Control and Serial Communication Cables

Final Checks

09 Operation

Overview

Overview of Local Operator Panel

Operating Conditions

Safety

Status Messages

Starting the Drive

Stopping the Drive

Emergency-Off

10 CDP Control Panel

Overview

CDP Control Panel Functions

CDP Control Panel Modes

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

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