—
SYSTEM DRIVES
ACS1000 air-cooled
User manual
OWNING ORGANIZATION
DATE
STATUS
SECURITY LEVEL
ABB Switzerland Ltd.
2022-03-17
Approved
Public
DOCUMENT KIND
DOCUMENT ID.
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User manual
3BHS213401 E01
J
en
© Copyright 2011 ABB All rights reserved.
CONTENTS
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Contents
1. About this manual................................................................................................................. 13
1.1. Equipment covered by this manual ......................................................................................13
1.2. Structure of the user documentation..................................................................................13
1.3. Terms and abbreviations.........................................................................................................14
1.5. Target groups and required qualification........................................................................... 17
1.6. User’s responsibilities..............................................................................................................18
1.7. Intended use of equipment....................................................................................................18
1.8. Quality certificates and applicable standards...................................................................19
1.9. Items covered by delivery ....................................................................................................... 20
1.10. Identifying the delivery ........................................................................................................... 20
2. Important safety information ........................................................................................... 21
2.1. Safety standards........................................................................................................................21
2.2. Safety messages........................................................................................................................21
2.3. Product safety labels............................................................................................................... 22
2.4. General safety instructions.................................................................................................... 23
2.5. The 7 steps that save lives...................................................................................................... 24
2.6. Possible residual risks............................................................................................................. 26
2.7. Main circuit breaker protection device ................................................................................27
2.8. Maintenance recommendation............................................................................................. 29
3. Power electronics and cabinet features ............................................................................ 31
3.1. Overview ......................................................................................................................................31
3.2. Drive topology........................................................................................................................... 32
3.3. Power supply configurations ................................................................................................ 33
3.4. Drive topology........................................................................................................................... 35
3.5. Cooling system ......................................................................................................................... 43
3.5.1. Fan configurations ....................................................................................................... 43
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AC redundant fans - operating principles..............................................................44
Air flow overview (AC and EC fans) ..........................................................................46
Adjustable parameters................................................................................................48
3.6. Cabinet design..........................................................................................................................48
3.7. Door locking system................................................................................................................49
Optional cabinets .........................................................................................................49
3.8. Arc resistant design (optional) .............................................................................................50
Internal arc classification (IAC)..................................................................................50
Associated protection requirement.........................................................................50
3.9. Space heaters.............................................................................................................................51
4. Control system......................................................................................................................53
4.1. Overview ..................................................................................................................................... 53
4.2. Main components .................................................................................................................... 54
4.3. I/O interfaces ............................................................................................................................60
Pulse encoder interface NTAC (option)...................................................................66
5. Transportation, storage and disposal ............................................................................... 67
5.1. Safety ......................................................................................................................................... 67
5.2. Transport conditions............................................................................................................... 67
5.3. Unpacking and inspection..................................................................................................... 67
5.4. Lifting and transportation..................................................................................................... 67
General notes on transportation ............................................................................68
Using a crane .................................................................................................................68
5.5. Storage........................................................................................................................................ 70
Storage and handling of spare parts .....................................................................71
5.6. Disposal of packaging materials and components .........................................................71
6. Mechanical installation ........................................................................................................ 73
6.1. Safety ......................................................................................................................................... 73
6.2. Overview of installation work................................................................................................ 73
6.3. General notes on installation .............................................................................................. 73
Fire protection............................................................................................................... 73
Cable duct material...................................................................................................... 74
6.4. Preparing the floor................................................................................................................... 74
6.5. Fixing the cabinet to the floor .............................................................................................. 74
6.6. Assembling and installing the air exhaust hood.............................................................. 75
6.7. Installing the redundant fan unit.......................................................................................... 76
7. Electrical installation ...........................................................................................................79
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7.1. Safety ......................................................................................................................................... 79
7.2. Overview of installation work................................................................................................ 79
7.3. Cable requirements ................................................................................................................. 79
7.4. Cable entries..............................................................................................................................80
Cable entry with type 1 sealing modules.................................................................81
Preparing the cable entry and the cables ............................................................. 83
Connecting the cables.................................................................................................88
7.6. Auxiliary power, control and serial communication cables ........................................... 92
Power supply cable for redundant fan unit .......................................................................98
7.8. Final checks................................................................................................................................99
8. Commissioning ................................................................................................................... 101
8.1. Overview ....................................................................................................................................101
Required qualification ..............................................................................................101
Commissioning procedure ......................................................................................101
Commissioning checklist .........................................................................................101
Customer assistance ................................................................................................101
Customer acceptance ...............................................................................................101
8.2. Commissioning checklists ................................................................................................... 102
Motor checklist............................................................................................................ 103
9. Operation.............................................................................................................................105
9.1. Safety ....................................................................................................................................... 105
9.2. Overview ................................................................................................................................... 105
9.3. Operating conditions ............................................................................................................ 105
9.4. Sound pressure level.............................................................................................................. 105
9.5. Local operator panel.............................................................................................................. 106
9.6. Status messages.....................................................................................................................107
Start sequence of the drive .................................................................................... 108
Stop sequence of the drive .................................................................................... 109
Emergency off sequence of the drive ..................................................................110
9.7. Starting the drive ...................................................................................................................110
9.8. Stopping the drive ..................................................................................................................113
9.9. Emergency-off .........................................................................................................................114
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CONTENTS
Initiating an emergency-off ......................................................................................114
Starting the drive after an emergency-off............................................................115
10.1. Overview .................................................................................................................................... 117
10.2. CDP control panel functions.................................................................................................118
10.3. CDP control panel modes......................................................................................................118
10.3.1. Identification mode.....................................................................................................118
10.3.2. Actual signals mode....................................................................................................119
10.3.3. Parameters mode ..................................................................................................... 126
10.3.4. Functions mode ...........................................................................................................132
10.4. Local and remote control ..................................................................................................... 134
10.4.1. Local control................................................................................................................. 134
10.4.2. Remote control.............................................................................................................135
10.5. Operational commands........................................................................................................ 136
10.5.1. Setting the direction of rotation............................................................................. 136
10.5.2. Entering a reference value .........................................................................................137
11.1. General information............................................................................................................... 139
Spare parts................................................................................................................... 139
11.2. Identifying electrical equipment ........................................................................................ 140
11.2.1. Device identification .................................................................................................. 140
11.2.2. Cables and wires......................................................................................................... 140
11.2.3. Understanding wiring diagrams ............................................................................ 140
11.3. Alarm / fault indications....................................................................................................... 140
Messages...................................................................................................................... 140
11.3.2. Error message levels...................................................................................................141
11.3.3. Fault handling.............................................................................................................. 142
11.3.4. Standard troubleshooting procedure ................................................................... 143
11.4. Removing the CDP control panel........................................................................................ 144
11.5. LEDs and switches on circuit boards................................................................................ 145
11.5.2. IOEC I/O modules....................................................................................................... 146
11.6. Corrective maintenance.........................................................................................................147
11.6.2. De-energizing the drive locally ................................................................................ 148
11.6.3. Grounding..................................................................................................................... 148
11.6.4. Grounding switch is not released ......................................................................... 149
11.6.6. Visual checks on the drive..........................................................................................152
Cleaning the drive ......................................................................................................152
11.6.8. Checking wire and cable connections ..................................................................153
11.6.9. Cleaning and replacing filter mats..........................................................................153
11.6.10. Inspecting and replacing batteries........................................................................ 155
11.6.11. Replacing the non-redundant fan .........................................................................157
11.6.12. Replacing a redundant fan ....................................................................................... 160
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FIGURES
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Figures
Figure 1–1 Delivered items ............................................................................................. 20
Figure 2–1 Product warning label examples (label placement depends on
Figure 2–3 MCB opening timing diagram .................................................................... 29
Figure 3–2 Block diagrams of an ACS1000A with a 12-pulse rectifier (A)
and a drive with a 24-pulse rectifier (B) ...................................................................... 32
Figure 3–3 Drive overview with power supplies .......................................................... 33
Figure 3–4 ACS1000 air-cooled topology ...................................................................... 35
Figure 3–5 Control and terminal compartments ........................................................ 36
Figure 3–7 Grounding switch ........................................................................................ 38
Figure 3–8 Three-level voltage source inverter principle............................................. 39
Figure 3–11 Principle diagram ...................................................................................... 40
Figure 3–12 Braking chopper design ............................................................................ 41
operation (A) and Intermittent drive operation (B) ................................................... 44
Figure 3–14 Operating principles of redundant EC fans ........................................... 45
Figure 3–15 Air flow– non-redundant fan (1) configuration ........................................46
Figure 3–17 Air pressure switches ................................................................................ 47
Figure 3–18 Door locks ...................................................................................................49
control system (B) and power electronics (C) ............................................................. 53
Figure 4–2 Control compartment .................................................................................54
Figure 4–3 Control compartment – I/O devices ......................................................... 55
Figure 4–4 AMC circuit board ....................................................................................... 56
Figure 4–5 Direct torque control .................................................................................. 57
Figure 4–6 PID control mode ........................................................................................ 59
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FIGURES
Figure 4–7 IOEC interfaces overview ........................................................................... 60
Figure 4–8 IOEC module ................................................................................................ 63
Figure 4–9 IOEC module identification .......................................................................64
Figure 4–10 NTAC-02 pulse encoder interface ............................................................66
Figure 6–1 Leveling the drive .......................................................................................... 74
Figure 6–3 Assembling and installing the air exhaust hood ....................................... 75
Figure 6–5 Redundant fan unit – Installation ................................................................ 76
Figure 7–1 EMC plate example ..................................................................................... 80
Figure 7–5 Cable entry with cable glands ..................................................................... 82
Figure 7–6 Preparing cables for EMC plates: (A) cables with an outer
screen or shield, (B) cables without an outer screen or shield .................................. 85
Figure 7–8 Preparing power cables for cable glands ................................................. 87
Figure 7–9 Power cable terminals in 12-pulse ACS1000A (top row) and
24-pulse ACS1000A (bottom row) ................................................................................89
Figure 7–10 Grounding the drive system .................................................................... 90
Figure 7–11 Bolted busbar connections ....................................................................... 91
Figure 7–12 Cable entry from top (A) and from bottom (B) ........................................ 92
Figure 7–13 Preparing control cables for EMC plates .................................................. 93
Figure 7–14 Frame with sealing modules ....................................................................94
Figure 7–15 Preparing control cables for sealing modules ......................................... 95
Figure 7–16 Preparing control cables for cable glands ..............................................96
Figure 7–17 Shield grounding point for encoder cable .............................................. 97
Figure 10–1 CDP control panel ..................................................................................... 117
Figure 10–2 Control panel - Actual signals mode ...................................................... 121
Figure 10–3 Control panel - Parameters mode .......................................................... 128
Figure 10–4 Control panel - Functions mode ............................................................ 132
Figure 11–2 AMC circuit board ..................................................................................... 145
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FIGURES
Figure 11–3 IOEC module ............................................................................................. 146
Figure 11–4 Location of I/O modules and fuses ....................................................... 149
Figure 11–5 Filter panel (1) and filter mat (2) on rectifier and inverter
Figure 11–6 Control compartment – battery location .............................................. 155
Figure 11–11 Installing the non-redundant fan .......................................................... 159
Figure 11–13 Redundant fans - tools and devices ..................................................... 160
Figure 11–17 Redundant fan unit – using a crane ........................................................ 163
Figure 11–18 Redundant fan unit – using a platform .................................................. 163
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TABLES
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Tables
Table 1–1 Terms and abbreviations.........................................................................................................14
Table 1–7 Encoder........................................................................................................................................16
Table 3–2 ABB arc resistant classes .......................................................................................................50
Table 4–1 IOEC module configuration - analog inputs......................................................................61
Table 4–5 24 V internal voltage supply.................................................................................................. 62
Table 4–6 IOEC module identification ..................................................................................................64
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ABOUT THIS MANUAL
1. About this manual
1.1. Equipment covered by this manual
This manual covers a standard drive and provides generic information on the drive. The
manual does not claim to cover all variations and details of the drive, nor to consider all
eventualities that may arise during installation, commissioning, operation and
maintenance of the drive.
If the drive is adapted to specific customer needs or applications, and handling, installation
and operation of the drive are affected by these modifications, information on these
modifications is provided in the appropriate documentation (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.
NOTE – These appendices are NOT included in this document.
–
Appendix A - Additional manuals provides manuals about additional equipment
delivered with the drive (such as project-specific options such as pulse encoder or
fieldbus interfaces), or information on modifications of the standard drive.
–
–
Appendix B - Technical data contains the technical data sheets of the drive.
Appendix C - Mechanical drawings provides the outline drawings of the drive. The
drawings are generated according to the customer-specific project.
–
Appendix D - Wiring diagrams contains the circuit diagrams with information on
device identification, cross-reference and device identification conventions. The
diagrams are generated according to the customer-specific project.
“Setting of protective devices” is generated according to the customer-specific project.
–
–
Appendix E - Parts list produced for each project and contains all information to
identify a component.
Appendix F - Test reports and certificates provides the test reports of the drive.
Quality certificates, and codes and standards the drive complies with are added if
necessary for the project.
–
Appendix G - Signal and parameter table includes descriptions of actual signals,
control and status words, and control parameters and their default settings.
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ABOUT THIS MANUAL
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.
Table 1–1 Terms and abbreviations
Term/Abbreviation
ACS1000A
Definition
ACS1000 air-cooled drive
AMC circuit board
Application and Motor Controller
The digital signal processor is the heart of the control system of the drive.
Cluster
CDP
A cluster is a synonym for a group of hardware modules of the drive
control system.
Control and display panel
Basic user interface for operating and monitoring the drive when local
operating mode is selected.
DDCS
Distributed drive control system
DDCS is an acronym for a serial communication protocol designed for data
transfer via optical fibers.
Drive
Short form for ACS1000A drive
Drive system
The drive system includes all equipment used to convert electrical into
mechanical power to give motion to the machine.
DriveBus
Communication link dedicated for ABB drives
DriveDebug
DriveDebug is part of ABB’s DriveWare® software tools for drives using the
DDCS communications protocol. DriveDebug runs on computers with
Windows® operating systems. DriveDebug is a specialist’s tool used to
diagnose, tune and troubleshoot ABB drives.
DriveWindow
DriveWindow is a DriveWare® product. DriveWindow is a 32 bit Windows®
application for commissioning and maintaining ABB drives equipped with
optical communication links.
Equipment
EMC
Frequency converter and related equipment
Electromagnetic compatibility
All measures to suppress electromagnetic disturbances caused by
different electrical equipment in the same electromagnetic environment,
and to strengthen the immunity of the equipment to such disturbances.
Ground
Earth
To ground
The conducting path (eg, conductor) between the electric equipment (eg,
frequency converter) and the earth. The electric equipment is connected to
the earth, eg, by a grounding set or a grounding switch.
INU
Inverter unit of the drive. The INU converts the DC voltage to the required
AC motor voltage and frequency.
IOEC module
The IOEC module is an active input and output device for digital and
analog signals.
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ABOUT THIS MANUAL
Table 1–1 Terms and abbreviations (continued)
Term/Abbreviation
Line voltage
MCB
Definition
RMS voltage of the main power supply of the drive
Main circuit breaker
The MCB is a major protection device of the drive and is the main
connection and disconnection point between the main power supply and
the drive.
Molykote
PCB
Brand name for lubricants
Printed circuit board
PCC
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. The utility
is responsible to provide clean voltage and current with respect to
harmonic distortion up to the PCC. The industrial customer is responsible
not to distort voltage and current by its electrical systems.
PID controller
Proportional-integral-derivative controller
Control loop feedback system for controlling process variables (eg,
pressure, flow)
PE
Protective earth
PPCS
Power plate communication system
PPCS is an acronym for a serial communication protocol designed for data
transfer via optical fibers between AMC circuit board and INTerface circuit
boards.
RTD
Resistance temperature detector or device
The RTD is a temperature sensor where the change in electrical resistance
is used to measure the temperature.
Supervisory signal
Indicates the operating condition of a circuit or device.
Software
SW
TC
Short form for terminal compartment of the drive
Uninterruptible power supply
UPS
Zero speed threshold Used in the manual to indicate that the drive has reached the value “zero
speed” that is set in a parameter. The value can be set in the range of 0 and
maximum speed (the unit for the speed is rpm).
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ABOUT THIS MANUAL
1.4. Related documents
Table 1–2 Maintenance
Title
Document number
ACS1000A preventive maintenance schedule
3BHS855276 E01
Table 1–3 Technical data
Title
Document number
Technical data from DriveSmart(1) (configuration software for medium
voltage drives)
(1)
Configuration software for medium voltage drives
Table 1–4 Schematics
Title
Document number
Layout drawing
Project-specific
Table 1–5 Specifications and guidelines
Title
Document number
3BHS301179 E01
3BHS104785 E01
3BHS356582 E01
3BHS260163 E01
3BHS189994 E01
3BHS542290 E01
3BHS813742 E01
3BHS817511 E30
Retrofit guideline
Input circuit breaker engineering guideline
Main transformer specification
Induction motor specification
Power cable specification
Power cables engineering guideline
Auxiliary power and control cables guideline
Permission for working and permit to work for test work at test
stations
Table 1–6 Serial communication interfaces
Title
Document number
3AUA0000096939
3AFY58919772
Ethernet - NETA-21 remote monitoring tool user manual
Modbus - NMBA-01 installation and start-up guide
Profibus - NPBA-12 installation and start-up guide
DeviceNet - NDNA-02 installation and start-up guide
3BFE64341588
3AFY58919829
Table 1–7 Encoder
Title
Document number
Installation and start-up guide for the pulse encoder module NTAC-0x
3AFY58919730
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ABOUT THIS MANUAL
1.5. Target groups and required qualification
The drive presented in this manual is part of an industrial environment where voltages are
present that contain a potential hazard of electric shock and / or burn. For this reason, only
personnel who have a thorough knowledge of the drive and the industrial environment and
have obtained the required qualification should handle, install, operate, or maintain
the drive.
The manual addresses personnel who are responsible for unpacking, transportation,
installation, operation and maintenance of the drive. The personnel must carry out the
below listed tasks in a manner that does not cause physical harm or danger, and ensures
the safe and reliable functioning of the drive.
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.
1.5.2. Mechanical installation
The personnel must be qualified to prepare the installation site according to the site and
equipment requirements and to perform the installation accordingly.
1.5.3. Electrical installation
The personnel must have a sound knowledge of the relevant electrical codes and
specifications covering low and medium voltage equipment, be experienced with electrical
wiring principles and know the electrical symbols typically used in wiring diagrams.
1.5.4. Operation
The personnel include all persons who operate the drive from the local operator panel of the
drive. The personnel must know the functions of the operator panel, be adequately trained
for the drive, and know the driven process. Special knowledge of frequency converter
technology is not required.
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ABOUT THIS MANUAL
1.5.5. Maintenance
The personnel include all persons who
–
Are qualified to carry out preventive and corrective maintenance on drive as described
in this manual
–
–
Are thoroughly familiar with the drive
Have a sound knowledge of the relevant electrical codes and specifications covering low
and medium voltage equipment
–
–
Are able to assess the hazards associated with the energy sources of the drive and act
correspondingly
Know the safe shutdown and grounding procedures for the drive system
1.6. User’s responsibilities
It is the responsibility of those in charge of the drive to ensure that each person involved in
the installation, operation or maintenance of the drive has received the appropriate
training and has thoroughly read and clearly understood the instructions in this manual and
the relevant safety instructions.
1.7. Intended use of equipment
Those in charge of the drive must ensure that the drive is only used as specified in the
contractual documents, operated under the conditions stipulated in the technical
specifications and on the rating plate of the drive, and serviced in the intervals specified by
ABB.
Use of the drive outside the scope of the specifications is not permitted.
Intended equipment use also implies that only spare parts recommended and approved by
ABB must be used.
Unauthorized modifications and constructional changes of the drive are not permitted.
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ABOUT THIS MANUAL
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
–
–
EC declaration of conformity
List of standards the drive complies with
Table 1–8 Standards
Standard
Title
ANSI Z535.6
American national standard for product safety information in product
manuals, instructions, and other collateral materials
ISO 3864-2
2004 (E) - Graphical symbols – Safety colors and safety signs – Part 2: Design
principles for product safety labels
ISO 7010
2011 (E) - Graphical symbols - Safety colours and safety signs - Registered
safety sign
EN 50110
European standard code for electrical work safety
ISO 13849-1
Safety of machinery - Safety-related parts of control systems - Part 1: General
principles for design, section 6.2.6 Category 3
IEC 60204-1
IEC 60721-3-1
IEC 60721-3-2
Safety of machinery - Electrical equipment of machines - Part 1: General
requirements
Classification of environmental conditions: Classification of groups of
environmental parameters and their severities; Storage
Classification of environmental conditions - Part 3-2: Classification of groups
of environmental parameters and their severities - Transportation and
Handling
IEC 60721-3-3
IEC 62477-2
IEC 81346-1
Classification of environmental conditions - Part 3: Classification of groups of
environmental parameters and their severities - Section 3: Stationary use at
weather-protected location
Safety requirements for power electronic converter systems and equipment –
Part 2: Power electronic converters from 1 000 V AC or 1 500 V DC up to
36 kV AC or 54 kV DC
Industrial systems, installations and equipment and industrial products -
Structuring principles and reference designations - Part 1: Basic rules
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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 inside the drive
documents.
–
–
–
–
Strain relief rails
Air exhaust hood
Redundant fan unit (option)
Set of bolts, nuts and washers
1
2
3
4
5
Figure 1–1 Delivered items
1) Door keys
4) Control compartment door
2) Rating label
5) Inside control compartment door
3) Box with USB stick
For a complete list of the items in the delivery, see the shipping note.
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.
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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 standards
The following industry standards are observed:
–
–
–
–
2.2. Safety messages
The following safety messages are provided to help prevent personal injury and damage to
This is the safety alert symbol. It is used to alert you to potential physical injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury
or death.
DANGER Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
WARNING Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE Is used to address practices not related to physical injury, but which can
result in equipment damage.
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IMPORTANT SAFETY INFORMATION
2.3. Product safety labels
Safety labels are affixed to the drive components to alert personnel of potential hazards
when working on the equipment. For more information, see the label placement document
for the drive. The instructions on the safety labels must always be followed and the labels
must be kept in a perfectly legible condition.
1
2
3
4
Figure 2–1 Product warning label examples (label placement depends on the drive)
1) Danger label
2) Warning label
3) Caution label
4) Notice label
Additional safety labels, including the following, might also be provided:
Electricity warning
This sign can also have additional text below it, eg, “High voltage”.
Hot surface
Crushing of hands
No access for people with active implanted cardiac device
The magnetic field of the drive can influence the functioning of pacemakers. The
pacemaker sign should be installed at the entrance to the drive room or at a
minimum distance of 6 m from the drive to stop personnel with pacemakers
approaching the drive.
Firefighting sign
Outlines the procedure when fighting fire in electrical equipment. The sign must
be installed well visible near the drive.
High voltage sign
Must be installed clearly visible at the main circuit breaker in the switchgear room.
The sign alerts personnel to the high voltage which can be present on the
secondary side of the input transformer until the main circuit breaker has been
opened and secured and the drive has been de-energized and grounded.
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IMPORTANT SAFETY INFORMATION
2.4. General safety instructions
1) Minimize hazards
2) Before energizing the drive:
•
•
•
•
Remove all foreign objects from the drive
Fasten all internal and external covers securely
Close, lock, and/or bolt all doors
Move the release dial of the door safety switches into the locked position
Before working on the drive:
•
•
Turn off, lock out, and tag out the main and auxiliary power supplies to the
drive
•
•
•
De-energize the drive
Ensure that the safety ground connections are in place
Ensure that the appropriate personal protective equipment (PPE) is
available and used when required
•
•
Inform the involved personnel about the potential safety hazards
Wear hearing protection when a drive is running.
3) While working on the drive:
•
•
DO NOT step on the roof
DO NOT install foreign objects on the roof
4) Before working simultaneously on the drive and on other drive
system equipment:
•
•
•
•
Observe the relevant safety codes and standards
Turn off all energy sources for the equipment
Ensure that all lockout and tagout devices are in place
Install barriers around and use appropriate covers on the equipment that is
still energized
•
Inform the involved personnel about the potential safety hazards
5) In case of fire in the drive room:
•
•
Observe the established rules and regulations for fire safety
Only allow firefighters with the appropriate PPE to enter the drive room
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IMPORTANT SAFETY INFORMATION
2.5. The 7 steps that save lives
ABB’s 7 steps that save lives concept is a series of actions that must take place prior to
commencing work on or near electrical installations.
1) Prepare for the work: do an on-site risk assessment or job hazard analysis
that considers the limits of approach for shock and arc-flash.
•
•
Be in possession of a clear work order to execute the work.
When required, the access or work permit is to be obtained by a person who
is authorized for the specific electrical system.
•
Engage the person responsible for electrical equipment or system to review
single-line diagrams, schematics, switching plans, etc.
•
•
•
Ensure the competence of workers.
Check for proper tools for the job.
Determine and select the proper arc-rated Personal Protective Equipment
(PPE).
•
Decide of the appropriate work methods and initiate the Permit To Work
(PTW) process.
For an example “Permit to Work”, see “Permission for working and permit
2) Clearly identify the work location and equipment.
•
•
•
Use your senses (sight, hearing and smell) to identify problem areas.
Define the work area via barriers and barricading and label equipment.
Avoid distractions such as talking or texting on the phone.
3) Disconnect all sources of supply and secure against reconnection by
applying Lockout/Tagout.
•
If ABB is responsible for switching and it cannot be done remotely, then the
person performing the switching must be properly trained and wearing the
proper PPE identified in step 1.
•
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.
•
Apply Lockout/Tagout (LOTO) to the energy isolation device and if multiple
energy isolation devices are involved, then Group LOTO must be
implemented with the PICW serving as the Group LOTO Leader.
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IMPORTANT SAFETY INFORMATION
4) Verify the absence of operating voltage: always test before you touch!
Only use properly rated and inspected voltage detection devices and wear
proper PPE identified in step 1:
•
•
•
Test voltage detection device
Test for voltage
Test voltage detection device
It is highly important that the voltage detection device is tested on a known
voltage source such as a Proving Unit or by performing an internal self-test,
according to the manufacturer’s instructions, before and after testing for the
absence of operating voltage.
5) Carry out earthing and short-circuiting.
•
Close and lock the earthing switch if the electrical equipment is designed
for this purpose or apply portable equipment for earthing and short-
circuiting.
If this is carried out by the customer, then the PICW must ensure that this
equipment is properly earthed as a part of the integration/verification and
during step 7 when the PICW walks the PTW.
6) Protect against adjacent live parts and take special precautions when close
to bare conductors.
•
Determine minimum approach distances, apply screening or shrouding,
and when applicable, padlock both cable and busbar shutters.
•
If working within the restricted approach boundary or vicinity zone where
inadvertent movement could cause contact with live parts, special
precautions must be employed, such as the use of the properly rated
insulated gloves and tools.
7) Complete the permit to work and “Walk the Permit”.
•
•
•
•
•
•
•
Check isolation points
Verify that all circuits are isolated and secured
Ensure all parties are integrated with the Lockout/Tagout
Check the earths are properly applied
Answer specific questions from the working group
Ensure the work can proceed without danger
Complete and verify the “Permit to Work”
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IMPORTANT SAFETY INFORMATION
2.6. 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:
1) Electric power equipment generates electro-magnetic fields which can
cause a hazard to people with metal implants and / or a pacemaker.
2) Drive system components can move unintentionally when being
commissioned, operated, or serviced due to:
•
•
•
•
•
•
•
Operation of the equipment outside the scope of the specifications
Incorrectly assembled or installed equipment
Wrongly connected cables
External influence on, or damage of the equipment
Wrong parameter settings
Software errors
Faulty hardware
3) Hazardous touch voltages can be present on drive system components,
which can be caused by:
•
•
•
•
•
Operation of the equipment outside the scope of the specifications
External influence on, or damage of the equipment
Induced voltages by external equipment
Condensation on equipment components, or pollution
Faulty hardware
4) High temperatures, noise, particles, or gases can be emitted from drive
system components caused by:
•
•
•
•
•
Operation of the equipment outside the scope of the specifications
External influence on or damage of the equipment
Wrong parameter settings
Software errors
Faulty hardware
5) Hazardous substances can be emitted from drive system components, eg,
due to incorrect disposal of components
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IMPORTANT SAFETY INFORMATION
2.7. 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. The MCB is located on the primary side of the converter transformer.
3
4
2
1
9
5
6
7
8
Figure 2–2 Drive system overview
1) Main power supply
2) MCB control interface
3) Higher-level control system
4) Local MCB control
5) MCB
6) Protection relay
7) Converter transformer
8) Drive
9) Motor
NOTE – MCBs and protection relays are not included in the drive supply.
Typical MCBs devices
–
–
–
Vacuum circuit breakers
SF6 circuit breakers
Fused contactors or motor control centers
Dedicated protection relay
–
–
–
–
Transformer or drive primary cable protection (DTL)
Transformer protection (if applicable)
Transformer secondary cable protection (if applicable)
Backing up the drive protection
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IMPORTANT SAFETY INFORMATION
2.7.1. 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.
The safety requirements for the drive are based on the following standards:
–
–
2.7.2. Minimum requirements for MCB and MCB control
The following safety requirements are also in the MCB specifications for the drive:
–
The MCB open and / or trip command has to be wired directly from the drive to the MCB.
•
•
It is not permitted to wire the trip command through any PLC or DCS system if it is
not certified to meet SIL three-level requirements and to fulfill the timing
requirements outlined below.
Opening of the MCB by the drive must be possible at any time. It is not permitted to
interrupt the open and / or trip command, eg, by a local-remote switch in the MCB.
–
–
When the MCB is in service position, the drive must have exclusive control of closing the
MCB. Local closing of the MCB is not permitted.
The maximum opening time of the MCB must never exceed the product- or project-
specific maximum time defined in the MCB specifications.
Typical maximum values for the drive are defined as follows:
–
Maximum protection trip time: 120 ms
The maximum protection trip time is the maximum allowed breaking time (open and
arcing) of the breaking device after the open command has been initiated to prevent
further damage to the drive, such as diode failures.
–
Maximum safety trip time: 250 ms
The maximum safety trip time is the maximum allowed time to ensure safe
disconnection of the main power supply to prevent any hazard to personnel.
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IMPORTANT SAFETY INFORMATION
1
2
3
5
4
6
Figure 2–3 MCB opening timing diagram
1) Short-circuit occurs
2) Open and or trip command is set at the drive control output
3) No further damage to the drive
4) No hazard to personnel
5) Maximum protection trip time
6) Maximum safety trip time
In order to meet the stipulated safety requirements, ABB recommends one of the following:
–
–
MCB is equipped with 2 independent opening coils
MCB is equipped with an opening coil and an undervoltage coil for monitoring of the
control voltage
–
Upstream protection coordination scheme is provided which uses the “breaker failure”
(ANSI 50BF) signal to automatically trip the upstream breaker, in case the MCB does not
open.
IMPORTANT! The upstream breaker must open within the maximum safety trip time
after a failure has occurred.
2.8. Maintenance recommendation
The MCB trip circuits should be checked annually.
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POWER ELECTRONICS AND CABINET FEATURES
3. Power electronics and cabinet features
3.1. Overview
The air-cooled ACS1000A 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.
The following sections provide an overview of:
–
–
–
–
–
Drive topology and main features
Available main and auxiliary power configurations
Power electronic components of the drive
Cooling system
Cabinet features such as the grounding switch and the electro-mechanical door
interlock
Figure 3–1 ACS1000 air-cooled
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3.2. Drive topology
A
1
2
3
4
5
6
7
8
B
1
2
3
4
5
6
7
8
Figure 3–2 Block diagrams of an ACS1000A with a 12-pulse rectifier (A) and a drive with a 24-
pulse rectifier (B)
1) Medium voltage switchgear, including main 5) DC link
circuit breaker and transformer protection
6) Inverter
7) Filter
2) Transformer
3) Rectifier
8) Motor
4) Protection IGCTs
The drive system consists of the following main components:
–
–
–
–
Transformer: see the Transformer specification.
Drive
Asynchronous motor: see the motor specification.
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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
2
3
5
4
1
6
10
7
14
8
9
11
12
13
Figure 3–3 Drive overview with power supplies
1) Auxiliary power supply
2) ACS1000A
8) MCB
9) Transformer
3) Control and cooling system
4) Auxiliary power distribution
5) Cooling system
10) Power electronic components
11) Rectifier
12) DC link
6) Control system
13) Inverter
7) Main power supply
14) Motor
3.3.1. Main power supply configurations
The drive is connected to the main power supply via a three-winding oil or dry-type
transformer.
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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:
–
Through a common power supply
•
•
The total auxiliary power is supplied to the drive by a three-phase AC power supply.
If the power supply is interrupted, drive internal batteries provide a backup for the
control system, thus enabling the drive to ride-through and/or to perform a
controlled shutdown.
–
Through separate power supplies
•
The auxiliary power is supplied to the drive by a three-phase AC power supply and by
an UPS to a separate one-phase AC or DC input.
•
Feeding the control power separately by an UPS has the advantage that the main
control hardware will remain energized, the full ride-through capabilities of the drive
can be used, and the communication to a higher-level control system will not be lost
in the event of an auxiliary power outage.
IMPORTANT! The power feed for the auxiliary supply must be protected with a suitable
circuit protection rated for the inrush current.
Wiring diagrams”. For information on the rated voltage(s) and current(s), see the rating
plate of the drive.
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3.4. Drive topology
This section describes the main design features and introduces the major power
electronics components of a typical drive.
3.4.1. Overview
1
2
Figure 3–4 ACS1000 air-cooled topology
1) Control compartment and terminal
compartment
2) Rectifier and inverter compartment
3.4.2. Control compartment and terminal compartment
The left compartment of the drive comprises:
–
system of the drive.
–
and motor cables, the ground cable and the cable screens. A hinged bolted partition
separates the terminal compartment from the control compartment.
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1
2
120°
Figure 3–5 Control and terminal compartments
1) Control compartment
2) Terminal compartment
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3.4.3. Rectifier and inverter compartment
1
6
3
4
5
7
2
9
8
10
Figure 3–6 Rectifier compartment
1) Second 12-pulse rectifier
2) 12-pulse rectifier with protection IGCTs
3) Inverter phase U
6) Grounding switch
7) Common mode choke (option)
8) Filter choke
4) Inverter phase V
9) Filter capacitors
5) Inverter phase W
10) DC-link capacitors
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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.
The grounding switch is electro-mechanically interlocked with a discharge monitoring
circuit that prevents closing of the switch while the DC link capacitors are still charged.
Grounding the drive is only possible after the main power supply has been disconnected,
and the DC link has discharged. When the voltage is below 50 V (DC), the lamp grounding
2
1
Figure 3–7 Grounding switch
1) Grounding switch unlocked lamp is on
2) Grounding switch in grounded position
When the grounding switch is in position grounded, the doors of the medium voltage
compartments are released, and the doors can be opened.
3.4.5. Rectifier
The diode rectifier converts the AC voltage of the main power supply and connects its
output to the minus, neutral point, and plus side of the DC link.
Depending on the harmonics requirements for the main power supply, the drive is equipped
with a 12-pulse or a 24-pulse rectifier.
3.4.6. Protection IGCTs
The drive features a fuseless protection design. The IGCTs are placed between the rectifier
and the DC link. If necessary, the IGCTs directly isolate the inverter from the main power
supply.
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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. The output is switched between positive DC
voltage, neutral point (NP) and negative DC voltage. Hence, the drive can control the output
voltage and the frequency continuously from zero to maximum using direct torque control.
+
0
U=
-
Figure 3–8 Three-level voltage source inverter principle
3.4.8. Filter
The filter at the drive output reduces the harmonic content of the motor voltage and
generates a nearly sinusoidal motor-friendly voltage waveform. The filter also eliminates all
high dv/dt effects. Therefore, standard motors can be used, and voltage reflections in the
motor cables are eliminated.
Figure 3–9 Voltage and current waveforms at drive output
Output voltage: 4.16 kV
Output frequency: 60 Hz
3.4.9. Optional Braking Chopper
The optional braking chopper uses resistor braking to provide motor braking and shorter
deceleration times, eg, for:
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POWER ELECTRONICS AND CABINET FEATURES
–
–
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.
1
Figure 3–10 ACS1000A with braking chopper (1)
The braking chopper is controlled and monitored by the ACS1000A.
1
2
3
VC1
C1
4
Rb
C2
VCs2
VC2
Figure 3–11 Principle diagram
1) Rectifier
3) Inverter
2) Braking chopping
4) Braking resistor
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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.
1
Figure 3–12 Braking chopper design
1) Semiconductor stack
3.4.9.2. Monitoring and protective functions
Current monitoring
Input currents of the braking chopper are monitored for overcurrent and imbalance in order
to detect any defective component in the circuit. The current can become imbalanced if one
of the IGCTs conducts a current permanently or if an IGCT fails to be switched on.
If a short-circuit or an imbalance is detected in the braking chopper, the drive is shut down.
Thermal protection
The braking chopper and the braking resistors are monitored for over-temperature by
the ACS1000A.
In addition, an external thermal protection device can be connected to a digital input. As
soon as the temperature of the braking resistors exceeds the response threshold of the
external thermal protection device, the operation of the braking chopper is disabled and an
alarm message is displayed on the control panel of the ACS1000A. Braking is then only
possible when the temperature falls below the threshold.
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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
The relation between maximum braking energy (Ebrake max) and maximum chopper braking
power (Pchopper max) is as follows:
E
brake maxMWs = PchoppermaxMW 30 sec
(1)
After a braking period of 30 s with maximum braking power (2.5 MW), a cooling time of one
hour is required. If two braking sequences of 30 s are necessary within an hour, the
maximum braking power has to be reduced to 50% of the maximum possible braking
power.
Table 3–1 Braking ratings
ACS1000A
Braking chopper
Type
Max. DC-link
voltage (V)
Max. braking
power (MW)
Max. braking
power (MW)
Max. braking
energy (MW)
ACS1012-A1
ACS 1013-A1
ACS 1014-A1
4200
6000
7270
0.426
0.426
0.426
2500
75
75
75
75
75
75
ACS1012-A2
ACS 1013-A2
ACS 1014-A2
4200
6000
7270
0.672
0.672
0.840
2500
2500
2500
2500
2500
ACS1012-A3
ACS 1013-A3
ACS 1014-A3
4200
6000
7270
0.960
1.080
0.960
ACS1012-W1
ACS 1013-W1
ACS 1014-W1
4200
6000
7270
1.350
1.500
1.350
ACS1012-W2
ACS 1013-W2
ACS 1014-W2
4200
6000
7270
1.680
2.130
2.130
ACS 1013-W3
ACS 1014-W3
6000
7270
2.500
2.500
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POWER ELECTRONICS AND CABINET FEATURES
3.4.9.5. Cabinet dimensions and weight
Length
Depth
Width
Height
644 mm
902 mm
2002 (2070 including lifting eyes)
460 kg
3.4.9.6. Braking resistor cables
Cable type
Shielded
70 mm2
Minimum cross sectional
area
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.
Maximum length
50 m
The configuration and dimensions of the braking resistors depend on the specific
application. For information, see the “Dimensioning of braking resistors” application note.
3.5. Cooling system
3.5.1. Fan configurations
The cooling system of the drive is equipped with one of the following fan configurations:
–
–
configuration enables continuous operation of the drive if a fan fails.
3.5.2. Type of fan
The drive is equipped with one of the following types:
–
AC fans: The AC fans are turned on and off with digital signals which switch contactors
to connect or disconnect the 3-phase auxiliary power. The AC fan speed is not controlled.
–
EC fans: The electronically commutated (EC) fans are controlled via an analog signal
from the drive based on the inverter current. The EC fan speed is controlled depending
on the required cooling.
3.5.3. Starting, stopping the cooling system
The drive switches on the cooling system when the main circuit breaker (MCB) closes. When
the MCB opens, the cooling system switches off after a delay. The delay corresponds to the
discharging time of the drive and takes up to 5 minutes.
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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
A
B
1
2
3
4
4
7
8
5
5
7
8
6
Figure 3–13 Operating times of the AC fan units during continuous drive operation (A) and
Intermittent drive operation (B)
1) Cycle time
2) Fan 1
5) 6 hours
6) 4 hours
7) On
3) Fan 2
4) 10 hours
8) Off
When the drive operates continuously, AC fan 1 switches off after six hours and fan 2
switches on for four hours.
When the drive operates intermittently, the AC fan that is due for operation is switched on
and off in the same pattern as the drive until the programmed operating time has elapsed.
If one AC fan fails, the second AC fan switches on and runs continuously.
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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.
100%
3
4
2
5
1
6
Both fans are running
Fan 1 fails, fan 2 increases speed
Fan 1 is stopped, Fan 2 is running at nominal speed
Fan 1 resumes operation, fan 2 decreases speed
Figure 3–14 Operating principles of redundant EC fans
1) Fan 1
4) Nominal fan speed
5) Reduced fan speed
6) Minimum fan speed
2) Fan 2
3) Drive load
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POWER ELECTRONICS AND CABINET FEATURES
3.5.6. Air flow overview (AC and EC fans)
1
Figure 3–15 Air flow– non-redundant fan (1) configuration
1
2
Figure 3–16 Air flow– redundant fan configuration
1) Fan 1
2) Fan 2
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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. For EC fans, the supervision is
integrated in the EC fan electronic board.
the drive.
1
2
Figure 3–17 Air pressure switches
1) Air pressure switch
2) Location of optional air pressure switch
When the pressure decreases and the response threshold of the pressure switch is reached,
the following takes place:
–
Drives with non-redundant fan configuration: The alarm FanDiffPres displays on the
local control panel and the drive shuts down.
–
Drives with redundant fan configuration: The alarm FanDiffPres displays on the local
control panel and the drive switches on the stand-by fan. When the stand-by fan also
fails, the drive shuts down.
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POWER ELECTRONICS AND CABINET FEATURES
3.5.7.2. Air pressure across filter mat (AC and EC fan types)
the filter mat in the air intake. When the filter mat is clogged and the pressure drop reaches
the specified final pressure loss, the alarm AirFiltSupv displays on the local control panel.
The reaction of the drive on the alarm is programmable.
3.5.8. Adjustable parameters
For information on the parameters for the cooling system and their settings, see
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. The
inside walls of the cabinet are not painted, because paint tends to reduce the effectiveness
of metallic bonding which is important for successful EMC.
Accordingly, only the front of the cabinet is painted while all other walls are galvanized.
However, the cabinet can be ordered optionally with the whole of the outside painted. EMC
performance is further enhanced by the use of metal cable ducts.
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POWER ELECTRONICS AND CABINET FEATURES
3.7. Door locking system
To ensure safety and to prevent the doors being opened unintentionally, all doors are
lockable. The doors of compartments where medium voltages are present during operation
Additionally, the doors of the medium voltage compartments have locks with different
inserts than the control compartment door. The different lock inserts ensure that these
doors can only be opened by personnel authorized to do so.
1
2
2
2
Figure 3–18 Door locks
1) Door of control compartment: lockable
2) Doors of rectifier and inverter compartment:
electro-mechanically locked
Partition of terminal compartment behind
control compartment: bolted
Doors cannot be opened when the drive
is energized.
3.7.1. Optional cabinets
If medium voltages are present in an optional cabinet during operation (eg, braking
chopper and output disconnector), the door is secured by an electro-mechanical lock as well
as a door monitoring switch. If the cabinet is UL certified, the door is further secured with
extra screws. The lock and the switch release the door after the DC link of the drive has
discharged and the drive has been grounded.
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POWER ELECTRONICS AND CABINET FEATURES
3.8. Arc resistant design (optional)
The optional “Arc Resistant Design” provides the drive with arc fault protection in
accordance with IEC 62477-2.
Depending on the drive configuration, classes I and II are available for an ACS1000A.
For information on the arc resistant design class of your drive, see the project-specific
Table 3–2 ABB arc resistant classes
ABB class
Class I
Description
Class II
Protection based on arc resistant cabinet structure, IAC certified by 3rd body
according to IEC 62477-2
Class III
Class IV
Protection based on external arc fault limitation and elimination. HV fuses are
applied externally to limit the arc fault current, IAC certified by 3rd body according
to IEC 62477-2
Fast arc detection and elimination, IAC certified by 3rd body according to
IEC 62477-2
3.8.1. Internal arc classification (IAC)
The arc fault rating, which is based on arc fault tests, is on the label underneath the drive
rating plate of the drive.
Internal Arc Classification (IAC)
ABB Class II
IAC
F
L
R
T
B
IA
tA
APR SC
No
IEC 62477-2
Distance [m]
2b
2b
2b
1
-
1
-
5 kA 0.5 s Yes
0.3
0.3
0.3
3BHB049908R1205
Figure 3–19 IAC label example
3.8.2. Associated protection requirement
The arc resistant design requires associated protections that are not included in the scope
of the delivery, ie, a main circuit breaker.
For more information on the MCB:
–
–
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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.
Figure 3–20 Space heaters
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CONTROL SYSTEM
4. Control system
4.1. Overview
The control compartment incorporates the hardware for the control, monitoring and
protection functions of the drive, and the communication interfaces to the local control
panel and to the remote control devices. Depending on the control concept of the drive
system, the remote control devices include a higher-level control system and / or remote
operator stations.
2
A
1
3
7
4
4
6
B
5
4
4
8
11
12
13
14
9
10
9
C
Figure 4–1 Block diagram of control system with customer interface (A), control system (B)
and power electronics (C)
1) ABB Ability
2) Higher-level control system
3) Fieldbus
8) AMC circuit board
9) Fiber-optics
10) INT circuit board
11) IOEC1
4) DDCS
5) RS485
12) IOEC2
6) CDP control panel
7) PC tools
13) IOEC3 (optional)
14) IOEC4 (optional)
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CONTROL SYSTEM
4.2. Main components
This section provides an overview of the main hardware components of the control system
and their interconnection.
1
2
8
3
4
5
6
7
Figure 4–2 Control compartment
1) Control power supply
5) IOEC1 module
2) AMC circuit board and INT circuit board
3) Pulse encoder (option)
6) Motor starters and circuit breakers
7) Control power supply
8) Local control panel
4) Fieldbus interface (option)
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CONTROL SYSTEM
1
2
3
4
Figure 4–3 Control compartment – I/O devices
1) IOEC2 module (standard)
2) IOEC4 module (option)
3) Auxiliary voltage terminals
4) IOEC3 module (option)
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.
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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.
The circuit board is fitted with a Motorola DSP processor and features two PPCS and eight
DDCS communication channels. These communication channels are used for high-speed
data transfer via the INT circuit board to the inverter.
1
2
Figure 4–4 AMC circuit board
1) AMC circuit board
2) Interface circuit board (INT)
4.2.2.1. Control tasks
The AMC circuit board has specific control and closed-loop tasks assigned to it. It
processes drive and status information, performs the speed and torque control tasks, and
monitors the operation of the drive.
All relevant drive variables (eg, speed, torque, current, voltage) are continuously monitored
by the control system. Pre-programmed protection functions ensure that these variables
remain within certain limits in order to maintain safe operation of the drive. These internal
functions are not programmable by the user.
Optionally, the AMC circuit board can monitor signals from external equipment. These can
be activated and adjusted with parameters.
Other general control, protection and monitoring tasks regarding the whole drive include
control and monitoring of:
–
–
–
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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.
For more information on the parameters for signal allocation, signal type selection, signal
4.2.2.3. Main circuit breaker
The main circuit breaker (MCB) is an important switching and protection device of the drive
system. Therefore it must only be controlled and monitored by the drive.
For more information, see the Main circuit breaker engineering guideline and section 2.7,
4.2.2.4. Direct torque control
The speed and torque of the motor is controlled by DTC (Direct Torque Control). DTC
provides accurate speed and torque control, and high dynamic speed response.
1
8
6
7
5
2
3
4
9
10
11
12
Figure 4–5 Direct torque control
1) Torque reference
7) Motor model
8) Switching logic
9) Switch positions
10) Voltage
2) Speed reference
3) Actual reference
4) Speed controller
5) Torque reference controller
6) Torque-flux comparator
11) Current
12) Motor
Switching of the semiconductors in the inverter is directly controlled in accordance with the
motor core variables flux and torque.
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CONTROL SYSTEM
The measured motor currents and DC link voltages are inputs to an adaptive motor model.
The model produces exact values of torque and flux every 25 microseconds. Motor torque
and flux comparators compare the actual values to reference values which are produced by
the torque and flux reference controllers.
Depending on the outputs from the hysteresis controllers, the switching logic directly
determines the optimum switch positions every 50 microseconds and initiates switching
whenever required.
4.2.2.5. Peripheral I/O devices
The peripheral input and output devices connected to the AMC circuit board include:
–
–
Local CDP control panel
–
–
–
Serial communication interface (fieldbus) for serial data transfer to a higher-level
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 with ABB Ability monitoring contract (optional): monitoring and diagnostics
tool that allows access to the drive from any location in the world via a secure
Internet connection.
4.2.2.6. Control modes
The drive provides the following control modes:
–
Speed control mode: Default control mode of the drive. The control mode can be used
for applications where constant speed is required, such as pumps, fans and conveyors.
–
Torque control mode: used for processes that require torque control (eg, mixers and
slave drives). The torque reference comes from a process control system or a control
panel.
–
PID control mode: controls the process variable (eg, pressure, level or flow) by
adjusting the speed of the motor accordingly.
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CONTROL SYSTEM
1
3
2
4
Figure 4–6 PID control mode
1) Reference value
2) Level transducer
3) Actual value
4) Pump
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.
–
Sequential control mode: used in processes that require different constant speed
settings and/or different acceleration and/or deceleration settings in addition to an
adjustable speed reference value.
Up to seven constant speed settings and two acceleration and/or deceleration settings
are possible. The selection of the different settings can be automated by a process
control system or can be made manually by selector switches that are connected to the
corresponding digital inputs of the drive.
The preset values of a control mode can be left unchanged or they can be set individually by
the commissioning engineer as required for the application.
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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.
–
Hand-auto operating mode: suitable for applications where the speed has to be
controlled automatically by a process automation system and manually by an external
control panel. The active control station is selected via a digital input.
The operating mode is also recommended when two external control stations exist from
where the reference value can be set and the drive can be started and stopped. The
external control station is selected via a digital input.
4.3. I/O interfaces
4.3.1. IOEC I/O modules
Internal and external, analog and binary I/O signals are connected to the control system by
IOEC modules.
The standard I/O includes one external module (IOEC 2, IOEC 3) and one module that is
internal to the drive operation (IOEC 1). The standard I/O provides standard control and
supervision functionalities sufficient for most applications.
The drive can include an optional expansion I/O that includes an external module (IOEC 4).
These expansion modules provide extra inputs and outputs for control and supervision as
may be required by the drive or the customer to support various control options.
5
1
2
6
3
7
4
7
6
Figure 4–7 IOEC interfaces overview
1) IOEC 1
2) IOEC 2
3) IOEC 3
4) IOEC 4
5) AMC circuit board
6) Standard
7) Option
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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 4–1 IOEC module configuration - analog inputs
No. of I/O
4
Resolution
10 bit
Signal interface
Signal level
Floating, galvanically isolated
0 - 20 mA, 4 - 20 mA, 0 - 10 V, 2 - 10 V
Individually scalable by parameter
Input resistance
Rin = 105 Ω for current input
Rin = 250 k Ω for voltage input
Common mode voltage
Isolation level
Maximum: 48 V
350 V (AC)
Table 4–2 IOEC module configuration - analog outputs
No. of I/O
2
Signal range
Resolution
Isolation level
0 - 20 mA (load impedance: max. 250 Ω)
12 bit
350 V (AC)
Table 4–3 IOEC module configuration - digital inputs
No. of I/O
14
Signal level
22 - 120 V (DC) *
*for the 80 to 120V range, an IOEC adapter board is required
22 - 250 V (AC)
Logical threshold
Input current
< 13 V (AC or DC) ≙ “0”, > 16 V (AC or DC) ≙ “1”
13 mA steady state (14 mA max. inrush) at 24 V (DC)
11.5 mA steady state (80 mA max. inrush) at 120 V (DC)
10.5 mA steady state (92 mA max. inrush) at 230 V (AC)
Isolation level
1350 V (AC)
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CONTROL SYSTEM
Table 4–4 IOEC module configuration - digital inputs
No. of I/O
6
Signal level
Maximum: 120 V (DC) or 250 V (AC)
4000 V (AC)
Isolation level
Switching capacity
Voltage
24 V (DC)
24 V (AC)
48 V (DC)
48 V (AC)
120 V (DC)
120 V (AC)
230 V (AC)
Switching current
Steady state current
8 A
8 A
6 A
6 A
6 A
6 A
6 A
6 A
6 A
1 A
8 A
0.4 A
8 A
8 A
4.3.1.2. Internal voltage supply (24 V)
One isolated DC/DC converter supplies an overload protected voltage of 24 V (DC) to
operate digital inputs from passive contacts. The output is protected by a PTC-resistor
against short-circuit and external applied overvoltages.
Table 4–5 24 V internal voltage supply
Output voltage
Available output voltage
Unregulated 24V
180 mA
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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
X21-1
X21-2
6
DO1
X21
X21-3
X22-1
7
X22-2
DO2
X22-3
X22
24V DC
X6-1
X6-2
X6-3
X6-4
X23-1
X23-2
X23-3
8
DO3
DO4
X23
X24
X25
X28
X24-1
X24-2
X24-3
1
POWER
OK
X25-1
X25-2
X25-3
DO5
DO6
X26-1
X26-2
X26-3
LINK
ERROR
NODE
ADDRESS
X11-1
DI1
X11-2
DI1
DI2
X11-3
DI2
X11-4
X11-5
DI3
DI4
X11
X12
X13
DI3
X11-6
X11-7
DI4
X11-8
X11-9
DI5
DI6
DI7
DI8
DI5
X11-10
X12-1
DI6
X12-2
X12-3
DI7
X12-4
X12-5
DI8
X12-6
2
X12-7
DI9
X12-8
DI9
X12-9
DI10
X12-10
DI10
DI11
DI12
DI13
DI14
X13-1
DI11
X13-2
9
10
X13-3
DI12
X13-4
X13-5
DI13
X13-6
X13-7
DI14
AI1 20mA
AI1 10 V
AI2 20mA
AI2 10 V
AI1 20mA
X13-8
X13-9
X13-10
AI1 10 V
AI2 20mA
AI2 10 V
24 V
IR
S1
S2
S1
S2
3
OV
IR
S1
S2
AI1 20mA
AI1 10V
1
2
3
4
OV
+10V
AI3 20mA
AI3 10 V
AI4 20mA
AI4 10 V
AI3 20mA
AI3 10 V
AI4 20mA
AI4 10 V
AI2 20mA
AI2 10V
+AI1
+AI2
+AI3
+AI4
-AI1
-AI2
-AI3
-AI4
-AO1
-AO2
X31
X31
4
X32
X32
AI3 20mA
AI3 10V
1
2
3
4
AI4 20mA
AI4 10V
+AO1
+AO2
IOEC
I/O-INTERFACE
5
Figure 4–8 IOEC module
1) Digital outputs
2) Digital inputs
6) DDCS fiber optics
7) I/O Emergency OFF function
8) Power supply (factory-installed wiring)
9) Voltage mode
3) 24 V internal voltage
4) Analog inputs
5) Analog outputs
10) Current mode
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CONTROL SYSTEM
4.3.1.4. I/O device identification
wiring diagram, and in the software by the wiring diagram identification number (2 in
Fig. 4–9).
1
2
A5191
A5191
Figure 4–9 IOEC module identification
1) Identification label
2) Identification number
The way the identification number is built directly corresponds to the wiring diagram as can
three digits are the page number the part is located on, page 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.
Table 4–6 IOEC module identification
I/O module type
IOEC1
Wiring diagram designation for module identification
A5191
A5201
A5211
A5221
IOEC2
IOEC3
IOEC4
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CONTROL SYSTEM
4.3.2. Serial communication interface (fieldbus)
Wiring diagrams”. For more information on the device, consult the relevant manual:
–
–
–
–
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CONTROL SYSTEM
4.3.3. Pulse encoder interface NTAC (option)
The NTAC interface is part of the control system of the drive if pulse encoder feedback is
used to control the motor.
+24V 0V 24 15 24/15 +V
-V
-V
X2
X1
A+ A-
B+ B- Z+ B- SH SH
Figure 4–10 NTAC-02 pulse encoder interface
Terminals X1
Terminals X2
1
A+
A-
Channel A
Channel B
Channel Z
Shield
1
-V
0 V
2
3
4
5
6
7
8
2
3
4
5
6
7
8
-V
24 V
B+
B-
+V
24/25
15
Z+
Z-
24
SH
SH
0 V
+24 V
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TRANSPORTATION, STORAGE AND DISPOSAL
5. Transportation, storage and disposal
5.1. Safety
The drive must only be handled by personnel who are skilled and experienced in
unpacking and transporting heavy equipment.
5.2. Transport conditions
–
–
Transport conditions: 2K12 / 2B1 / 2C2 / 2S5 / 2M4
Maximum transport time: 2 months
5.3. Unpacking and inspection
1. Remove all packaging material carefully.
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).
5.4. Lifting and transportation
Mechanical drawings”, at hand before transporting the cabinet:
–
–
“Layout drawing” document
“Fixing and Lifting details” document
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TRANSPORTATION, STORAGE AND DISPOSAL
5.4.1. General notes on transportation
NOTICE Risk of component damage!
▶
DO NOT lift and move the drive or a transport unit using a forklift.
The frame of the cabinets could be damaged. If a crane is not available, contact
ABB for instructions on other means of moving.
▶
▶
Transport the cabinet in upright position.
Keep the doors closed to ensure that dirt cannot enter.
Metallic dust in particular can cause damage and failure when the drive
is energized
▶
If the drive is delivered in several transport units, DO NOT lift and move the
drive by crane after the transport units have been joined.
Use appropriate transport means eg, heavy load hydraulic rollers or air
cushions. If in doubt, contact ABB for instructions.
5.4.2. Using a crane
5.4.2.1. Cabinets with redundant fan unit
NOTICE Risk of component damage!
If the cabinet is lifted at the eye bolts, the fastening screws of the fan unit tear off,
and fan unit and cabinet are damaged.
▶
DO NOT attach lifting equipment to the eye bolts of the redundant fan unit.
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5.4.3. Cabinets without redundant fan unit
–
Use lifting equipment (eg, web slings, chain slings, round slings, safety hooks, shackles)
that corresponds to the weight of the cabinet.
–
–
–
–
The rails can be removed after the cabinet has been installed at its final location.
To attach a sling, use appropriate safety hooks or shackles.
1
1
60°
60°
Figure 5–1 Transporting the cabinet by crane
–
Lift the cabinet slowly and steadily to the required clearance height maintaining the
cabinet in upright position.
–
Check the horizontal position of the cabinet. Reposition the slings if necessary.
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3BHS213401 E01
J
en
TRANSPORTATION, STORAGE AND DISPOSAL
5.5. Storage
5.5.1. Storage conditions
–
Conditions: 1K22 / 1B1 / 1C2 / 1S11 / 1M11
5.5.1.1. Storage time
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. Remove the batteries (if applicable).
2. Cover all cable inlets and ventilation slots with an impermeable plastic or aluminum foil
and a wooden panel.
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/m2 foil
•
4. Close and lock the doors of the cabinet.
5. Use polyethylene or equivalent for packaging:
•
0.3 g/m2/24h water vapor diffusion
6. Attach humidity indicators to the packaging.
The storage conditions and the packaging should be checked regularly. Any damages that
occur during the storage period should be repaired immediately.
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TRANSPORTATION, STORAGE AND DISPOSAL
5.5.3. Storage and handling of spare parts
NOTICE Risk of component damage!
Electronic devices (eg, circuit boards, semiconductors) are sensitive to
electrostatic discharge (ESD), which can damage these devices. Observe the
following to maintain spare parts in good condition and to keep the warranty valid
during the warranty period:
▶
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
Store printed circuit boards in antistatic bags or boxes
Storage temperature range: -5 °C to +55 °C
Storage place requirements:
•
•
•
Free of vibration and shock
Protected against dust, sand, vermin and insects
Free of corrosive gases, salt or other impurities that could damage
electronic equipment
•
•
Dry with NO condensation
Relative air humidity: 5 to 85%
If in doubt whether the maximum allowed humidity is exceeded, protect the spare
parts with an external heater.
–
–
DO NOT touch a component without wearing a wrist grounding strap.
Put the component on a grounded working surface protected against
electrostatic discharges
–
Hold the component only at the edge
5.6. Disposal of packaging materials and components
Dispose of the packaging materials and the components at the end of the lifetime of the
drive according to local regulations.
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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:
–
–
–
–
6.3. General notes on installation
NOTICE Risk of component damage!
Foreign matter and particularly metallic dust can cause failure and damage when
the drive is energized.
▶
Ensure that foreign matter cannot enter the cabinet:
•
Close the doors and cover openings completely when work
is discontinued.
•
Retrieve any foreign matter which accidentally dropped into the cabinet.
6.3.1. Dimensions and clearances
–
–
–
Cabinet dimensions
Clearances to be observed
Mounting hole sizes
6.3.2. Cabinet roof
The cabinet roof is not designed as a mounting base for, eg, foreign devices, cable ducts.
Therefore, it is not permitted to install any foreign device on the roof.
6.3.3. Fire protection
To prevent fire spreading into the drive, apply suitable fire protection measures.
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MECHANICAL INSTALLATION
6.3.4. Cable duct material
–
Use non-flammable material with non-abrasive surface.
–
To prevent dust, humidity and animals entering the cabinet, protect the cable entries.
6.4. Preparing the floor
Condition of the floor:
–
–
–
–
–
Must support the weight of the cabinet
Overall incline across 5 m must not exceed 5 mm
Even
Non-flammable, smooth and non- abrasive
Protected against humidity diffusion
6.5. Fixing the cabinet to the floor
IMPORTANT! If the doors of medium voltage compartments cannot be opened, contact the
ABB service organization
1. Drill fixing holes into the floor as indicated on the layout drawing.
2. When the cabinet is in place, check if the doors are misaligned.
NOTE – If the doors DO NOT open and close properly, place leveling plates at the
3. Recommended size: 80 x 300 x 0.5 mm
Figure 6–1 Leveling the drive
4. Fix the cabinet to the floor.
screws and nuts.
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MECHANICAL INSTALLATION
5. Insert the screws from the ends of the cabinet base or via the holes inside the cabinet.
Figure 6–2 Fixing the cabinet to the floor
6.6. Assembling and installing the air exhaust hood
This section applies to drives with an internal fan.
–
–
Assemble and install the air exhaust hood as illustrated.
Use the supplied screws.
1
2
3
4
Figure 6–3 Assembling and installing the air exhaust hood
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MECHANICAL INSTALLATION
6.7. Installing the redundant fan unit
This section applies to drives with a redundant fan unit.
–
Included in delivery: screws
IMPORTANT! Move the drive to its final location before you install the redundant fan unit.
1
4
3
2
Figure 6–4 Redundant fan unit – Removing lifting rails and cover
CAUTION! The redundant fan weighs approximately 300 kg.
1
1
Figure 6–5 Redundant fan unit – Installation
4. Orientate the redundant fan unit with the cable pointing to the left.
5. Lift the redundant fan unit above the cabinet.
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MECHANICAL INSTALLATION
6. Before you lower the redundant fan unit onto the cabinet roof, check that the gasket
between cabinet roof and redundant fan unit is properly placed.
7. Fasten the redundant fan unit on both sides to the cabinet roof.
1
3
2
8. Attach the sound absorbing panels to the right side of the redundant fan unit.
Recommended sequence: 1, 2, 3.
1
3
2
9. After the power supply cable of the redundant fan unit and the transformer and motor
cables have been entered into the cabinet, attach the sound absorbing panels to the
left side of the redundant fan unit.
10. Continue with the electrical installation of the power supply cable.
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ELECTRICAL INSTALLATION
7. Electrical installation
7.1. Safety
DANGER Hazardous voltage!
Improper work can result in DEATH or life-threatening injury.
▶
The electrical installation must be carried out by qualified personnel according
to the site and equipment requirements, and the relevant electrical codes.
▶
When the electrical installation is completed, the main and auxiliary power
supply to the drive must not be switched on without the consent of the ABB
commissioning personnel.
▶
Take appropriate measures to prevent main and auxiliary power supply being
switched on during installation.
7.2. Overview of installation work
The electrical installation includes the following wire and cable connections:
–
–
–
7.3. Cable requirements
For information on the requirements for power cables, ground cable and equipotential
bonding conductor, see:
–
–
For information on the requirements for the auxiliary power cable and the control cables,
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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
Cable entry with sealing modules, type 2
Cable entry with cable glands
7.4.1. Cable entry with EMC plates
–
Usage:
•
•
Power cables, ground cables and bonding conductors
Auxiliary power cables and control cables
–
grommets (2)
1
2
1.5 mm
Ø45 mm
Figure 7–1 EMC plate example
1) EMC sleeves
2) Sealing grommets
–
control cables.
1
Figure 7–2 EMC cushion
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ELECTRICAL INSTALLATION
7.4.2. Cable entry with type 1 sealing modules
–
–
–
Usage: power cables, ground cables and bonding conductors
1
2
2
Figure 7–3 Type 1 sealing modules (example)
1) Cable entry frame
2) Sealing modules
7.4.3. Cable entry with type 2 sealing modules
–
–
–
–
Usage: auxiliary power cables and control cables
1
2
Figure 7–4 Type 2 sealing modules example
1) Frame
2) EMC sealing modules
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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
Figure 7–5 Cable entry with cable glands
7.5. Power cables, ground cables and equipotential
bonding conductor
–
–
–
–
Project-specific cable entry
Distance between point of cable entry and terminals
Busbar and fastening hole dimensions
Busbar designations
device identification.
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ELECTRICAL INSTALLATION
7.5.1. Preparing the cable entry and the cables
NOTICE Risk of damage or malfunction!
Waste inside the cabinet can cause damage or malfunction.
▶
▶
If possible, DO NOT cut cables inside the terminal compartment
Remove any waste that was accidentally dropped in the cabinet
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 7–1 Maximum number of cables per phase
ACS1000A
type
2.3 kV nominal
voltage
3.3 kV nominal
voltage
4.0 kV nominal
voltage
A1
A2
A3
1 cable per phase
2 cables per phase
2 cables per phase
1 cable per phase
1 cable per phase
2 cables per phase
1 cable per phase
1 cable per phase
1 cable per phase
7.5.1.2. 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.
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ELECTRICAL INSTALLATION
7.5.1.3. Splitting multi-core cables
This section applies to drives without an additional cabinet.
–
–
–
Check the distance between point of cable entry and closest busbar.
Check the cable diameter.
If distance and cable diameter do not allow for the bending the cable inside the terminal
compartment, separate the conductors outside of the terminal compartment.
Continue with:
–
–
–
7.5.1.4. 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.
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.
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ELECTRICAL INSTALLATION
3. If necessary, remove the entry plate and push the cable through the entry holes.
4. Prepare the cables as illustrated.
•
for EMC bonding with the metal enclosure of the cabinet.
•
5
A
1
B
6
7
2
3
8
4
Figure 7–6 Preparing cables for EMC plates: (A) cables with an outer screen or shield, (B)
cables without an outer screen or shield
1) Grommet
6) Entry plate
2) EMC sleeve
7) Conductor insulation removed to expose
cable shield
3) Cable tie
8) Cable screen extension to connect to the
PE busbar
4) Heat-shrinkable termination
5) Outer cable sheath
5. Route the equipotential bonding conductor through an unused hole in the entry plate.
NOTE – If all of the holes are used for conductors, route the equipotential bonding
conductor together with a conductor.
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ELECTRICAL INSTALLATION
7.5.1.5. 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.
–
Prepare cables with an outer cable screen or shield for EMC bonding with the metal
enclosure of the cabinet as illustrated in Fig. 7–7.
1
7
2
3
8
9
4
5
10
6
11
Figure 7–7 Preparing power cables for sealing modules
1) Sealing module
8) Cable sheath removed to expose cable
shield
2) Frame
9) Shield extension to be connected to PG
busbar
3) Conductive foil of sealing module
4) Cable clamp
10) Screen extension to be connected to the
PG busbar
5) Shrinkable sheath seal
6) Heat-shrinkable termination
7) Outer cable sheath
11) Cable lug as specified by the cable supplier
and suitable for M12 bolt
–
Install the sealing modules according to the instructions of the sealing module supplier.
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ELECTRICAL INSTALLATION
7.5.1.6. 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. 7–8.
1
3
2
4
5
6
Figure 7–8 Preparing power cables for cable glands
1) Outer cable sheath
2) Cable gland
4) Plate
5) Screen extension to be connected to
PE ground busbar
3) Conductor insulation removed to expose
cable shield
6) Heat-shrinkable termination
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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.
7.5.2.2. Connections
CAUTION Risk of flashover!
High voltages will be present in the terminal compartment. High voltages can
cause flashover between conductors with different electric potential, and
between a conductor and earth.
▶
Maintain the following minimum clearances:
•
•
20 mm between conductors
40 mm between a conductor and earth
Power and grounding cables
–
Connect the feeder cable conductors to busbars
•
•
1U1, 1V1, 1W1, 2U1, 2V1, 2W1 (12-pulse and 24-pulse drive, Fig. 7–9)
3U1, 3V1, 3W1, 4U1, 4V1, 4W1 (24-pulse drive, Fig. 7–9)
–
–
Connect the motor cables to busbars U2, V2, W2 (Fig. 7–9).
Connect the screens of all conductors and the shields of all cables to the PE ground
busbar (1 in Fig. 7–9).
–
–
Connect the equipotential bonding conductor to the PE ground busbar.
Tie the cables to the strain relief rails (2 in Fig. 7–9).
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ELECTRICAL INSTALLATION
2
A
B
2U1
2V1
2W1
U2
2U1
2V1
2W1
U2
1
2
1
2
V2
V2
W2
1U1
W2
1U1
1V1
1V1
1W1
1W1
2
2
A
B
2U1/4U1
2V1/4V1
2W1/4W1
U2
1
2
1
2
V2
W2
1U1/3U1
1V1/3V1
1W1/3W1
2
Figure 7–9 Power cable terminals in 12-pulse ACS1000A (top row) and 24-pulse ACS1000A
(bottom row)
1) PE ground busbar
2) Strain relief rails
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ELECTRICAL INSTALLATION
V1
W1
U1
1
4
U2
U2
V2
V2
PE
W2
W2
5
6
7
5
PE
1V1
U2
1W1
2V1
W2
2W1
1U1
2U1
2
ACS1000
V2
5
U
V
W
PE
3
8
Figure 7–10 Grounding the drive system
1) Input transformer
2) Drive
5) Ground cable
6) Cable screen
3) Motor
7) Equipotential bonding conductor
8) Motor
4) Earth electrode
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.
Depending on the comparative tracking index (CTI) of the insulation material of the cable,
the following minimum creepage distances apply:
Table 7–2 Minimum creepage distance between cable and busbar
CTI
Minimum creepage distance
1
600
63 mm
71 mm
80 mm
2
3
400 - 600
175 - 400
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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.
7.5.4.2. Connection type
connected to a busbar:
–
NOTE – Other washers can be used, provided they maintain the required contact
pressure.
1
2
3
4
2
1
Figure 7–11 Bolted busbar connections
1) Spring washer
2) Flat washer
3) Busbar
4) Cable lug
–
Use cable lugs suitable for M12 bolts.
7.5.4.3. Lubrication
If stainless steel bolts and nuts are used, lubricate the thread and head contact surface of
the bolt using recommended pasts, eg, Molykote D paste.
NOTE – If a coated nut (eg, with bonded molybdenum-disulfide [MoS2] coating) is used, the
connection does not need to be lubricated.
7.5.4.4. Tightening torque
Tighten bolted connections with bolts of sizes M10 and greater with the recommended
nominal torque for the bolt size used.
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ELECTRICAL INSTALLATION
7.6. Auxiliary power, control and serial
communication cables
–
–
Project-specific cable entry
Dimensions between point of cable entry and terminals
–
–
Conventions for cross-references and device identification
Terminal designations
7.6.1. Preparing the cable entry and the cables
7.6.1.1. Determining the cable length
1. Determine the required length of a cable between the point of entry and the connection
2. Cut the cable to the required length before connection.
A
B
1
1
Figure 7–12 Cable entry from top (A) and from bottom (B)
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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. If necessary, remove the entry plate and pull the cable through the entry holes.
4. Loosen the screws of the EMC cushion brackets and push the cushions apart (arrows).
5. If the outer cable screen is non-conductive, cut open the cable screen in the middle of
the stripped area (1), pull the screen ends over the cable insulation (2) and then connect
the screen ends with a continuous conducting foil (3).
1
2
3
2
Figure 7–13 Preparing control cables for EMC plates
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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
2
1
Figure 7–14 Frame with sealing modules
1) Sealing modules
2) Compression wedge
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ELECTRICAL INSTALLATION
2. Prepare the cables with an outer cable screen for EMC bonding with the metal
1
2
3
4
4
4
Figure 7–15 Preparing control cables for sealing modules
1) Sealing module
2) Conductive foil
4) Conductor screen extension to be
connected to PE terminal
3) Cable sheath removed to expose
cable shield
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ELECTRICAL INSTALLATION
7.6.1.4. Preparing cables for cable entries with cable glands
–
Prepare the cables with an outer cable screen for EMC bonding with the metal enclosure
of the cabinet as illustrated in Fig. 7–16.
1
4
2
3
5
Figure 7–16 Preparing control cables for cable glands
1) Outer cable sheath
2) Cable gland
4) Plate
5) Conductor screen extension to be
connected to PE terminal
3) Conductor insulation removed to expose
cable shield
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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.
–
Leave unshielded conductor ends as short as possible (not longer than 50 mm).
7.6.2.3. Cable shields
–
–
Connect the shield of serial communications cables to the fieldbus adapter.
Connect the overall shield and the individual shields of the encoder cable to the separate
17).
different sizes are supplied.
1
2
3
Figure 7–17 Shield grounding point for encoder cable
1) Encoder adapter
3) Grounding clamp
2) Shield ground bracket
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ELECTRICAL INSTALLATION
7.7. Power supply cable for redundant fan unit
This section applies to drives that are equipped with the optional redundant fan.
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.
For more information on cable entry, see:
•
•
•
of entry. If necessary, seal the gaps according to the type of cable entry used.
1
2
3
3
3
3
Figure 7–18 Routing, connecting the cable of the redundant fan unit
3. Connect the wires according to the terminal number on the marker sleeves.
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ELECTRICAL INSTALLATION
7.8. Final checks
–
Check that the entry plates are properly fastened.
–
If EMC entry plates with grommets are used, check that the grommets fit tightly
(arrows) to prevent water from entering the cabinet.
–
If necessary, seal gaps with silicone.
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COMMISSIONING
8. Commissioning
8.1. Overview
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.
8.1.3. Commissioning checklist
In order to ensure uncomplicated and speedy commissioning, it is important that
drive and associated equipment are ready for commissioning. Reviewing and
completing the items in the commissioning checklist before the commissioning
personnel arrive on site will help to achieve this.
8.1.4. Customer assistance
During the commissioning period, the customer is requested to provide qualified
personnel for assistance, who are:
–
Experienced with medium and low voltage equipment and with the local
safety regulations,
–
–
Familiar with the driven process
Authorized to operate associated medium and low voltage equipment (eg,
input circuit breaker, other low and medium voltage switchgear)
–
Authorized to operate the driven process for functional tests
8.1.5. Customer acceptance
When commissioning has been completed, the commissioning report is signed by
the responsible commissioning personnel and by the customer as a sign of
acceptance. A copy of the report and a copy of the actual parameter settings are
handed out to the customer.
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COMMISSIONING
8.2. Commissioning checklists
The checklists are designed to help you prepare the drive and associated equipment
for commissioning.
8.2.1. Mechanical installation checklist
1) Drive installed according to the instructions in this user manual (3BHS213401
E01).
2) Drive securely fastened to the floor (if applicable).
3) Redundant fan unit installed (if applicable).
4) Visual inspection:
•
•
•
No badly affixed or damaged components
No foreign objects left in the cabinet
No dirt, dust or moisture in the cabinet
8.2.2. Electrical installation checklist
1) Types and cross sections of control cables suitable for the signal type and signal
level.
2) Types and cross sections of power cables selected according to the instructions
in this user manual (3BHS213401 E01).
3) Pulse encoder cable shields are connected to the shield earthing point and not
connected directly to the pulse encoder interface (applies only to drives with
pulse encoder interface).
4) Cable entries prepared according to the instructions in the user manual
(3BHS213401 E01).
5) Control cable screens and conductors are connected as instructed in the user
manual, labeled appropriately, and the customer side connections are completed.
6) Equipotential bonding conductor of drive securely connected at both ends.
7) Converter transformer and motor cables not connected at both ends (cables and
drive must be insulation resistance tested (Megger test) before connection)
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COMMISSIONING
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
4) MCB protection relay settings tested
5) Safety devices (eg, door locks) are tested and in operation.
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.
2) Motor is not coupled to driven load.
3) Grounding is completed
4) Motor auxiliaries (eg, bearing lubrication) are ready
5) Control and monitoring signals are connected.
8.2.6. Insulation tests checklist
1) All power cables to converter transformer, between converter transformer and
drive, and from drive to motor insulation resistance tested (Megger test), and
measured values within the required limits.
2) Test report of the Megger insulation resistance test available
IMPORTANT! If the test is carried out by the commissioning engineer of the drive, an
additional day per drive motor combination needs to be reserved. After the test, the
feeder cables can be connected, except at the drive end. The test must comply with
the specification.
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COMMISSIONING
8.2.7. Power supply checklist
1) Medium voltage available for start-up of drive.
2) Low voltage is available for start-up of drive.
8.2.8. Miscellaneous checklist
1) Sufficient number and correct type of spare parts available
2) Air conditioning of drive room ready for load run of drive
3) Optional equipment ready
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OPERATION
9. Operation
9.1. Safety
The drive must only be operated by qualified and authorized personnel, ie,
personnel who are familiar with the operation of the drive and the
hazards involved.
9.2. Overview
The chapter outlines the local operation of the drive.
Control of the drive via a PLC or higher-level control systems is not described in this
chapter. If the drive is controlled from remote, see the appropriate manuals for
information.
The panel messages and parameter settings used in this chapter are typical examples to
illustrate the related instructions and display functions and can therefore differ from the
actual messages and parameter settings in the drive.
9.3. Operating conditions
–
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)
–
Redundant fan: < 85 dB (A)
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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
Set the reference value
Start and stop the drive
Display actual values, status messages, alarms and fault messages
View and setting parameters
Reset alarm and fault messages
Activate the emergency off circuit
1) Control and data panel (CDP)
• Starts and stops the motor
• Displays status messages
• Displays alarm and fault messages of the drive and
monitored foreign equipment
• Resets alarm and fault messages
2) OFF illuminated push button
• Opens the main circuit breaker
3) ON illuminated push button
1
• Charges the DC link and closes the main
circuit breaker
4) GND SWITCH UNLOCKED push button
• Lights up to indicate that the grounding switch of the
drive can be turned to the grounded or
ungrounded position
2
3
5) EMERGENCY OFF push button
4
• Prevents starting when pressed at standstill of
the drive
• Main circuit breaker opens immediately and DC link
discharges when pressed during operation of
the drive
5
Figure 9–1 Local operator panel
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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.
For information on other status messages, such as fault status messages in particular, see
RdyForMCBOn
The status message signals that the drive is healthy and ready for the ON
command. The ON command initiates the charging of the DC-link capacitors and
the closing of the main circuit breaker of the drive. Depending on the control place,
the command can either be sent from the higher-level control system to the drive
or be initiated by pressing the Main circuit online push button on the control
compartment door.
Charging
The status message RdyForMCBOn changes to Charging when the DC-link
capacitors of the drive are being charged.
Rdy to Strt
The status message Rdy to Strt tells the operator that the drive is energized and
ready for operation. As soon as the start command is initiated, the motor is
magnetized and the drive starts to modulate.
Magnetizing
The status message Rdy to Strt changes to Magnetizing when the firing pulses of
the inverter are released.
Running
When the drive is in Running state, it is running and operating according to the set
speed or torque reference value. When in remote control mode, the reference value
is set by the higher-level control system. When in local control mode, the value is
entered into the CDP control panel.
Stopping
Indicates that the drive has received a stop command and that a ramp or coast stop
has been initiated. The stopping mode depends on the parameter setting. The
status message changes to Rdy to Strt when the zero speed threshold is reached.
When a start command is given while the drive is stopping, the drive resumes
operation and the status message changes to Running again.
Discharging
The status message Rdy to Strt changes to Discharging when the MCB has opened
and the DC-link capacitors are discharging.
Tripped
The status message indicates that a fault condition has occurred that requires a
shutdown of the drive. The status message always alternates with the specific fault
message. The type of shutdown depends on the fault class the fault condition is
assigned to in the drive software.
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OPERATION
9.6.1. Start sequence of the drive
NotReadyOn
1
ReadyOn conditions:
•
•
•
•
Doors closed and locked
Drive not grounded
No emergency off
No fault
ReadyForMCBOn
2
3
On command
4 Charging
•
•
•
DC link charges
Fan switches on
MCB closes
5 Rdy To Strt
6 Start command
•
Inverter starts to modulate
Magnetizing
7
8 Running
9 Operation
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OPERATION
9.6.2. Stop sequence of the drive
Operation
1
Running
2
Stop command
3
4 Stopping
•
•
Speed ramps down
Inverter stops modulating
5 Ready To Strt
6 Off command
Discharging
7
•
•
•
MCB opens
DC link discharges
Fan switches off after a delay
8 RdyForMCBOn
•
•
•
Drive is grounded
Doors are released for opening
Auxiliary supply is switched off
9 NotReadyOn
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OPERATION
9.6.3. Emergency off sequence of the drive
Operation
1
Running
2
Emergency off command
3
•
•
•
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.
▶
All covers must be screwed in place
9.7.1. Checks before starting the drive
Consult the following reference material for the initial local start of the drive after
commissioning:
–
–
CDP control panel
When the drive is put into service after it has been commissioned, or after it has been taken
out of service for a longer period, check the drive according to the following list:
–
–
–
–
–
–
–
Tools and foreign objects are inside the cabinet.
All auxiliary power supplies from external sources are switched on.
All internal circuit breakers of the drive are closed.
All covers are mounted and the doors are closed, locked or bolted.
Grounding switch is in the ungrounded position.
MCB is in operating position.
No run interlocks are active.
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OPERATION
9.7.2. Starting the drive remotely
When the drive is operated from remote through a higher-level control system or an
operator control desk, follow the instructions in the appropriate manuals.
9.7.3. Starting the drive locally
1. Enable the local control mode of the drive.
LOC
REM
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.
RESET
•
If a fault cannot be reset, it must be rectified by the responsible personnel.
When no alarms and faults are present and the drive is ready, the CDP control panel
displays RdyForMCBOn:
1 L ->
Status
0.0 rpm
RdyforMCBon
MotorSpeed 0.00 rpm
Power 0.0%
3. Press the MAIN SUPPLY ON push button on the control compartment door to close the
MCB and charge the DC link.
The push button lights up and the status line of the CDP control panel changes to
Charging.
1 L ->
Status
0.0 rpm
Charging
MotorSpeed 0.00 rpm
Power 0.0 %
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OPERATION
After charging has been finished, the protection IGCTs are closed, the status line of the
CDP control panel changes to Rdy to Strt and the motor can be started.
1 L ->
Status
0.0 rpm
Rdy to Strt
0
MotorSpeed 0.0 rpm
Power 0.0 %
4. Enter the reference value.
1 L ->
Status
[600.0 rpm] 0
Rdy to Strt
MotorSpeed 0.0 rpm
Power 0.0 %
5. Start the motor.
1 L ->
Status
[600.0 rpm] 0
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. When the
motor speed has reached the reference value, the run status indication lights
up permanently.
The display shows Running to indicate that the drive is operating.
1 L ->
Status
600.0 rpm
Running
I
Motor Speed 600.0 rpm
Power 75.0 %
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OPERATION
9.8. Stopping the drive
1. Press the STOP key on the CDP control panel.
The motor stops according to the preset stop function and the drive stops modulating.
While the motor stops, the status line of the display shows Stopping. The run status
message blinks during the stop sequence.
1 L ->
Status
600.0 rpm
Stopping
I
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.
1 L ->
Status
600.0 rpm
Rdy to Strt
0
MotorSpeed 0.0 rpm
Power 0.0 %
NOTE – As long as the MCB has not been opened, the motor can be started again.
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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.
1) and features a latching switch action.
IMPORTANT! Pressing the EMERGENCY-OFF push button does not disconnect the auxiliary
power supply from the drive.
9.9.1. Initiating an emergency-off
To initiate an emergency off, press the EMERGENCY-OFF push button on the control
compartment door, or an external EMERGENCY-OFF push button (if present) linked to the
emergency-off circuit.
When an emergency-off is initiated during drive operation, the following takes place:
–
–
–
MCB opens
Drive coasts down
Status line of the CDP control panel displays the message Emerg Off
1 L ->
600.0 rpm
ACS 1000
*** FAULT ***
Emerg Off
–
The DC link of the drive discharges.
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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. To reset the emergency-off safety relay of the drive, press the RESET button on the
control keypad.
RESET
After resetting, the status message of the drive changes to RdyForMCBOn.
1 L ->
Status
0.0 rpm
RdyforMCBon
MotorSpeed 0.00 rpm
Power 0.0%
The main power supply can be connected to the drive and the drive can be started again.
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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
2
3
4
5
11
12
6
ENTER
LOC
REM
RESET
REF
7
13
14
8
9
15
10
I
0
Figure 10–1 CDP control panel
1) Display
9) Forward key
10) Backward key
2) Status line
3) Actual signal names and values
4) Keypad
11) Slow navigation key for selecting signals or
fault messages
12) Enter key, terminates a procedure
13) Reference key
5) Mode selection keys
6) Fast navigation key for selecting the actual
signals display or the fault memory display
14) Start key
7) Local / remote selection key
8) Reset key
15) Stop key
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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.
You can perform the following tasks with the CDP control panel:
–
–
–
–
–
–
Enter start-up data
Control the drive with a reference value, and start, stop and direction commands
Display actual values (three values can be read simultaneously)
Display and adjust parameters
Display information on the most recent forty fault events
Upload and download complete parameter sets from one drive to another
10.3. CDP control panel modes
The CDP control panel provides the following modes:
–
–
–
–
10.3.1. Identification mode
The identification mode informs the user about the CDP control panel version and the ID
number of the drive. The information appears on the display when the:
–
–
Power supply is switched on
CDP control panel is connected to the drive and the auxiliary voltage has already been
switched on.
When the CDP control panel is initialized as described before, the display changes as
follows:
CDP312 PANEL V5.30
........
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CDP CONTROL PANEL
After 2-3 seconds, information on the drive (1, 2) and the drive identification (3) is displayed.
1
2
ACS1000 xxxx
<Device Name>
3
ID-NUMBER 1
After another few seconds:
1 L ->
Status
0.0 rpm
InitSeq....
MotorSpeed 0.00 rpm
Power 0.0 %
After another few seconds, the display changes to the actual signals mode.
1 L ->
Status
0.0 rpm
ErthIsoClos
MotorSpeed 0.00 rpm
Power 0.0 %
10.3.2. Actual signals mode
10.3.2.1. Overview
Two displays can be selected in the actual signals mode:
–
–
Actual signals display
Fault memory display
The actual signals display appears first when entering the actual signals mode. However,
when the drive is in a fault condition, the fault memory display appears instead.
The actual signals display is used to monitor the drive without interfering with its
operation. It continuously displays three selectable actual values.
The CDP control panel automatically returns to the actual signals display from other modes
if no key is actuated within one minute (an exception from this is the fault memory display).
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CDP CONTROL PANEL
10.3.2.2. Actual values
The actual values are organized in groups.
Group
Description
Group 01
Group 02
Group 03
Group 04
Group 05
Group 06
Group 07
Group 08
Group 09
Measured or calculated motor values
Measured or calculated drive values
Speed and torque reference values
I/O values
Data values
Information: software version, drive and motor nominal values
Control words
Status words
Fault and alarm words
10.3.2.3. Fault memory
The fault memory display provides information on the 64 most recent fault events that
occurred in the drive. It displays the name of the fault and the time it occurred. For
When the drive generates a fault or alarm, the corresponding message displays
immediately.
Changing from the fault memory mode to other modes is possible without resetting the
fault first. When no key is actuated, the fault or warning text is displayed as long as the fault
is active.
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CDP CONTROL PANEL
Control panel overview
1
2
1 L ->
600.0 rpm
PAR
FUNC
DRIVE
3
5
4
6
LOC
REM
RESET
REF
Figure 10–2 Control panel - Actual signals mode
1) Status line
5) Slow navigation key for selecting signals or
fault messages
2) Actual signal names and values
3) Selection key for actual signals mode
6) Enter key for confirming the selection
4) Fast navigation key for selecting the actual
signals display or the fault memory display
10.3.2.4. Opening the actual signals display
–
To open the actual signals display, press the ACT key.
ACT
1 L ->
Status
600.0 rpm
RdyForMCBon
0
MotorSpeed 0.00 rpm
Power
0.0 %
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CDP CONTROL PANEL
Toggle between actual signals display and fault history
–
To toggle between actual signals display and fault history display, press a fast
navigation key.
1 L ->
600.0 rpm
0
1 LAST FAULT
+ Panel Lost
0707730 12:30:02 3256
Displaying three actual signals
1. To display the full name of three actual signals, press and hold the ACT key.
ACT
1 L ->
600.0 rpm
0
DriveStatusWord
MotorSpeed
Power
2. To return to the actual signals display, release the ACT key.
Selecting actual signals
1. To select the actual signals display, press the ACT key.
ACT
1 L ->
Status
600.0 rpm
Running
I
Motor Speed 600.0 rpm
Power
75.0 %
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CDP CONTROL PANEL
To select a line where the actual signal is to be displayed, press the corresponding slow
navigation key.
A blinking cursor indicates the selected line.
1 L ->
Status
600.0 rpm
Running
I
Motor Speed 600.0 rpm
Power 75.0 %
2. To enter the actual signal selection function, press the ENTER key.
1 L ->
600.0 rpm
1 Actual Signals
10 ShaftPower
0.0 %
ENTER
3. To select a parameter group, press a fast navigation key.
1 L ->
600.0 rpm
0
2 Actual Signals
01 ControlMode
SPEED-CTRL
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
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CDP CONTROL PANEL
5. To confirm the selection and to return to the actual signals mode, press the ENTER key.
1 L ->
Status
600.0 rpm
Rdy to Strt
0
ENTER
MotorSpeed 0.00 rpm
DCVoltage Udc1 1000.0 V
6. To cancel the selection and keep the original selection, press any of the mode
selection keys.
The selected CDP control panel mode is entered.
ACT
PAR
FUNC
DRIVE
1 L ->
Status
600.0 rpm
Rdy to Strt
0
MotorSpeed 0.0 rpm
Power 0.0 %
10.3.2.5. Displaying and resetting the fault history
1. To enter the actual signals mode, press the ACT key.
ACT
1 L ->
Status
600.0 rpm
Rdy to Strt
0
MotorSpeed 0.0 rpm
Power
0.0 %
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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.
1 L ->
600.0 rpm
0
2 LAST FAULT
+ Panel Lost
0707730 12:21:02.2452
4. To clear the fault memory, press the RESET key.
1 L ->
600.0 rpm
0
1 LAST FAULT
H MIN S
RESET
5. To return to the actual signals display, press a fast navigation key.
1 L ->
Status
600.0 rpm
Rdy to Strt
0
MotorSpeed 0.0 rpm
Power
0.0 %
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CDP CONTROL PANEL
Displaying and resetting an active fault
1. To display an active fault, press the ACT key.
ACT
1 L ->
600.0 rpm 0
ACS1000
*** FAULT ***
MCB CloseControl
2. To reset the fault, press the RESET key.
1 L ->
Status
600.0 rpm
Rdy to Strt
0
MotorSpeed 0.0 rpm
Power 0.0 %
RESET
10.3.3. Parameters mode
NOTICE Risk of component damage.
Running the drive system with incorrect data can result in improper operation,
reduction of control accuracy and damage to equipment.
▶
▶
Parameters must only be set by qualified personnel.
DO NOT change a parameter if the effects of the change are unclear.
10.3.3.1. Overview
the required drive configuration depending on the application.
The parameters are organized in functional groups, so called parameter groups.
Table 10–1 Parameter groups
Group
Description
Group 07
Group 08
Group 09
Control words
Status words
Fault and alarm words
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CDP CONTROL PANEL
Table 10–1 Parameter groups (continued)
Group
Description
Group 11
Group 12
Group 13
Group 14
Group 15
Group 16
Group 17
Group 18
Group 19
Group 20
Group 21
Group 22
Group 23
Start, stop, direction, MCB and control
Reference selection
Basic analog inputs
Basic digital outputs
Basic analog outputs
System control inputs
Utilities
Process speed
Data storage
Limits
Start, stop and process stop
Ramp functions
Speed reference
When entering the parameter mode for the first time after the auxiliary voltage of the drive
has been switched on, the CDP control panel displays the first parameter of parameter
group 99. The next time the parameters mode is entered, the previously selected parameter
displays.
Some parameter values cannot be changed while the drive is running. If tried, the following
warning displays.
** Warning **
Write Access Denied
Parameter Setting
Not Posssible
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CDP CONTROL PANEL
Control panel overview
1
2
3
4
1 L ->
600.0 rpm
75 OPTION MODULES
01 IOEC3 OptionBoard
YES
ACT
FUNC
DRIVE
5
6
7
8
LOC
REM
RESET
REF
Figure 10–3 Control panel - Parameters mode
1) Status line
6) Fast navigation key for selecting a
parameter group (and a parameter value)
2) Group number and name
3) Parameter number and name
4) Parameter value
7) Slow navigation key for selecting a
parameter (and a parameter value)
8) Enter key for confirming the selection
5) Selection key for parameters mode
10.3.3.2. Selecting and changing parameters
1. To enter the parameters mode, press the PAR key.
PAR
1 L ->
600.0 rpm
0
12 REFERENCE SELECT
01 KeypadRefSelect
1
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CDP CONTROL PANEL
2. To select a different group, press the corresponding fast navigation key.
1 L ->
600.0 rpm
0
75 OPTION MODULES
01 IOEC3 OptionBoard
YES
3. To select a parameter, press the corresponding slow navigation key.
1 L ->
600.0 rpm
0
75 OPTION MODULES
02 IOEC4 OptionBoard
NO
4. To enter the parameter setting function, press the ENTER key.
1 L ->
600.0 rpm
0
75 OPTION MODULES
02 IOEC4 OptionBoard
[NO]
ENTER
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]
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CDP CONTROL PANEL
6. To confirm the selection and to return to the actual signals display, press the ENTER
key.
1 L ->
600.0 rpm
0
75 OPTION MODULES
02 IOEC4 OptionBoard
[YES]
ENTER
7. To cancel the setting and keep the original selection, press any of the mode selection
keys.
The selected keypad mode is entered.
ACT
PAR
FUNC
DRIVE
1 L ->
600.0 rpm
0
75 OPTION MODULES
02 IOEC4 OptionBoard
[NO]
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CDP CONTROL PANEL
10.3.3.3. Enabling / unlocking a parameter lock
Unwanted parameter entry can be prevented by activating the parameter lock function.
The corresponding parameters are 16.02 PARAMETER LOCK and 16.03 PASSCODE and
belong to parameter group 16 SYSTEM CTRL INPUTS.
Enabling the parameter lock
1. Select parameter 16.02.
2. Set parameter 16.02 to 1 (LOCKED).
3. Confirm the setting and exit the parameters mode.
Unlocking the parameter lock
1. Select parameter 16.03.
2. Set the correct pass code.
3. Confirm the setting and exit the parameters mode.
10.3.3.4. User lock
NOTICE Risk of component damage.
ABB is not be liable for damages or losses caused by the failure to activate the user
lock with a new pass code.
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.
2. Enter the old pass code in 16.06 OldUserPasscode.
3. Enter the new pass code in 16.07 NewUserPasscode.
4. In 16.02 Parameter Lock, enable the user lock functionality.
NOTE – To reopen the lock, ie, to edit parameters 16.06 and 16.07, enter the new pass
code in 16.03 Passcode.
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CDP CONTROL PANEL
10.3.4. Functions mode
The functions mode is used to set the display contrast.
1
2
1 L ->
0.0 rpm
UPLOAD
DOWNLOAD
CONTRAST
<= <=
=> =>
4
ACT
PAR
DRIVE
3
4
5
LOC
REM
RESET
REF
Figure 10–4 Control panel - Functions mode
1) Status line
4) Slow navigation key for selecting a line (and
adjusting the contrast)
2) Selectable functions
3) Selection key for functions mode
5) Enter key for confirming the selection
10.3.4.1. Adjusting the display contrast
1. To enter the functions mode, press the FUNC key:
FUNC
1 L ->
UPLOAD
0.0 rpm
<= <=
0
DOWNLOAD => =>
CONTRAST
4
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CDP CONTROL PANEL
2. To select the contrast adjustment function, press the slow navigation keys until the
blinking cursor reaches the CONTRAST line.
1 L ->
UPLOAD
0.0 rpm
<= <=
0
DOWNLOAD => =>
CONTRAST
4
3. Press the ENTER key.
1 L ->
CONTRAST
0.0 rpm
[4]
0
ENTER
4. To change the contrast value, press a slow navigation key.
1 L ->
CONTRAST
0.0 rpm
[6]
0
5. To confirm the selection and to return to the actual signals display, press the ENTER
key.
1 L ->
UPLOAD
0.0 rpm
<= <=
0
ENTER
DOWNLOAD => =>
CONTRAST
6
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CDP CONTROL PANEL
6. To cancel the setting and keep the original setting, press any of the mode selection
keys.
The selected keypad mode is entered.
ACT
PAR
FUNC
DRIVE
1 L ->
UPLOAD
0.0 rpm
<= <=
0
DOWNLOAD => =>
CONTRAST
6
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
10.4.1. Local control
In local control mode, full operational control of the drive is enabled from the local operator
panel. Commands from remote have no effect.
Entering local control mode
–
To enter the local control mode, press the LOC-REM key.
Local control is indicated by the letter L.
1 ->
Status
600.0 rpm
Rdy to Strt
0
MotorSpeed 0.00 rpm
Power
0.0 %
LOC
REM
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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.
– 11.01 EXT1 START/STOP/DIR = 10 (KEYPAD) or
12.03 EXT REF1 SELECT = 1 (KEYPAD) and
12.02 EXT1/EXT2 SELECT = 1 (EXT1)
– 11.02 EXT2 START/STOP/DIR 10 (KEYPAD) or
12.06 EXT REF2 SELECT = 1 (KEYPAD) and
12.02 EXT1/EXT2 SELECT = 2 (EXT2)
Entering remote control mode
–
To enter remote control, press the LOC-REM key.
•
Full remote control from a higher-level control system is indicated by a blank space.
1
600.0 rpm
Rdy to Strt
0
Status
MotorSpeed 0.00 rpm
Power 0.0 %
LOC
REM
•
Partial remote control (some commands enabled locally) is indicated by the letter R.
1
Status
600.0 rpm
Rdy to Strt
0
MotorSpeed 0.00 rpm
Power
0.0 %
LOC
REM
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CDP CONTROL PANEL
10.5. Operational commands
For instructions on how to start and stop the drive system from the CDP control panel, see
10.5.1. Setting the direction of rotation
Setting the direction of rotation from the CDP control panel is possible in:
–
–
Local control mode L
Remote control mode R
The arrow on the display indicates the direction of rotation:
–
–
When the motor is running, the arrow indicates the actual direction.
When the motor is not running, the arrow indicates the preselected direction.
Procedure
–
To set the direction of rotation, press the forward or backward key.
If you change the direction while the motor is running, the motor automatically ramps
down to zero speed and re-accelerates in the opposite direction to the preset speed.
The arrow changes at zero speed.
•
Forward key
1 L
Status
600.0 rpm
Running
MotorSpeed 600.00 rpm
Power
75.0 %
I
•
Backward key
1 L
Status
600.0 rpm
Running
MotorSpeed 600.00 rpm
Power
75.0 %
0
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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 L
Remote control mode R
Procedure
1. Press a mode selection key.
ACT
PAR
FUNC
DRIVE
1 L ->
Status
600.0 rpm
Running
I
MotorSpeed 600.00 rpm
Power 75.0 %
2. To enter the reference value input mode, press the REF key.
1 L ->
Status
[600.0 rpm] I
Running
MotorSpeed 600.00 rpm
Power 75.0 %
REF
3. To enter / change the reference value, press the corresponding fast or slow navigation
key.
1 L ->
Status
[550.0 rpm] I
Running
MotorSpeed 600.00 rpm
Power
75.0 %
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CDP CONTROL PANEL
4. To exit the reference value input mode, press any of the mode selection keys.
ACT
PAR
FUNC
DRIVE
1 L ->
Status
550.0 rpm
Running
I
MotorSpeed 550.00 rpm
Power
75.0 %
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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.
11.1.1. Required qualification
To maintain safe and reliable operation of the drive, ABB recommends taking out a service
contract with the ABB service organization.
11.1.2. Maintenance schedule
Perform all maintenance tasks according to the maintenance schedule and the applicable
service instructions, on time and at the intervals stated in the “ACS1000A preventive
11.1.3. Logbook
ABB recommends that you keep track of all troubleshooting and maintenance work in a
logbook including:
–
–
Date and time
Detailed description
11.1.4. Spare parts
To ensure safe and reliable operation, use only spare parts recommended and
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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
Figure 11–1 Device identification
11.2.2. Cables and wires
Cables and wires in the drive are equipped with marker sleeves which carry the same
identification number as in the wiring diagrams.
11.2.3. Understanding wiring diagrams
11.3. Alarm / fault indications
11.3.1. Messages
When a failure occurs in the drive or in the equipment monitored by the drive (eg, main
circuit breaker, transformer, cooling system), the 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. The fault logger can also be called up
on the CDP control panel.
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11.3.2. Error message levels
Two error message levels are used in the drive:
–
Alarm: Does not shut down the drive. If the condition causing the alarm is not corrected,
a persisting alarm can lead to a fault. An alarm cannot be reset manually. The alarm
message is deleted from the display as soon as the alarm condition has been corrected.
NOTE – An exception is when an alarm of the cooling system (eg, FanDiffPres,
AirFiltSupv) is not reset automatically. To reset the alarm, set parameter
41.04 FanAlarmReset to RESET.
–
Fault: Shuts down the drive. The type of shutdown depends on the origin of the fault.
Depending on the type of fault, the drive opens the main circuit breaker (MCB) or keeps
it closed. A fault condition must be corrected and the fault be manually reset before the
drive can be started again.
11.3.2.1. Alarm / fault messages
If an alarm or a fault occurs, a specific message is saved in the fault buffer of the drive.
Information on the 64 most recent fault and alarm events are saved.
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PREVENTIVE AND CORRECTIVE MAINTENANCE
11.3.3. Fault handling
The faults are entered into the fault logger as they occur and are numbered:
–
–
The last fault entered always has number 1 assigned to it.
The first fault always has the highest number in the fault buffer.
Date and time stamps facilitate fault tracing, especially when a fault leads to several
subsequent faults.
Example:
1) -Fault RESET FAULT
2) +Fault Undervoltage
3) +Warn Undervoltage
4) +Fault MCB Disturb
2011-04-26 14:57:56.5370
2011-04-26 14:47:41.1110
2011-04-26 14:47:41.1000
2011-04-26 14:47:38.0230
In the above example:
4) +Fault MCB Disturb is the reason for the failure of the drive, as it occurred first.
3) +Warn Undervoltage occurred approximately 3 seconds after the first fault.
2) +Fault Undervoltage immediately followed the warning.
1) -Fault RESET FAULT informs that the fault has been reset.
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PREVENTIVE AND CORRECTIVE MAINTENANCE
11.3.4. Standard troubleshooting procedure
If a fault shuts down the drive, proceed as follows:
1) DO NOT switch off the auxiliary supply voltage or try to reset a fault
message before all information at the time of the occurrence of the fault
condition has been saved.
2) Select the fault history display on the CDP control panel, but DO NOT clear
the buffer!
3) Identify the fault and make a logbook entry.
4) Save the content of the data logger when a PC is available that has the
DriveWindow or DriveDebug tool installed.
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:
•
•
Operating, ambient and load conditions
Unusual events
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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.
If the parameter is set to NOT USED, the panel can be removed without interrupting
drive operation. For information on setting parameters, see
“Appendix G - Signal and parameter table”.
2. Proceed as illustrated.
The green LED (4) signals that the control voltage has been switched on.
1
2
3
4
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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. The LEDs provide information on the status of the devices and can be used for
diagnostic purposes.
11.5.1. AMC circuit board
F
R
M
P
T1
S3
S2
T2
S1
S0
Figure 11–2 AMC circuit board
LED
Color
Description
Status when software
has loaded
Status when software
has not loaded
Booting
ON
ON
OFF
Booting
ON
ON
ON
F
R
Red
Fault
Run
Green
Green
Green
Yellow
OFF
OFF
OFF
OFF
M
P
ON
OFF
ON
ON
Supply OK
ON
ON
ON
ON
T1
Receiving data on
DDCS channel 0
Flashing
ON / OFF
Flashing
ON / OFF
T2
Yellow
Receiving data on
DDCS channel 3
Flashing
ON / OFF
Flashing
ON / OFF
S3
S1
S2
S0
Yellow
Yellow
Yellow
Yellow
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
Flashing
Flashing
Flashing
Flashing
Flashing
Flashing
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PREVENTIVE AND CORRECTIVE MAINTENANCE
11.5.2. IOEC I/O modules
11.5.2.1. LEDs
1
2
4
5
3
Figure 11–3 IOEC module
LED
Description
1
Status LEDs of digital outputs
Link error light
On when output is energized
Only on when there is a problem with the optical fibers.
Sets the address
2
3
4
5
Rotary switch
Status LEDs of digital inputs
On when input is energized
On when energized
Status LED of the 24 V internal
voltage supply
11.5.2.2. Cluster address
Each IOEC module has a unique cluster address that identifies the module in the software
and links it to a parameter.
must not be changed.
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PREVENTIVE AND CORRECTIVE MAINTENANCE
11.6. Corrective maintenance
Overview on maintenance tasks:
–
–
–
–
–
–
–
11.6.1. Safety
DANGER Hazardous voltages!
Before starting to work on the drive, make sure that:
▶
Main and auxiliary power supply to the drive is switched off, locked out, and
tagged out
▶
▶
▶
▶
Drive is de-energized
Safety ground connections are in place
Personal protective equipment is provided and used when required
Everyone involved is informed
Before energizing the drive again, make sure that:
▶
▶
All foreign objects are removed from the drive
All internal and external covers are securely fastened and all doors are closed,
locked and / or bolted
NOTICE Risk of component damage.
Foreign matter and particularly metallic dust can cause failure and damage when
the drive is energized.
Ensure that foreign matter cannot enter the cabinet:
▶
▶
Close the doors and cover openings completely when work is discontinued.
Retrieve any foreign matter which accidentally dropped into the cabinet.
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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.
•
•
DC link discharges for approximately five minutes
2.
11.6.3. Grounding
1. If the yellow lamp is on, turn the grounding switch to the grounded position.
When the grounding switch is in the grounded position, the status line of the CDP
control panel displays ErthIsoClos.
(Earth isolator closed = grounding switch is in grounded position).
1 L ->
Status
0.0 rpm
ErthIsoClos
MotorSpeed 0.00 rpm
Power 0.0 %
2. To de-energize the drive completely, switch off and lockout all auxiliary voltages from
external sources.
NOTE – To open the doors of medium voltage compartments and additional cabinets of
the drive that are equipped with an electromechanical lock, the auxiliary voltage must be
switched on.
3. If necessary, connect a grounding set.
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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.
NOTE – To identify the components referred to in the checklist, see the wiring
4
1
2
3
5
Figure 11–4 Location of I/O modules and fuses
1) Fuses
4) IOEC2 / -A5201 (standard)
5) IOEC3 / -A5221 (option)
2) IOEC1 / -A5191 (standard)
3) IOEC4 / -A5211 (option)
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PREVENTIVE AND CORRECTIVE MAINTENANCE
11.6.5. Checking the release conditions for the grounding switch
1) Check that the auxiliary voltage is switched on.
2) Main power supply is disconnected from the drive.
–
Check that the MCB is open.
When the MCB is open, secure it against closing.
–
Check that the feedback signal “MCB is open” arrives at the drive, ie, if the
following indicators are lit:
•
LED of digital input DI08 of I/O module -A5201 (-A2)
–
(LED is not lit) Check the control-signal wiring between switchgear and
drive as per applicable wiring diagram.
•
MAIN SUPPLY ON push button -S5152 (-S2)
When the LED and the push button are lit, the feedback signal MCB is open has
arrived at the drive.
–
(Push button is not lit) Check if the 24 V blade-type fuse (X27_P2:14) is
blown.
The fuse protects the control circuit of the pushbutton.
3) Discharge level of the DC link.
–
Check if the value of parameter 2.06 DC VOLTAGE is below 50 V.
When the value is below 50 V, the DC link is regarded as discharged. For
information on reading actual values on the CDP control panel, see section 10.3.2,
4) GROUNDING SWITCH UNLOCKED lamp and the wiring of the lamp.
–
Check if the CDP control panel displays a fault.
A fault prevents the lamp GROUNDING SWITCH UNLOCKED from lighting.
•
•
If a fault cannot be rectified and reset, contact the ABB service organization.
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PREVENTIVE AND CORRECTIVE MAINTENANCE
–
–
If the CDP control panel does not display a fault, check that digital output DO04
of I/O module -A5191 (-A1) is energized.
•
DO04 releases the grounding switch and lights the lamp
GROUNDING SWITCH UNLOCKED (–H5152).
•
When the LED of DO04 is lit and the control voltage is present at terminals
X24:2 and X24:3 of DO04, DO04 is energized.
If digital output DO04 of the I/O module is not energized, check the I/O module
-A5191 (-A1).
To do this, check if the auxiliary voltage is present at the supply terminals of the I/
O module.
•
•
X6:1.....24 V (DC)
X6:2.....0 V
–
–
Check that LED V726 and LED V740 of the I/O module -A5191 are lit.
When the LEDs are lit, the I/O module functions properly.
•
•
LED V726.....24 V (DC)
LED V740.....5 V (DC)
If digital output DO04 I/O module -A5191 is energized, check that the control
voltage is present at the terminals of the lamp GROUNDING SWITCH UNLOCKED.
•
If the control voltage is present but the lamp is not lit, the lamp is burnt out and
must be replaced.
•
If the control voltage is not present, check the wiring of the lamp. Correct the
wiring if necessary.
5) Check that hazardous voltages from the motor cannot be fed into 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.
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11.6.6. Visual checks on the drive
Check the drive and its immediate vicinity visually at the intervals stated in the maintenance
schedule and pay attention to the following items:
–
–
–
–
–
–
–
–
Humidity inside the drive
Permitted range of ambient air temperature and humidity of the drive
Dust built-up inside the drive
Appropriate fastening of cables and wires and connections of cable screens
Integrity of cable insulation
Signs for overheated components, wires, cables or busbars
Corrosion on circuit boards, connectors or busbars
Correct type of signal and power cables
For more information, see the applicable cable specifications.
11.6.7. Cleaning the drive
NOTICE Risk of component damage!
The drive contains components which are sensitive to electrostatic discharge.
Apply ESD handling precautions before handling these devices.
▶
Dust on electrical components and wiring can cause failure and damage the
components. Dust and moisture can build up in loose connections and cause loss
of low-level signals.
▶
Check the cabinet regularly for signs of dust and humidity and clean
if necessary - alcohol and solvents can damage the components.
▶
Use appropriate and recommended cleansing agents.
When cleaning the drive, mind the following:
–
–
To prevent dirt falling into equipment, cover the equipment.
Clean circuit boards with special care. To prevent the components being damaged, use
antistatic brushes and a vacuum cleaner with a soft nozzle.
–
–
Remove dust on assemblies and busbars inside the cabinet with a vacuum cleaner and
lint-free cleaning cloths.
Remove water, oily or greasy deposits on assemblies, components and busbars with
water- and oil-absorbing microfibers such as 3M Scotch Brite.
–
–
Use a nylon brush or a vacuum cleaner for removing dust or deposits from recesses.
Clean the outside of the cabinet with a vacuum cleaner and cleaning cloths.
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11.6.8. Checking wire and cable connections
NOTICE Risk of component damage.
Capacitor bushings are damaged when excessive force is applied.
DO NOT exceed the maximum tightening torque.
▶
•
The tightening torque value is printed on a label which is attached to
the capacitor.If not specified, the maximum torque must not exceed 20 Nm.
Vibration can loosen electrical connections and cause occasional malfunction or
equipment failure.
▶
▶
Inspect all power and control cable connections and tighten them if necessary.
Inspect that all plugs and connectors are tight.
11.6.9. Cleaning and replacing filter mats
The filter mats are in the control as the inverter compartments.
For information on inspection and replacement intervals, see the “ACS1000A preventive
Table 11–1 Filter mat specifications
Drive compartment
ABB ID
Dimensions
(L × W)
Filter class
(EN779)
Filter type
Control
Inverter
3BHL001134P0001
3BHL001141P0001
132 × 320 mm
818 × 1228 mm
G4
G3
T15/350
T15/150
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. Open the door of the control compartment.
NOTE – You can open the door when the drive is running.
2. Pull the filter out of the sleeve at the bottom.
3. Depending on its condition, clean or replace the filter mat:
•
Clean the filter mat with compressed air or a vacuum cleaner and slide the filter mat
back into the sleeve.
•
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PREVENTIVE AND CORRECTIVE MAINTENANCE
11.6.9.2. Rectifier and inverter compartment filter mat
WARNING Hazardous voltage!
Removing the filter mat while the drive is running can cause serious injury or
DEATH. Foreign objects can be sucked into the exposed air intake and cause
FATAL short-circuits.
▶
Keep long, thin objects, such as wires and screwdrivers, away from the
exposed air intake.
▶
DO NOT stop work for long periods while the air intake is exposed.
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. Remove the 6 screws (circles) from the
louvered panel (1).
NOTE – Depending on your drive, you
might need a slot or Torx screwdriver.
1
1228 mm
2
2. Remove the louvered panel.
3. Starting at the top, roll the filter mat (2)
down to remove it.
818 mm
4. Depending on its condition, clean or
replace the filter mat.
•
•
Clean the filter mat with compressed
air or a vacuum cleaner.
T30
Replace the filter mat with a new one
Figure 11–5 Filter panel (1) and filter mat (2)
on rectifier and inverter compartment
5. Reinstall the louvered panel (1) with the
6 screws (circles).
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PREVENTIVE AND CORRECTIVE MAINTENANCE
11.6.10. Inspecting and replacing batteries
Figure 11–6 Control compartment – battery location
1) Power supply unit for battery pack 1
2) Alarm LED
3) Battery pack 1
11.6.10.1. Checking and replacement indications
The end of the battery life is indicated as follows:
–
–
CDP control panel displays an alarm message.
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.
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11.6.10.2. Replacing a battery
CAUTION Heavy object.
A battery weighs approximately 10 kg!
Figure 11–7 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.
4. Install the new battery in reverse order of removal.
5. Record the date of battery replacement in the logbook.
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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
Figure 11–8 Fan location, dimensions and weight
1
4
5
2
3
Figure 11–9 Fan - tools and devices
1) ¼”
4) Trolley
5) Lift truck
2) ~70 mm
3) 10 mm and 13 mm
1.
IMPORTANT! DO NOT drop washers and bolts into the cabinet.
5. Move the fan onto the lift truck by one of the following methods:
6. Place the lift truck or height-adjustable trolley in front of the fan and pull the fan onto
the platform.
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PREVENTIVE AND CORRECTIVE MAINTENANCE
7. Unplug the optical fibers (V3001:A1, V3002:A1) from the protection IGCTs (3) and stow
the optical fibers in a position where they cannot be damaged when the fan is replaced.
1
4
5
6
3
2
Figure 11–10 Replacing the non-redundant fan
1) Power supply cable
2) Bolts
4) ¼”
5) ~70 mm
6) 13 mm
3) Optical fiber cables
8. Push the lift truck under the fan, ensure that the lift truck does not catch cables
and components and lift the fan a little and remove it from the cabinet while avoiding
sudden movements.
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11.6.11.1. Installing the non-redundant fan
2. If they are damaged, replace them.
3. If they can be re-used, attach them to the new fan.
towards the back of the cabinet.
2
3
1
4
Figure 11–11 Installing the non-redundant fan
1) Mounting supports
2) Groove
3) ¼”
4) 10 mm
5. Check that all screws are properly fastened.
6. Install the new fan in reverse order of removal.
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11.6.12. Replacing a redundant fan
For information on inspection and replacement intervals, see “ACS1000A preventive
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
Figure 11–12 Redundant fans – location, dimensions and weight
1
2
3
8
4
5
6
7
9
Figure 11–13 Redundant fans - tools and devices
1) ¼”
6) Cordless drill
2) ~70 mm
3) 13 mm and 17 mm
4) 13 mm
7) 3 × M10×20
8) Height-adjustable platform
9) Lift truck
5) T 30
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PREVENTIVE AND CORRECTIVE MAINTENANCE
Procedure
1.
148Remove the panels.
3. If the fan is removed towards the front of the cabinet, the top panel can stay on the
cabinet.
4. If the rear panel is not accessible, remove the sound absorbing panels on the side
where the fan is replaced.
T 30
Figure 11–14 Redundant fan unit – removing the panels
5. Unplug the power supply cable.
Figure 11–15 Redundant fan unit – Unplugging the power supply cable
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PREVENTIVE AND CORRECTIVE MAINTENANCE
6. Remove the fixing bolts.
4
5
6
1
7
2
3
8
4
5
Figure 11–16 Redundant fan unit – removing the fixing bolts
1) Bolt
5) 13 mm
2) Cover
6) 13 mm
3) Mounting support
4) ¼”
7) Cordless drill
8) T 30
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PREVENTIVE AND CORRECTIVE MAINTENANCE
7. 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.
1
2
3
Figure 11–17 Redundant fan unit – using a crane
1) ¼”
3) 3 × M10 × 20
2) 17 mm
–
Height-adjustable platform: place the platform as close as possible to the fan and then
pull the fan onto the platform.
Figure 11–18 Redundant fan unit – using a platform
8. Remove the mounting supports from the fan housing to be replaced and attach the
mounting supports to the new fan housing.
9. If the new fan housing does not have screw holes for the mounting supports, drill holes
into the underside of the fan housing.
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PREVENTIVE AND CORRECTIVE MAINTENANCE
For information on the exact hole positions, see drawing number 3BHS128478 E01 in
2
1
10. Check that all screws are properly fastened.
11. Install the new fan in reverse order of removal.
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