ACS 1000 Medium Voltage AC Drives - firstfame.co.th · ACS 1000 Medium Voltage AC Drives ... The data stated in this manual is for product description purposes and ... 2.2 Fuseless

ACS 1000Medium Voltage AC Drives

for speed and torque control of315 to 5000 kW / 400 to 6700 hp

squirrel cage induction motors

Technical Catalog

3BHS125029, Rev. B

Effective: May 24, 2002

ABB Schweiz AG. All Rights Reserved.

We reserve all rights to this document, also in the event of patent issue or registration of any other industrial property protection right. Misuse and in particular duplication and forwarding to third parties are not permitted.

This document has been checked with care. However, should the user find any errors, they should please be reported to ABB Schweiz AG.

The data stated in this manual is for product description purposes and does not represent assured characteristics. As we aim to keep our prod-ucts up to the most modern standard, differences may occur between entries in this technical catalog and the actual product.

ACS 1000 Technical Catalog

Table of Contents

Chapter 1 - Overview 5

1.1 Introduction 51.2 The Standard Solution 51.3 Key Technology 51.4 Technical Benefits 61.5 ACS 1000 Types 7

Chapter 2 - Main Features 9

2.1 IGCT Power Semiconductors 92.2 Fuseless Design 92.3 Direct Torque Control 102.4 Input Stage 112.5 Output Stage 112.6 Elementary Diagram 12

Chapter 3 - Hardware Description 15

3.1 Electromagnetic Compatibility 153.2 ACS 1000 Cabinet Layout 153.2.1 Air-Cooled Type 153.2.2 Water-Cooled Type 173.2.3 Power Terminals 183.3 Control Equipment 193.4 Door Locks 203.5 IP Ratings 213.6 Lifting Arrangements 213.7 Standard Color 213.8 Additional Cabinets 21

Chapter 4 - User Interfaces 23

4.1 Overview 234.2 CDP 312 Control Panel 234.3 Standard I/Os 244.4 Fieldbus Adapter Modules 294.5 PC Tools 29

ACS 1000 Technical Catalog 1 / 104

Chapter 5 - Parameters and Application Macros 31

5.1 Overview 315.2 Suitable Applications for Different Macros 315.3 Macro I/O interfaces 33

Chapter 6 - Standard Functions 37

6.1 General 376.2 Standard Control Functions 376.2.1 General Functions 376.2.2 Main Circuit Breaker Control 406.2.3 Local and Remote Control 406.2.4 Diagnostics 416.2.5 Programmable Digital and Analog Outputs 416.2.6 Scalable Analog Inputs 426.2.7 Input Signal Source Selections and

Signal Processing 426.3 Standard Protection Functions 436.3.1 Programmable Fault Functions 436.3.2 Pre-programmed Protection Functions 456.3.3 Other Protection Functions 476.4 Other Functions 476.4.1 Customer Specific Options 48

Chapter 7 - Options 49

7.1 Environmental Conditions 497.2 Converter Enclosure 497.3 Input Section 507.4 Motor Side 527.5 Converter Cooling 547.6 Converter Isolators and Bypass 577.7 Auxiliary & Control Interfaces 597.8 PC Tools 59

Chapter 8 - Selecting the Drive System 61

8.1 Overview 618.2 Main Circuit Breaker 618.2.1 Main Circuit Breaker Control 618.2.2 Tripping Loop 628.2.3 Main Circuit Breaker Features 638.3 Converter Input Transformer Selection 66

2 / 104 ACS 1000 Technical Catalog

8.4 Selection of the ACS 1000 Converter 678.4.1 ACS 1000 Output Filter 678.4.2 Non Quadratic Load Applications 678.4.3 ACS 1000 Selection Tables 688.5 Motor Selection 718.5.1 Load Capacity Curves 718.5.2 Selection Criteria 728.5.3 Retrofit 728.5.4 Torsional Excitation 73

Appendix A - Installation Guidelines 75

Ambient Conditions 75Mounting 75Power Equipment Installation 78

General 78Transformer Primary Cables 79Transformer Secondary Cables 79Motor Cables 80Power Cable Dimensions 80Equipment Grounding 80Auxiliary Power Cables 80Control Cables 81Cable Routing 81ACS 1000 Cable Entry and Termination 82Transformer Connection Diagram for 12-Pulse ACS 1000 83Transformer Connection Diagram for 24-Pulse ACS 1000 84Motor Connection Diagram for 12 / 24-Pulse ACS 1000 84

Appendix B - Technical Data 85

Transformer Connection / Converter Input 85Converter Output / Motor Connection 86Auxiliary Supply 86Environmental Aspects 87Derating of Drive Power 88

Air-Cooled Converters 88Water-Cooled Converters 89

Transportation and Storage 89


Cooling 90Air-Cooled Converters 90Water-Cooled Converters 90

Protection Functions 91Analog Inputs 92Analog Outputs 92Digital Inputs 93Digital Outputs 93Auxiliary Power Output 93Reference Voltage Output 94DDCS Fiber Optical Link 94Enclosures 94

Appendix C - Dimensions and Weights 95

Appendix D - Applicable Codes and Standards 99

CE Marking 99Low Voltage Directive 99Machinery Directive 99EMC Directive 100Emissions 100Immunity 100

UL Marking 101Applicable Codes and Standards 101

Appendix E - ACS 1000 Type Code 103


Chapter 1 - Overview

This Technical Catalog describes the main electrical, mechanical and environmental features of the ACS 1000 – ABB’s contribution to new solu-tions of medium-voltage AC drives. In addition, the Catalog looks at the various options available for the drive and offers advice on selecting a motor and drive combination. It also provides useful installation tips.

The ACS 1000 is a standard, medium-voltage AC drive, rated from 315 to 5000 kW (400 to 6700 hp) for motor voltages of 2.3, 3.3 and 4.0 kV.

The drive has been designed as a standard product rather than an engi-neered drive. It is, therefore, a core product of ABB, forming part of the company’s ACS family. As such, the drive uses standard components, software tools and design principles as employed in the low voltage ACS range. This vastly increases the reliability of the drive and offers users a consistent addition to the extensive ACS product range.

As a standard solution the ACS 1000 has many of the benefits associated with engineered drives already included. This meets the most common system specifications with minimal engineering. In addition, because the drive is pre-engineered, shorter delivery times to end-users are possible.

About 85% of all medium-voltage drives are applied in standard applica-tions such as fans, pumps, conveyors and compressors, where the customized engineering content is minimal. The ACS 1000 is ideally suit-able for retrofit applications, where only a small portion of the world’s motors are fitted with drives.

Industries, which can benefit from this approach, include oil and gas, mining, water, pulp & paper, cement and power generation.

Two main technology features distinguish the ACS 1000 from other types on the market:

• The motor control platform is based on Direct Torque Control (DTC) which achieves the ultimate torque and speed performance.

DTC allows the speed of any standard squirrel cage induction motor to be controlled without the need for expensive and fragile encoders or tachogenerator feedback devices.

1.1 Introduction

1.2 The Standard Solution

1.3 Key Technology



• For the first time in any AC drive, a new power semiconductor switch-ing device is utilized. Known as IGCT (Integrated Gate Commutated Thyristor), the device provides an intrinsically less complex, more ef-ficient and reliable drive. This is achieved by fast switching and inher-ently low losses which mean less cooling equipment is needed.

IGCTs do not require snubber circuits and allow power bridge imple-mentation with fewer power devices than conventional medium-voltage drives. While reliability is improved, the physical size of the ACS 1000 is compact.

The technology described above brings many more practical benefits to the ACS 1000, as described within this Catalog.

For instance, the use of IGCTs together with active feedback control by means of an LC filter results in a sinusoidal output voltage. This proves useful in retrofit applications, as the drive is compatible with existing squirrel cage motors without the need to derate it. There are no undue voltage rises stressing the motor insulation and voltage reflections are eliminated on long cable runs.

Furthermore, DTC avoids any torque pulsations, which can be damaging to loads and their associated mechanical connections.

The ACS 1000 is available for use with a separately mounted input isola-tion transformer (standard) or alternatively with an integrated dry-type transformer. This provides installation flexibility and allows for the use of oil filled transformers which are typically mounted outdoors.

The ACS 1000 meets all common standards including IEC and EN. In order to meet the requirements of the North American market, the ACS 1000 is also UL and Canadian UL listed. In addition, ABB has under-taken much development work to ensure that the converter adequately meets the requirements of the world’s harmonics standards, such as IEEE 519-1992.

For details please refer to Appendix D - Applicable Codes and Standards.

The ACS 1000 features a selection of pre-programmed and standardized application macros for the configuration of inputs, outputs, signal processing and other parameters.

1.4 Technical Benefits



The ACS 1000 is available as air-cooled and water-cooled types. The air-cooled ACS 1000 covers rated power outputs from 400 HP to 2250 HP (315 kW to 1600 kW). For higher power output ratings ranging from 2500 HP to 6700 HP (1800 kW to 5000 kW), the converters are water-cooled.

The ACS 1000 converter is available for 3 different medium voltage levels. These are the standard motor voltages of 2.3 kV, 3.3 kV and 4.0 kV. For information on solutions for retrofit applications with motor voltages of up to 7.2 kV please contact your ABB representative.

The table below provides an overview of the rated output power range, covering air and water-cooled converters for all three medium voltage levels.

For further details, refer to Chapter 8 - Selecting the Drive System.

Table 1-1 Standard Power Ranges for ACS 1000 Converters

** The power ratings apply to typical 4 pole motors. For those motors the frequency converter has a built-in overloadability of 10%. When selecting the frequency converter it should be observed that the rated current of the ACS 1000 must be higher than or equal to the rated motor current in order to achieve the rated motor power given in the table.

Note: For air-cooled units (with enclosure class IP21) the load capacity (current and power) depends on the altitude and the ambient temperature at the installation site. In case of water-cooled units the load capacity depends on the cooling water temperature at the installation site. For details on the derating factors, see Appendix B - Technical Data.

1.5 ACS 1000 Types

Motor Voltage

(kV)

Type ofCooling

Rated MotorPower Range**

HP

Max. cont. Power of ACS 1000

(kVA)

Frame Size

2.3 Air 400 - 1500 400 - 1350 A1 - A2

3.3 Air 400 - 2250 400 - 2150 A1 - A3

3.3 Water 2500 - 6700 2400 - 5950 W1 - W3

4.0 Air 400 - 2250 400 - 2000 A1 - A3

4.0 Water 2500 - 6700 2300 - 5800 W1 - W3




Chapter 2 - Main Features

ABB researched and designed the Integrated Gate Commutated Thyristor (IGCT) specifically for the medium voltage market. IGCTs provide high speed switching like IGBTs (Insulated Gate Bipolar Transistors) and at the same time provide high voltage blocking and low loss conduction like GTOs (Gate Turn-Off Thyristors). The result is a fast, low loss device that can be used at medium voltage levels without resorting to series topolo-gies. It transcends both of the older technologies from which it evolved. IGCTs also provide other benefits:

• Freewheeling diode is integrated into the same package

• Snubber circuits are not required

• Gating circuitry is packaged with the power device

• High reliability (low total parts count)

• High power density (combination of low total parts count and low power losses)

• Self-protecting against destructive failures.

All these features combined provide a medium voltage power switching device with the best combination of performance, reliability, efficiency, and space effectiveness available in the market today.

The ACS 1000 features a fuseless protected medium voltage drive.

The patented design uses the new power semiconductor switching device, IGCT, for circuit protection.

The IGCT, which is placed between the DC link and the rectifier, can, unlike conventional fuses, directly isolate the inverter of the drive system from the power supply side. This is achieved within 25 microseconds, which is 1000 times faster than the operational performance of fuses.

Using the IGCT as an integrated protection device leads to a lower parts count within the drive system making the ACS 1000 a drive with outstanding reliability.

The reason why IGCTs are capable of performing a protection function, unlike other power semiconductor devices, lies in their low onstate losses and their ability to turn off at high speed at medium voltage levels.

2.1 IGCT Power Semiconductors

2.2 Fuseless Design



Direct Torque Control (DTC) is a unique motor control method for AC drives. The inverter switching is directly controlled according to the motor core variables flux and torque.

The measured motor current and DC link voltage are inputs to an adaptive motor model which produces exact actual values of torque and flux every 25 microseconds. Motor torque and flux comparators compare actual values to the reference values produced by the torque and flux reference controllers. Depending on the outputs from the hysteresis controllers, the pulse selector directly determines the optimum inverter switch positions.

Figure 2-1 DTC Block Diagram

2.3 Direct Torque Control

Switch positions

Torque reference

Speed reference

Rectifier

=~Inverter

Torque comparator

Flux comparator

Adaptivemotor model

Torque reference controller

PID

Flux reference controllerU

fU

fT

f

Speed controller+ acceleration compensator

Actual speed

Internal fluxreference

Actual torqueActual flux

Inverter currentDC bus voltage

DC bus

Fluxstatus

Torque status

Controlsignals

ASIC

Switch position commands

Mains

Internal torquereference

Optimumpulse selector

Filter current

Output filter

(3 measurements)

(4 measurements)

M3~



How does DTC differfrom PWM Flux Vector

Drives?

In DTC, each switching instance is determined separately based on the values of flux and torque, rather than switching in a predetermined pattern as in conventional PWM flux vector drives.

Table 2-1 DTC versus PWM Flux Vector Controlled Drives

For more information on DTC, please refer to the Technical GuideNo. 1 Direct Torque Control (3AFY 58056685 R0025).

The ACS 1000 features a 12-pulse diode rectifier input stage. This is adequate for most networks and normally meets the harmonic require-ments demanded by standards such as IEEE 519.

For networks that are more demanding, the ACS 1000 can be supplied optionally with a 24-pulse configuration for water-cooled and for air-cooled types.

As a standard the ACS 1000 is equipped with a low pass LC sine filter in its output stage. Current feedback is used to actively control filter opera-tion. The low pass frequency is designed to be well below the lowest switching frequency used by the inverter output stage. This greatly enhances the purity of both the voltage and current waveforms applied to the motor. This in turn provides many important benefits:

• Harmonic heating is virtually eliminated. The drive may be used to supply standard medium voltage motors (existing or new) without ap-plying thermal derating factors.

DTC Flux Vector

Switching based on core motor variables Flux and Torque

Switching based on separate control of magnetising and torque producing components of current

Shaft speed and position not required Mechanical speed is essential. Requires shaft speed and position (either measured or estimated)

Each inverter switching is determined separately (every 25 µs).

Inverter switching based on average references to a PWM modulator. This results in delays in response and wasted switchings.

Torque Step Rise Time (open loop) is less than 10 msec.

Torque Step Rise TimeClosed Loop 10 to 20 msec.Sensorless 100 to 200 msec.

2.4 Input Stage

2.5 Output Stage



• Voltage reflection and the associated occurrence of voltage doubling at the motor input terminals is no longer an issue (the causal high fre-quency content does not exist). Therefore, any standard medium volt-age winding insulation system (existing or new) is compatible with the ACS 1000.

• The maximum length of the motor cables is not limited by the ACS 1000 (normal voltage drop restrictions as found in any electrical installation still apply).

• Motor bearing failures attributable to capacitively coupled high fre-quency current are no longer a problem (the causal high frequency common mode voltage is eliminated).

• Motor insulation is not subject to the common mode voltage typical for other drive topologies.

Figure 2-2 and Figure 2-3 show the elementary circuit diagram of the 12-pulse and the 24-pulse versions of the ACS 1000.

The 3-phase AC line voltage is supplied to the rectifier bridges through the 3-winding converter transformer. In order to obtain 12 or 24-pulse rectifi-cation, appropriate phase shift is necessary between the secondary wind-ings of the transformer.

The two fuseless rectifier bridges in the 12-pulse scheme (Figure 2-2) are connected in series, such that the DC voltages are added up. Therefore, the full DC bus current flows through both bridges. In the 24-pulse scheme, 2 such bridge arrangements are connected in parallel as shown in Figure 2-3.

Figure 2-2 Elementary Diagram - ACS 1000, 12-Pulse Version

2.6 Elementary Diagram

NP M

3 ConverterTransformer

Main CircuitBreaker

MediumVoltage Switchgear

DiodeRectifier

ProtectionIGCTs

Intermediate DC Link

Three LevelInverter

OutputSine Filter

Squirrel CageInduction Motor

MNP



Figure 2-3 Elementary Diagram - ACS 1000, 24-Pulse Version

Each leg of the 3-phase inverter bridge consists of a combination of 2 IGCTs for 3-level switching operation: with the IGCTs the output is switched between positive DC voltage, neutral point (NP) and negative DC voltage. Hence both the output voltage and the frequency can be controlled continuously from zero to maximum, using Direct Torque Control.

At the converter output a LC filter is used for reducing the harmonic content of the output voltage. With this filter, the voltage waveform applied to the motor is nearly sinusoidal (see Figure 2-4). Therefore, standard motors can be used at their nominal ratings. The filter also eliminates all high dv/dt effects and thus voltage reflections in the motor cables and stresses to the motor insulation are totally eliminated.

Figure 2-4 Voltage and Current Waveforms at Converter Output

ConverterTransformer

Main CircuitBreaker

MediumVoltage Switchgear

DiodeRectifier

ProtectionIGCTs

Intermediate DC Link

Three LevelInverter

OutputSine Filter

Squirrel CageInduction Motor

ACS 1000ACS 1000 Output voltage: 4.16kVOutput frequency: 60Hz




Chapter 3 - Hardware Description

The riveted and folded cabinet construction of the ACS 1000 ensures an extremely strong yet flexible and self-supporting framework which avoids the need for additional skeletal support. Compared with traditional bolted frames the cabinet provides extremely effective protection against electro-magnetic emissions.

The design fulfils the requirements of international standards like UL 347A. For details please refer to Appendix D - Applicable Codes and Standards.

Electromagnetic Compatibility (EMC) has been achieved by applying a cabinet design consisting of folded, galvanized sheet metal plates and minimizing the spacing between the rivets. The cabinet’s inside walls are not painted, because paint tends to reduce the effectiveness of metallic bonding which is paramount to successful EMC.

Accordingly, only the front of the ACS 1000 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 channels.

3.2.1 Air-Cooled TypeThe air-cooled type of the ACS 1000 is designed with inverter stacks, output filter and DC link capacitor in one section (see Figure 3-1). This section experiences maximum air flow which is advantageous for the temperature sensitive capacitors. The construction of the inverter stacks allows easy exchange of IGCTs by means of a specially designed tool which is part of the supply.

The middle section accommodates cooling fan, rectifier stack, protection IGCTs and filter reactor. The construction is such that the fan can be exchanged easily.

The air intake is provided with an air filter in order to prevent dust and particles from entering into the converter. The air filter can be replaced from outside while the drive system is in operation.

3.1 Electromagnetic Compatibility

3.2 ACS 1000 Cabinet Layout



Figure 3-1 The ACS 1000 Air-Cooled Type (12 / 24-Pulse)

1 Control section with separate power cable connection section

2 Grounding switch and filter reactor section (24-pulse version with additional rectifier stack)

3 Rectifier stack, protection IGCTs and cooling fan

4 Inverter stacks, air intake, output filter and DC link capacitors

2 3 41



3.2.2 Water-Cooled Type

12-Pulse Version The water-cooled type of the ACS 1000 (see Figure 3-2) is equipped with a closed circuit water cooling system. Part of the cooling system is a fan and an air-to-water heat exchanger to maintain cooling of all components which cannot be cooled by water.

As with the air-cooled type, the construction of the inverter stacks allows easy exchange of IGCTs by means of a specially designed tool which is part of the supply.

Figure 3-2 The ACS 1000 Water-Cooled Type (12-Pulse)

1 Control section with separate power cable connection section

2 Filter and DC components section (grounding switch, filter reactor and filter capacitors, DC link capacitors, common mode choke)

3 see item 2

4 Converter section (rectifier stack, protection IGCTs, inverter stacks)

5 Cooling unit

1 2 3 4 5



24-Pulse Version The cabinet layout of the water-cooled 24-pulse version of the ACS 1000 is identical to the 12-pulse version, with the exception that there is an addi-tional cabinet on the left hand side of the control section, containing the extra rectifier stacks for 24-pulse operation.

3.2.3 Power TerminalsThe leftmost section (Figure 3-1 and Figure 3-2) contains the swing frame with the control equipment (see Section Control Equipment, page 19). Behind this swing frame and a protective separation door is the drive’s power terminal section with busbars for mains and motor cables. To provide optimum access to the power terminals, the swing frame can be opened more than 120°.

Please refer to Appendix A - Installation Guidelines for further details on cable entry and connection.



The layout of the control cabinet is identical for all converter types.

The control hardware (processor and communication boards) are mounted on the swing frame. Details can be seen in Figure 3-3.The customer I/Os are located behind the swing frame on the right side wall (see Figure 3-4). Terminals for customer control and protection signals as well as for auxiliary power supply are also located there.

Figure 3-3 Control Section with Open Front Door

3.3 Control Equipment

Swing frame

Electronic powersupply board (EPS)

AMC3 control board

Interface board

IOEC1 board

∆p-transmitters(air-cooled

converters only)

Motor starters andcircuit breakers

Aux. supplytransformer

Batteries

Pulse encoder

Fieldbus interface



Figure 3-4 Control Section with Swing Frame Removed

All doors are hinged and locked using carriage key locks.

The doors of the power sections of the drive are electromechanically inter-locked with the safety grounding switch and with the main circuit breaker upstream of the converter transformer. This interlock system ensures that none of the power cabinets can be opened until the main source of power is disconnected, the DC link capacitors are discharged and the safety grounding switch is closed. Additionally the same interlock system insures that power cannot be initialized to the drive unless the doors are closed and the safety grounding switch has been opened.

IOEC2 board(standard)

Access door to powercable connection

section

IOEC3 board (stan-dard for water-cooled

converters)

IOEC4 board(optional)

Terminals for aux.voltages, control sig-

nals and tripping loop

3.4 Door Locks



The doors of the control section and of the cooling section (water-cooled type) are not linked to the interlocking system. They can be opened at any time. The high voltage busbar section is located behind the control swing frame and separated from the control section by a bolted protective shield.

The power section doors of all additional cabinets (e.g. additional rectifier cabinet, braking chopper cabinet) are monitored by separate door switches since they are not included in the electromechanical interlock system. These door monitoring switches are wired to the drive’s tripping loop. If any of the doors are opened during operation, the MCB will be tripped immediately.

The standard ACS 1000 cabinet is rated IP21 for air-cooled and IP 31 for water-cooled types. Higher IP ratings are available as options. See Chapter 7 - Options for further details.

The cabinets are fitted with lifting lugs as standard.

The standard color is RAL 7035 (light grey). Other colors are available on request.

The ACS 1000 cabinet system provides the flexibility to add further sections to the converter at any time. Sections can be added in width of 600, 800 and 1000 mm (24, 32 and 39 inches).

3.5 IP Ratings

3.6 Lifting Arrangements

3.7 Standard Color

3.8 Additional Cabinets




Chapter 4 - User Interfaces

The ACS 1000 can be controlled from several control locations:

• The detachable CDP 312 control panel mounted on the ACS 1000 front door of the control section

• External control devices, e.g. a supervisory control system, connected to the analog and digital I/O terminals on the standard I/O Boards (IOEC)

• Fieldbus adapter modules

• PC Tools (DriveWindow and DriveSupport) hooked up via a PC adapter to the ACS 1000 control board.

The CDP 312 Control Panel is the basic user interface for monitoring, adjusting parameters and controlling the ACS 1000 converter operation.

Figure 4-1 CDP 312 Control Panel

4.1 Overview

4.2 CDP 312 Control Panel

ACT PAR FUNC DRIVE

ENTER

LOC

REM

RESET REF

1 L -> 1242rpm I

SPEEDCURRENT

TORQUE

76.00 A1242.0rpm86.00 %

Enclosure class IP54 when attached to the Control Panel Mounting Platform

Multilingual Alphanumeric Display (4 lines x 20 characters)

Plain text messages available in several languages

Control Panel Mode Selection keys

Double Up Arrow, Up ArrowEnterDouble Down Arrow, Down Arrow

Local/Remote, Reset, Reference and Start keys

Forward, Reverse and Stop keys

ControlPanelDisplay

ControlPanelKeypad



Using the CDP 312 panel it is possible to

• enter start-up data into the drive

• set a reference signal and give 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.

The standard I/O-boards offer a number of pre-programmed analog and digital I/Os which are sufficient for most applications. For a wider range of signal interfaces optional I/O-boards can be ordered for water and air-cooled ACS 1000 to provide extended protection for transformer and motor, external cooling equipment (e.g. fans, chillers), on-line synchronization logic and other customer requirements.

The air-cooled ACS 1000 is equipped with two I/O-boards (IOEC1 and IOEC2) as a standard with the option of two additional I/O-boards (IOEC3 and IOEC4). The water-cooled ACS 1000 is equipped with three I/O-boards (IOEC1, IOEC2, IOEC3) with the option of one aditional I/O-board (IOEC4).

All I/O-boards are identical in design with the same number of I/Os. The analog and digital I/Os are floating and galvanically isolated with ratings as indicated in Table 4-1.

While the function of digital and analog inputs are fixed and cannot be altered, the signals allocated to digital and analog outputs can be changed by setting the corresponding parameters accordingly.

4.3 Standard I/Os

Table 4-1 I/O Board Configuration with Number and Type of I/O

Number Signal Type Ratings

4 Analog Inputs

(AI) 0...20 mA / 4...20 mA or 0...10 V / 2...10 Vscalable by parameter setting

2 Analog Outputs

(AO) 0...20 mA / 4...20 mAscalable by parameter setting

14 Digital Inputs

(DI) Opto-coupled, rated for 22...250 VAC or 22...150 VDC

6 Digital Outputs

(DO) With switch-over contact (SPDT),rated for 250 VAC, 2 A



Standard I/Os are marked in the following tables with a dot ( ). The letter (W) indicates that these I/Os are standard for the water-cooled ACS 1000. A signal name beginning with a slash (/) indicates a signal which is true when its status is low.i

Table 4-2 I/O Signals: Remote Control Interface

Type Signal Name Remarks Standard

DI STANDARD INPUT 1 Macro specific I/O *






DI DISABLE LOCAL Remote input to disable the possibility for a local/remote switch-over from the CDP 312 control panel

DI REM ORD MCB CLOSE Remote request for closing the main circuit breaker

DI REM ORD MCB OPEN Remote request for opening the main circuit breaker

DI REMOTE RESET Remote fault reset (some converter related faults cannot be reset remotely)

DO DRIVE READY Status output “Drive Ready”(i.e. MCB closed, DC link charged, no lockout active)

DO DRIVE RUNNING Status output “Drive Running”

DO DRIVE ALARM Status output “Drive Alarm”

DO DRIVE TRIP Status output “Drive Tripped”

DO LOCAL MODE Local mode operation status indication

AI REF VALUE 1 Macro specific I/O



* see Chapter 6 - Standard Functions

AI REF VALUE 2 Macro specific I/O

AO SHAFT SPEED ACT VAL Actual speed monitoring output

AO MOT CURRENT ACT VAL / MOT TORQUE ACT VAL

Actual current / torque monitoring output (programmable)

Table 4-3 I/O Signals: Main Circuit Breaker


DI MCB IS CLOSED Status feedback from the main circuit breaker

DI MCB IS OPEN Status feedback from the main circuit breaker

DI MCB IS AVAILABLE Status feedback from the main circuit breaker, showing that the breaker is faulty, drawn-out or in test position

DO MCB ORD CLOSE Drive command to close the main circuit breaker (pulse signal or maintained)

DO /MCB ORD OPEN Drive command to open the main circuit breaker (pulse signal or maintained)

DO /MCB ORD TRIP Hardware tripping loop to the main circuit breaker (signal active when low)

Table 4-4 I/O Signals: Transformer


DI /EXT TRAFO PROT TRIP Initiates a main circuit breaker trip (included in hardwired tripping loop)

DI OIL LEVEL ALARM Transformer oil level alarm indication

W

Table 4-2 I/O Signals: Remote Control Interface (continued)




DI OIL TEMP ALARM, or

TRAFO WDG TEMP ALARM

Transformer oil temperature alarm indication

Transformer winding temperature alarm indication

W

DI /OIL TEMP TRIP, or

/TRAFO WDG TEMP TRIP

Transformer oil temperature trip indicationTransformer winding temperature trip indication

W

DI BUCHHOLZ ALARM Transformer alarm indication from Buchholz relay

W

DI /BUCHHOLZ TRIP Transformer trip indication from Buchholz relay

W

AI OIL TEMP, or

TRAFO WDG TEMP

Temperature measurement of transformer oilTemperature measurement of transformer winding

W

Table 4-5 I/O Signals: Motor


DI /EXT MOT PROT TRIP Initiates a main circuit breaker trip (included in hardwired tripping loop)

DI EXT MOT PROT ALARM (External) motor protection alarm indication

W

DI MOT COOLING ALARM (External) motor cooling alarm indication

W

DI /MOT COOLING TRIP (External) motor cooling trip indication

W

DI VIBRATION SV ALARM Motor vibration alarm indication

W

DI /VIBRATION SV TRIP Motor vibration trip indication W

DI /OVERSPEED TRIP Motor overspeed trip (included in hardwired tripping loop)

W

AI MOT WDG TEMP PH U Motor winding temperature

AI MOT WDG TEMP PH V Motor winding temperature

AI MOT WDG TEMP PH W Motor winding temperature

Table 4-4 I/O Signals: Transformer (continued)




AI BRG TEMP DE Motor bearing temperature of driven end

W

AI BRG TEMP NDE Motor bearing temperature of non-driven end

W

Table 4-6 I/O Signals: Process


DI /PROCESS STOP Remote process stop input to stop the drive (signal active when low)

DI /INT/EXT EMERGENCY OFF Emergency OFF (signal active when low) from process side to trip the main circuit breaker instantaneously(included in hardwired tripping loop)

Table 4-7 I/O Signals: Others


DI /SUPPL VOLT UNBALANCE Trip from external voltage unbalance relay (signal active when low)

DI EXT WTR COOLING ALARM Alarm indication from external water cooling unit

DI /EXT WTR COOLING TRIP Trip (active when low) from external water cooling unit

DI BRAKE CHOP FAN ALARM Alarm signal from braking chopper

DI BRAKE CHOP TEMP TRIP Trip signal from braking chopper

DI INPUT ISOLATOR OPEN Status input

DI INPUT ISOLATOR CLOSED Status input

DI OUTPUT ISOLATOR OPEN Status input

DI OUTPUT ISOLATOR CLOSED

Status input

AI OUTSIDE AIR TEMP Temperature measurement of outside air

Table 4-5 I/O Signals: Motor (continued)




A fieldbus module may be used for controlling and monitoring the ACS 1000 instead of using the conventional hard-wired I/Os. There are several fieldbus adapter modules available for the ACS 1000.

For further details, see Chapter 7 - Options.

DriveWindow offers several functions for commissioning and monitoring ABB products. All the functions are available from the Menubar or the Toolbar of the program. In DriveWindow the user has the choice between two special displays and six different tools.

For further details, see Chapter 7.8 PC Tools.

4.4 Fieldbus Adapter Modules

4.5 PC Tools




Chapter 5 - Parameters and Application Macros

Parameters allow the user specific configuration of the ACS 1000. They can be set using the CDP 312 control panel.

The application macros consist of pre-programmed parameter sets that are adapted for a specific application. They offer pre-set signal interfaces for opening/closing the main circuit breaker, starting/stopping the drive system and setting reference values.

Depending on the process, the appropriate macro can be selected, thus enabling a quick and easy start-up of the ACS 1000.

Using an application macro has the advantage that the number of individual parameters to be set during start-up is minimized. All para-meters have factory-set default values. Leaving them unchanged, a good system performance is achieved in typical situations. These default values can be left unchanged or they can be set individually according to the needs of the customer.

The ACS 1000 can be operated with one of the following standard macros:

• Factory

• Speed Control

• Hand/Auto

• PID Control

• Torque Control

• Sequential Control

• Master/Follower

• User 1

• User 2

Factory The Factory Macro is the default-set macro. It covers most of the common applications, such as:

• Pump, fan and other industrial processes with a square torque char-acteristic

• Conveyors and other industrial drives requiring constant torque.

5.1 Overview

5.2 Suitable Applications for Different Macros



Speed Control The Speed Control Macro is essentially the same as the Factory Macro. The only difference to the Factory Macro is that a loading of the Speed Control Macro will not affect the currently set motor control parameters (when loading the Factory Macro all parameters will be reset to their default value).

Hand/Auto The Hand/Auto Macro is suitable for applications where the speed has to be controlled automatically by a process control system and manually by an external control panel. The active control location is selected via a digital input.

The macro is also recommended when the drive has to be controlled from two external control stations. The active control station for starting /stop-ping and setting of the reference value is selected via a digital input.

PID Control The PID macro is intended for the use with closed loop control systems such as pressure control, level control and flow control. For example:

• Booster pumps of municipal water supply systems

• Booster pumps of district heating systems

• Automatic level control of water reservoirs

• Speed control of different types of material handling systems where the material flow has to be regulated.

The PID controller is incorporated into the ACS 1000 software. It is acti-vated by selecting the PID macro.

A process reference value is set via an analog input or by using the control panel of the ACS 1000. The actual process value is connected to a dedi-cated analog input.

The internal PID controller of the ACS 1000 eliminates the need of a sepa-rate PID controller (no additional installation and wiring required).

Figure 5-1 Example of an Application with PID Control Loop

Actual Value

Reference

LevelTrans-ducer

Pump

ACS 1000 Converter



Torque Control The macro is intended for processes requiring torque control, e.g. mixers and slave drives. The torque reference comes from a process automation system or a control panel.

Sequential Control The Sequential Control Macro is aimed for processes where different constant speed settings and/or different acceleration/deceleration ramps are required in addition to an adjustable speed reference value. The different settings can be selected automatically by a process control system or they can be activated manually by selector switches which are connected to the corresponding digital inputs.

Master/Follower The Master/Follower Macro is designed for applications with several ACS 1000 where the motor shafts are coupled to each other by gearing, chain, belt etc. Thanks to the Master/Follower macro the load can be evenly distributed between the drives or depending on the process at some other ratio.

User 1 / User 2 The User Macro 1 and 2 allows to save a complete set of customized parameters and to recall it at a later instant or to download it to another ACS 1000.

The following tables give an overview of the pre-set digital and analog inputs and outputs, regarding opening/closing the main circuit breaker, starting/stopping the drive system, setting reference values and status feedback signals. All other customer interface signals are the same for each application macro, see Chapter 4 - User Interfaces.

All macro specific I/Os are available on the standard IOEC boards. Only the PID macro requires IOEC 4 board.

5.3 Macro I/O interfaces

Table 5-1 Macro Specific Digital and Analog Inputs

Macro I/Os I/O functions

FactorySpeed

DI MCB open/close commandsStart/ stop commandsSelection of direction Selection of 2 accel/decel ramps Selection of 2 const. speedsProcess stop or run enable

AI 2 speed reference values



The pre-set digital and analog outputs available for external use are the same for each macro.

Hand/Auto DI Selection of hand/auto modeMCB open/close commands in hand modeMCB open/close commnands in auto modeStart/ stop commands in hand modeStart/stop commands in auto modeSelection of 1 const. speedProcess stop or run enable

AI Speed reference value in hand modeSpeed reference value in auto mode

PID DI MCB open/close commandsStart/stop commandsSelection of directionSelection of reference valueSelection of 2 accel/decel rampsSelection of 3 const. speedsProcess stop or run enable

AI Reference valueActual value, process feedbackActual value process feedback

Torque DI MCB open/close commandsStart/stop commands Selection of speed/torque controlSelection of 2 accel/decel rampsSelection of 1 constant speedProcess stop or run enable

AI Speed reference valueTorque reference value

Sequential DI MCB open/close commandsStart/stop commandsSelection of 2 accel/decel rampsSelection of 7 const. speedsProcess stop or run enable

AI Reference value

Master Follower DI MCB open/close commandStart/stop commandSelection of 1 accel/decel rampSelection of 3 const. speedsProcess stop or run enable

AI Speed reference value

User 1 / User 2 Depends on application

Table 5-1 Macro Specific Digital and Analog Inputs (continued)




Table 5-2 Macro Specific Digital and Analog Outputs


FactorySpeedPIDTorqueSequentialMaster/Follower

DO Drive readyDrive runningDrive alarmDrive trip

AO Motor frequencyMotor torqueMotor speedMotor torque filtered




Chapter 6 - Standard Functions

The ACS 1000 is configured and customized by means of application parameters. These parameters can be altered by the user, either by means of the integrated CDP 312 control panel or by using a PC and the DriveWindow software package, as described in Chapter 7 - Options.

Control and monitoring functions of the ACS 1000 can be activated by setting parameters one by one or by invoking an Application Macro (see Chapter 5 - Parameters and Application Macros) which is optimized for a particular application. Therefore some of the functions described in this chapter will be configured automatically if an application macro is selected.

This chapter provides information about the standard control, monitoring and protection functions for the ACS 1000. A description of the basic I/O devices and the application macros of the ACS 1000 can be found in Chapter 4 - User Interfaces and Chapter 5 - Parameters and Application Macros.

6.2.1 General Functions

Motor ID Calculation Based on the nameplate data all ACS 1000 internal motor control parameters will be automatically calculated. This procedure is usually performed once during commissioning. However, the procedure can be repeated whenever required (e.g. when the ACS 1000 will be hooked up to another motor).

Full Torque at ZeroSpeed

A motor fed by the ACS 1000 can develop short-term motor nominal torque at start-up without any pulse encoder or tachogenerator feedback. This feature is essential for constant torque applications. However, if permanent operation at zero speed is required, a pulse encoder has to be used.

Enhanced Flying Start This feature allows a rotating motor (e.g. a turbo-pump or a fan) to be taken over by the ACS 1000. By means of the flying start function the frequency of the motor is detected and the motor is started-up again by the ACS 1000.

6.1 General

6.2 Standard Control Functions



Flux Optimization Flux optimization of the ACS 1000 reduces the total energy consumption and motor noise level when the drive operates below the nominal load. The total efficiency (ACS 1000 and motor) can be improved by 1...10%, depending on the load torque and speed. This function is activated by parameters.

Power Loss Ride-Through

If the incoming supply voltage is cut off the ACS 1000 will continue to operate in an active but non-torque producing mode by utilizing the kinetic energy of the rotating motor and load. The ACS 1000 will be fully active as long as the motor rotates and generates energy to the ACS 1000. Power loss ride through can be enabled by parameters.

Auxiliary Ride Through The auxiliary ride through function guarantees correct fault indication and proper trip sequencing, in the event that the auxiliary power source feeding the drive is lost. The function is activated by a parameter. During ride through the power for the control circuits of the ACS 1000 is supplied by internal batteries. The ride through time is limited to 1 sec.

Acceleration andDeceleration Ramps

ACS 1000 provides two user-selectable acceleration and deceleration ramps. It is possible to adjust the acceleration/deceleration times(0...1800 s) and select the ramp shape. Switching between the two ramps can be controlled via a digital input.

The available ramp shape alternatives are:

Linear: Suitable for drives requiring long acceleration/deceleration where S-curve ramping is not required.

S1: Suit. for short acc./dec. times.

S2: Suit. for medium acc./dec. times

S3: Suit. for long acc./dec. times.

S-curve ramps are ideal for conveyors carrying fragile loads, or other applica-tions where a smooth transition is required when changing from one speed to another.

Critical Speed There is a Critical Speed function available for applications where it is necessary to avoid certain motor speeds or speed bands, for example due to mechanical resonance problems. The ACS 1000 makes it possible to set up five different speed settings or speed bands which will be avoided during operation.

Linear

1 t (s)

Motor

1.25 2

S1

S2

S3

speed



Each critical speed setting allows the user to define a low and a high speed limit. If the speed reference signal requires the ACS 1000 to operate within this speed range the Critical Speeds function will keep the ACS 1000 operating at the low (or high) limit until the reference is out of the critical speed range. The motor is accelerated/decelerated through the critical speed band according to the acceleration or deceleration ramp.

Constant Speeds Up to 15 constant speeds can be programmed and selected by digital inputs. If activated the external speed reference is overwritten. If the Sequential Control Macro is used a standard set of parameter values is selected automatically.

Accurate SpeedControl

The static speed control error is typically +0.1% (10 % of nominal slip) of the motor nominal speed, which satisfies most industrial applications.

Accurate TorqueControl without Speed

Feedback

The ACS 1000 can perform precise torque control without any speed feed-back from the motor shaft. With torque rise time less than 10 ms at 100% torque reference step compared to over 100 milliseconds in frequency converters using sensorless flux vector control, the ACS 1000 is unbeatable.

By applying a torque reference instead of a speed reference, the ACS 1000 will maintain a specific motor torque value; the speed will be adjusted auto-matically to maintain the required torque.

Table 6-1 Typical Performance Figures for Torque Control, when Direct Torque Control is used

* When operated around zero frequency, the error may be bigger.

s 1 Lows1 High s2 Low s2 High

Speed

540 690 1380 1560

(rpm)

540690

1380

1560

(rpm)Motorspeed

reference

Torque Control ACS 1000no Pulse Encoder

ACS 1000with Pulse Encoder

Linearity error + 4 %* + 3 %

Torque rise time < 10 ms < 10 ms

100

t(s)

TTN

< 10 ms

90

10

(%)

Tref

Tact

TN = Rated Motor TorqueTref = Torque ReferenceTact = Actual Torque



6.2.2 Main Circuit Breaker ControlAll functions regarding the control of the main circuit breaker (opening, closing, tripping, monitoring) are included in the ACS 1000.

For detailed information see Chapter 8 - Selecting the Drive System, Main Circuit Breaker, page 61.

6.2.3 Local and Remote ControlOperation of the ACS 1000 is possible either in local or remote control mode.

Local/remote control is selected directly on the CDP 312 control panel by pushing the LOC/REM push-button. A capital L on the display indicates local control:.

Remote control is indicated with a blank:

Local Control If the converter is in local control, local operation using the push-buttons on the converter front door and the CDP 312 control panel is possible. In local operation mode no remote control command will be accepted.

Remote Control If remote control is selected, local operation from the push-buttons on the converter front door and from the CDP 312 control panel is not possible. Instead all commands for closing and opening the main circuit breaker or starting and stopping the drive are received via digital inputs from a remote control station. The speed reference value is given as an analog input signal.

Alternatively all remote control signals can be exchanged via an optional fieldbus interface.

Changing the control mode from local to remote and vice versa can be disabled by setting digital input “DISABLE LOCAL” (see also Table 4-2).

LOC

REM MotSpeed 0.00 rpmPower 0.0 %

1 L -> 0.0 rpm 0Status RdyForMCBOn

LOC

REM MotSpeed 0.00 rpmPower 0.0 %

1 -> 0.0 rpm 0Status RdyForMCBOn



6.2.4 Diagnostics

Actual SignalMonitoring

Three signals can be displayed simultaneously on the control panel.

Actual signals to be displayed can be selected in parameter group 1 to 5, Actual Signals.

For example:

• ACS 1000 output frequency, current, voltage and power

• Motor speed and torque

• DC Link voltage

• Active control location (Local / External 1 / External 2)

• Reference values

• ACS 1000 inverter air temperature

• Cooling water temperature, pressure and conductivity

• Operating time counter (h), kWh counter

• Digital I/O and analog I/O status

• PID controller actual values (if the PID Control Macro is selected)

Fault History The Fault History contains information on the forty most recent faults detected by the ACS 1000. Faults are displayed in alphanumeric charac-ters.

6.2.5 Programmable Digital and Analog Outputs

Programmable DigitalOutputs

Four digital outputs on the IOEC 2 board can be programmed individually. Each output has floating change-over contacts and can be allocated to an internal binary control or status signal via parameter setting.

Examples are:

• ready, running, fault, warning, motor stall, motor temperature alarm / trip, ACS 1000 temperature alarm / trip, reverse rotation selected, external control selected, preset speed limits, intermediate circuit voltage limits, preset motor current limit, reference limits, loss of reference signal, motor operating at reference speed, process PID controller actual value limits (low, high) etc.

If optional boards IOEC 3 and/or IOEC 4 are installed, a maximum of 12 additional digital outputs (6 on each board) are available.

1 L -> 600.0 rpm 1Status RunningMotSpeed 600.00 rpmPower 75.0 %



Programmable AnalogOutputs

Two programmable analog outputs on each IOEC board are at the user’s disposal.

Depending on the setting of the corresponding parameters, the analog output signals can represent for example:

• motor speed, process speed (scaled motor speed), output frequency, output current, motor torque, motor power, DC bus voltage, output voltage, application block output (process PID controller output), active reference, reference deviation (difference between the reference and the actual value of the process PID controller).

The selected analog output signals can be inverted and filtered. The minimum signal level can be set to 0 mA, 4 mA or 10 mA.

6.2.6 Scalable Analog Inputs

Each analog input can be adapted individually to the type and range of the connected input signal:

• signal type: voltage or current (selectable by DIP switches)

• signal inversion: if a signal is inverted, the maximum input level corre-sponds to the minimum signal value and vice versa

• minimum level: 0 mA (0 V), 4 mA (2 V) or by input tuning function (actual input value is read and set as minimum)

• maximum level: 20 mA (10 V) or by input tuning function (actual input value is read and set as maximum)

• signal filtering time constant: adjustable between 0.01..10 s.

The offset of the analog inputs can be calibrated automatically or manually.

6.2.7 Input Signal Source Selections and Signal Processing

Two ProgrammableControl Locations

The ACS 1000 can receive the Start/Stop/Direction commands and the reference value from the integrated control panel and the Closing/Opening commands for the main circuit breaker from the push buttons on the control section door.

Alternatively it is possible to predefine two separate external control loca-tions (EXT1 and EXT2) for these signals. The active external control loca-tion can be changed via the control panel or via a digital input.

The control panel always overrides the other control signal sources when switched to local mode.

Optionally, the converter can be equipped with a fieldbus adapter module, see Chapter 7 - Options.

Reference SignalProcessing

The ACS 1000 can handle a variety of speed reference schemes in addition to the conventional analog input signal and control panel signals.



• The ACS 1000 reference can be given using two digital inputs: one digital input increases the speed, the other decreases it. The active reference is memorized by the control software.

• The ACS 1000 can form a reference out of two analog input signals by using mathematical functions: addition, subtraction, multiplication, minimum selection, and maximum selection.

It is possible to override the actual speed reference with predefined constant speeds (see Constant Speeds, page 39).

It is possible to scale the external reference so that the signal minimum and maximum values correspond to a speed other than the nominal minimum and maximum speed limits.

The ACS 1000 offers several programmable fault functions and other non-user adjustable pre-programmed protection functions.

6.3.1 Programmable Fault Functions

Motor WindingTemperature

The motor can be protected from overheating by activating the motor winding temperature monitoring function.

The ACS 1000 standard solution offers three analog inputs for measuring and monitoring the motor winding temperature.

Values for alarm and trip levels can be set.

Motor Stall The ACS 1000 protects the motor if a stall condition is detected. The moni-toring limits for stall frequency (speed) and stall time can be set by the user. The user can also select whether the stall function is enabled and whether the drive responds with an alarm or a trip when a stall is detected.

The protection is activated if all the following conditions are fulfilled simultaneuously:

1 The output frequency is below the set stall frequency.

2 The drive is in torque limit. The torque limit level is a basic setup parameter that sets maximum drive output torque. Although it indirectly effects operation of the motor stall protection, it should not be considered a motor stall parameter.

3 The frequency and torque levels from conditions 1 and 2 have been present for a period longer than the set stall time.

Figure 6-1 Stall Region of the Motor

6.3 Standard Protection Functions

Stall regionTm.a

Stall

Torque

Frequencyf (Hz)



Underload Loss of motor load may indicate a process malfunction. The ACS 1000 provides an underload function to protect the machinery and the process in such a serious fault condition. This monitoring function checks if the motor load is above the specified load curve. 5 different load curves can be selected by the customer.

Monitoring limits: underload curve and underload time can be chosen as well as the drive response to the underload condition (alarm / trip indica-tion and stop the drive / no reaction).

Figure 6-2 Load Curves for Underload Function

The protection is activated if all the following conditions are fulfilled simul-taneously:

1 The motor load is below the underload curve selected by the user (see Figure 6-2).

2 The motor load has been below the selected underload curve longer than the time set by the user (Underload time).

Overspeed The motor speed as determined by DTC is monitored. If the motor speed exceeds the maximum permitted motor speed (user adjustable) a trip is initiated. In addition, an input for connection of an external motor over-speed trip is available. A converter trip is also initiated, if the external motor overspeed trip is activated (signal active when low).

Undervoltage In order to detect a loss of the mains power supply, the positive and negative DC link voltage levels are monitored. If these voltage levels drop below 70% of their nominal levels an undervoltage alarm is initiated and power loss ride through is activated (provided it is selected). If the DC link voltage levels drop below 65% of their nominal values an undervoltage trip is initiated.

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

110%

120%

130%

140%

curve 1

curve 2

curve 3

curve 4

curve 5

Torque

Speed



6.3.2 Pre-programmed Protection Functions

Motor Phase Loss The phase loss function monitors the status of the motor cable connections. The function is useful especially during motor starting:the ACS 1000 detects if any of the motor phases are not connected and refuses to start.

The phase loss function also monitors the motor connection status during normal operation. The motor operating frequency must be above a minimum level in order for this feature to function. Should a motor phase loss be detected a trip is initiated.

Motor Overload The 3-phase RMS value of the motor current is monitored and compared with three adjustable thresholds. A pickup delay for each threshold can also be set. In case an overload is detected an alarm message will be displayed and the converter will be shut down.

Overvoltage The levels of the positive and negative DC link voltage are monitored to detect whether an improper overvoltage condition develops. If these voltage levels rise above 130% of their nominal levels an overvoltage trip is initiated. On rare occasions, a combination of conditions can result in the motor entering a self excitation mode that can cause the DC link voltage to continue to rise, despite the fact that a trip has been initiated. If this condition occurs and if the DC link voltage levels rise above 135% of their nominal levels, a second overvoltage trip is initiated that causes the inner 6 IGCT’s to be gated simultaneously such, that the motor windings are effectively shunted together. This eliminates the self excitation voltage that is causing the DC link voltage levels to rise. To provide ultimate reliability the second overvoltage trip is implemented both in software and redundantly in hardware (140%).

Short Circuit in theRectifier Bridge

A short circuit in the rectifier bridge is detected by monitoring the DC link voltage. If a short circuit is detected, a trip is initiated and the drive is disconnected from the supply voltage.

Charging Fault The intermediate DC link voltage is monitored while the DC link is ener-gized. If the voltage does not reach a certain level after a preset time, a trip is initiated.

Supply Phase Loss If the voltage ripple in the intermediate DC link rises above a preset level, a trip is initiated because a supply phase may be lost.

Overcurrent The overcurrent trip limit for the ACS 1000 is 2.2 x IN RMS of the nominal inverter current. If this level is exceeded, a trip is initiated.

Inverter Temperature In order to insure that the inverter section does not exceed the tempera-ture limits, the current is monitored and limited to the maximum permitted level.

Cooling Circuit The operating condition of the cooling circuit is monitored. If any of the monitored signals such as water temperature, water pressure or conduc-tivity exceed a preset limit, a trip is initiated. In addition, the status of the



cooling water pumps, the water level in the expansion vessel and the auxiliary fan are monitored.

Short Circuit of theInverter

The inverter is monitored to ensure that a short circuit condition does not exist. If a short circuit is detected a trip is initiated.

Ground Fault The current in the output filter ground leg is monitored and compared with two thresholds. The first threshold is set to a fixed percentage of the peak value of the nominal inverter current. The second threshold is adjustable and compared with the RMS value of the ground current. If the ground current exceeds one of the thresholds a corresponding alarm message will be displayed and the drive will be shut down.

Ground faults will be detected in the area between the ACS 1000 trans-former secondary side and the motor.

Operating System The operating system of the microprocessor board monitores different functions within the control software and will initiate a trip if a malfunction is detected. Such faults are displayed as “Control SW fault”. Should one of these faults be detected during operation, the drive should be restarted.

Communication Fault Except for the measurement boards all communication links are realized by DDCS (Distributed Drive Control System). If one of these links fails a trip is initiated.

Measurement Loss On the ADCVI board (analog digital conversion for voltage and current) analog signals are converted into digital signals. The digital signals are then transmitted via PPCC (fiber-optic bus system) to the interface board which is the main interface to the converter control system.

In order to guarantee proper operation of the protection functions included in the converter, the status of the communication is monitored on the inter-face board. If a fault is detected a trip is initiated.

Battery Test The back-up batteries are checked periodically by applying a known load and by measuring the resulting voltage drop. If the charge of the batteries is deficient, a fault message is displayed and either a normal stop or an alarm is initiated.

ID-Run Fault During commissioning an identification run has to be carried out. The nominal data for identification of the system parameters has to be entered. If incorrect values are used and therefore the system parameters cannot be determined, a trip is initiated. In this case the identification run has to be repeated after the correct data has been entered.



6.3.3 Other Protection Functions

External MotorProtection Trip

If the customer uses an external motor protection relay, it can be connected to a pre-defined protection input of the ACS 1000. The motor protection input is integrated into the tripping loop by a normally closed (NC) contact.

External TransformerProtection Trip

If the customer uses an external transformer protection relay, it can be connected to a pre-defined protection input of the ACS 1000. The trans-former protection input is integrated into the tripping loop by a normally closed (NC) contact.

Line UnbalanceProtection Relay

An optional signal input is available to connect a line unbalance protection relay for initiation of a converter trip.

Process Stop A process stop button or relay can be connected to a pre-defined input of the ACS 1000. The actual process stop input must be closed during normal operation. If the digital input opens, the drive control initiates a stop command. The stop mode (ramp stop, stop at torque limit, or coast stop) can be selected by a parameter. When the drive is stopped the main circuit breaker is opened.

External EmergencyOff

The normally closed (NC) contacts of external emergency-off buttons can be wired into the tripping loop.

For further details see Chapter 4 - User Interfaces.

Automatic Restart The ACS 1000 can automatically reset itself after an undervoltage has occurred. This function is activated by two parameters one to enable the automatic restart function and one to select the undervoltage waiting time (adjustable between 0 and 600 s).

If the automatic restart feature is activated and an undervoltage is detected in the DC link, the waiting time is started. If the voltage recovers within the selected time, the fault will be reset automatically and the converter resumes normal operation. If the waiting time has elapsed and the voltage has not recovered the converter is tripped and the MCB is opened.

Monitoring of LimitValues

The values of several user selectable signals can be monitored for adjust-able low and high limits.

Adjustable limits can be set for: two speed values, a current value, two torque values, two reference values and two actual values of the PID controller. The digital status of the active limit appears on the control panel display and can also be allocated to digital output.

ACS 1000 Information The software version and the serial number of the ACS 1000 can be displayed on the CDP 312 control panel.

6.4 Other Functions



Parameter Lock The user can prevent unwanted parameter changes by activating the Parameter Lock.

6.4.1 Customer Specific OptionsInformation on additional user specific options that can be implemented in the ACS 1000 is given in Chapter 7 - Options.


Chapter 7 - Options

Extended AmbientTemperature: 45 °C

Above 40 °C the converter output power must be derated by 1.5% per 1 °C and filter capacitors, suitable for high operating temperatures, are supplied.

Extended Raw WaterTemperature

The extended raw water temperature is +27...+38 °C (+80...+100 °F). For deratings refer to Appendix B - Technical Data, Derating for Raw Water Temperature, page 89.

Corrosion ProtectedBusbars

For certain environmental conditions (e.g. salty air in combination with increased ambient temperature and high humidity) corrosion protected busbars can be chosen instead of the standard type. This choice is rele-vant for all power and grounding busbars of the converter.

Coated PCBs For certain environmental conditions (e.g. salty air in combination with increased ambient temperature and high humidity) the printed circuit boards (PCBs) can be ordered with a special varnish.

Converter Enclosure The standard IP classes of the converter enclosures are given in Appendix A - Installation Guidelines.

The following IP ratings are optional:

• IP22, IP31, IP32 and IP42 (for air-cooled converters)

• IP54 (for water-cooled converters)

Door Interlocking The ACS 1000 is equipped with an electromechanical door interlocking system as standard.

Alternative optional interlocking:

• Kirk key interlocking

If this option is required, contact your ABB representative.

Cabinet Color The standard color for the ACS 1000 converter is RAL 7035, “Light Grey”. Other RAL colors are available optionally and must be specified explicitly when ordered.

Cabinet Paint Finish The standard converter has painted front doors. Optionally, the entire cabinet exterior is available with painted surfaces (see also Cabinet Color).

7.1 Environmental Conditions

7.2 Converter Enclosure


Chapter 7 - Options

Split Cabinet The water-cooled ACS 1000 can be delivered with a shipping split for easy transportation. All materials necessary for joining the two parts are supplied with the drive.

Extended GroundingBusbar

The standard grounding busbar which is located in the power cable termination section of the ACS 1000 can be an extended throughout the medium voltage sections of the ACS 1000.

Input Bridges The following input rectifier bridges are available:

• 12-pulse diode rectifier (standard)

This type is sufficient for most network conditions to fulfill the network harmonic requirements according to IEEE 519-1992.

It is the ideal solution for a small converter footprint and if an outdoor transformer can be used.

• 24-pulse diode rectifier with integrated or external transformer configuration

This type is recommended if superior network behavior is required.

The 24-pulse diode rectifier is applicable if outdoor transformers are not required. In this case there is no need for an oil pit and no addi-tional cabling between transformer and converter is needed which can substantially reduce construction and installation costs.

Motor and TransformerProtection

Refer to Sections Extended Motor Monitoring Interface, page 52 and Extended Transformer Monitoring Interface, page 50.

Extended TransformerMonitoring Interface

In addition to the standard signal “Transformer Protection Trip” (wired into tripping loop) the signals according to Table 7-1 can be included optionally in the signal interface between the transformer and the ACS 1000.

Note: This option requires the IOEC 3 board. The option is standard for water-cooled converters (see Chapter 4 - User Interfaces, I/O Signals: Transformer, page 26).

7.3 Input Section


Chapter 7 - Options

The analog input "Oil Temperature" is suitable for an actual value in the range of 0..20 mA / 4..20 mA (or 0..10 V / 2..10 V) and can be used instead of the digital temperature alarm and trip inputs. The analog signal is monitored by the ACS 1000 for alarm or trip levels.

Line UnbalanceProtection Relay

A signal from a line unbalance protection relay can be monitored by wiring it into the tripping loop of the ACS 1000. If the signal is low the main circuit breaker is tripped immediately.

Common Mode Choke This option is needed if the cable length between the converter trans-former and the ACS 1000 exceeds the following limits:

• 30 m (98 ft) for ACS 1000, 12-pulse versions and

• 20 m (66 ft) for ACS 1000, 24-pulse versions.

If the cables are longer than the limits below, the ABB representative should be contacted:

• 200 m (656 ft) for ACS 1000, 12-pulse versions and

• 150 m (492 ft) for ACS 1000, 24-pulse, (water-cooled types only).

The DC link common mode choke functions like a transformer. Together with the common mode damping resistor it provides damping of the

Table 7-1 I/O Signals for Extended Transformer Monitoring

Type Signal Name Remarks

DI OIL LEVEL ALARM Transformer oil level alarm indication

DI OIL TEMP ALARM, or

TRAFO WDG TEMP ALARM

Transformer oil temperature alarm indication

Transformer winding temperature alarm indication

DI /OIL TEMP TRIP, or

/TRAFO WDG TEMP TRIP

Transformer oil temperature trip indicationTransformer winding temperature trip indication

DI BUCHHOLZ ALARM Transformer alarm indication from Buchholz relay

DI /BUCHHOLZ TRIP Transformer trip indication from Buchholz relay

AI OIL TEMP, or

TRAFO WDG TEMP

Temperature measurement of transformer oilTemperature measurement of transformer winding


Chapter 7 - Options

common mode voltages and limits the common mode currents experi-enced by the main power transformer and transformer secondary cables.

Extended MotorMonitoring Interface

In addition to the standard signal “Motor Protection Trip” (wired into trip-ping loop) the signals according to Table 7-2 can be included optionally in the signal interface between the motor and the ACS 1000.

Note: This option requires the IOEC 3 board. The option is standard for water-cooled converters (see Chapter 4 - User Interfaces, I/O Signals: Motor, page 27),

The analog inputs are suitable for actual values in the range of 0..20 mA / 4..20 mA (or 0..10 V / 2..10 V) and are monitored by the ACS 1000 for alarm and trip levels.

Ex-Zone SignalInterface for Motor

Measurements (ZenerBarriers)

For motor installations in hazardous areas (Ex-Zone) all interface signals from the motor have to be connected to Zener Barriers mounted in the converter. This applies to the winding temperature and bearing temperature measurements as well as to all digital signals e.g. external motor protection alarm and trip and external overspeed trip.


Pulse EncoderInterface Module

The Module allows a pulse encoder to be connected to the ACS 1000. A pulse encoder is advantageous in applications where the flying start function is used. The actual frequency of a rotating motor can be detected faster and rapid start-up by the converter can be achieved. It is also recommended if a highly accurate read-out of the speed is required.

7.4 Motor Side

Table 7-2 I/O Signals for Extended Motor Monitoring

Type Signal Name Remarks

DI EXT MOT PROT ALARM (External) motor protection alarm indication

DI MOT COOLING ALARM (External) motor cooling alarm indication

DI /MOT COOLING TRIP (External) motor cooling trip indication

DI VIBRATION SV ALARM Motor vibration alarm indication

DI /VIBRATION SV TRIP Motor vibration trip indication

DI /OVERSPEED TRIP Motor overspeed trip (included in hardwired tripping loop)

AI BRG TEMP DE Motor bearing temperature of driven end

AI BRG TEMP NDE Motor bearing temperature of non-driven end


Chapter 7 - Options

Another application for a pulse encoder would be for motors running at speeds below 5 Hz for longer periods.

The requirements for a pulse encoder are as follows:

• Supply voltage 12 VDC or 24 VDC (supplied by the module)

• Single ended or differential connection can be used

• Available signal channels: A, A inverted, B (90° electr. phase shift to A), B inverted (Z (zero channel), Z inverted - optional)

• The encoder should provide 2n pulses/revolution. The recommended pulse train is 2048 pulses/revolution. Maximum signal frequency should not exceed 100 kHz.

The module is fed from the ACS 1000 internal control power supply.

Increased OutputFrequency

The ACS 1000 can be ordered with an increased output frequency of 82.5 Hz as a maximum. This option requires an optimized sine filter configuration.

Braking Chopper Effective motor braking and short deceleration times can be achieved by using resistor braking. For resistor braking, the ACS 1000 converter must be equipped with a braking chopper and a braking resistor.

Braking choppers are available for all ACS 1000 types. The choppers can be ordered factory-installed or as add-on kits.

The operation of the braking chopper is controlled by the ACS 1000 control system. The braking chopper hardware is located in an additional cabinet.

The input currents of the braking chopper are monitored for overcurrent and unbalance in order to detect any defective component in the circuit. In case a short circuit or an unsymmetry in the braking chopper is detected a converter trip is initiated.

Braking chopper and braking resistors are each monitored for overtemperature by means of thermal models. Alarm and trip levels are determined and set during commissioning.

For more information about braking chopper and braking resistor, see the resistor specification or contact your ABB representative.

Braking Resistor The braking resistor has to be specified individually for each project by ABB Schweiz AG. For further information contact your ABB representative.

Circuit Breaker forMotor Space Heater

A motor space heater can be connected directly to a single-phase auxiliary power circuit breaker, installed in the converter cabinet. Based on the power rating of the heater, one of the circuit breaker sizes as indicated in Table 7-3 can be used.


Chapter 7 - Options

Motor Starter for MotorCooling Fan / Pump

A motor cooling fan or pump can also be connected directly to an auxiliary motor starter installed in the converter. Based on the power rating of the cooling fan or pump, one of the following motor starter sizes can be chosen:

Redundant CoolingFan (Air-cooled

ACS 1000)

The redundant cooling fan is an option intended for applications where enhanced reliability of the installation is required.

The redundant fan unit is supplied as a separate unit to be mounted on top of the ACS 1000 converter. If delivered together with the ACS 1000, both fans are already mounted in the unit. As add-on kit, only the redundant fan is supplied and the standard fan must be transferred from the converter cabinet to the redundant fan unit.

Table 7-3 Power Ratings for Different Circuit Breaker Sizes

Auxiliary Voltage (Single Phase)

Circuit Breaker Rating 120 VAC (50/60 Hz) 240 VAC (50/60 Hz)

0.5 A 60 W 120 W

1.0 A 120 W 240 W

2.0 A 240 W 480 W

3.0 A 360 W 720 W

4.0 A 480 W 960 W

5.0 A 600 W 1200 W

6.0 A 720 W 1440 W

10.0 A 1200 W 2400 W

Table 7-4 Power Ratings for Different Starter Sizes

Auxiliary Voltage (Three Phase)

OverloadCurrent Rating

400 VAC50/60 Hz

480 VAC60 Hz

575 VAC60 Hz

2.5 - 4.0 A 750 W - 1500 W(1.0 - 2.0 hp)

1100 W - 2000 W(1.5 - 2.7 hp)

1200 W - 2600 W(1.6 - 3.5 hp)

4.0 - 6.3 A 1500 W - 2200 W(2.0 - 3.0 hp)

2000 W - 3000 W(2.7 - 4.0 hp)

2600 W - 3600 W(3.5 - 4.8 hp)

6.3 - 10.0 A 2200 W - 4000 W(3.0 - 5.4 hp)

3000 W - 4000 W(4.0 - 5.4 hp)

3600 W - 6000 W(4.8 - 8.0 hp)

7.5 Converter Cooling


Chapter 7 - Options

With this option continuous operation of the drive is guaranteed even if one fan fails. Switch-over from the faulty to the stand-by device takes place automatically. To replace the faulty unit the converter must be stopped. The replacement of a fan takes about 30 minutes.

Figure 7-1 Standard Cooling Fan Unit

Figure 7-2 Redundant Cooling Fan Unit (Functional Principle)

If this option is ordered the derating of the drive output power needs to be considered (see Appendix B - Technical Data, Environmental Aspects, page 87).

Redundant CoolingFan (Water-cooled

ACS 1000)

The water-cooled ACS 1000 can be ordered with a redundant cooling fan, if continuous operation is required in case a fan fails.

The redundant fan unit is supplied as a separate unit and is mounted on top of the ACS 1000. If the redundant fan unit is ordered and delivered together with the ACS 1000, the cut-outs on the roof and the mounting holes are already prepared. If the redundant fan is purchased separately, the roof cut-outs and the mounting holes have to be prepared on side.

Redundant CoolingPump (Water-cooled

ACS 1000)

The water-cooled ACS 1000 can be equipped with a second pump [P2] in the cooling water circuit. This option is needed when continuous operation of the drive is required in case of a pump failure in the cooling unit. The redundant pump is installed in the cooling unit of the ACS 1000.

Control Box Rectifier Inverter

Air Duct

Control Box Rectifier Inverter


Chapter 7 - Options

Three-way Valve(Water-cooled

ACS 1000)

The cooling unit of the ACS 1000 can be ordered with a three-way valve [B14] in the raw water circuit. This option is recommended, if the raw water flow must be kept at a constant rate. If the cooling unit is equipped with a three-way valve, the water-to-water heat exchanger [E1] is bypassed and the total raw water flow is kept constant even if the water flow in the heat exchanger varies.

Cooling Unit (Water-cooled ACS 1000)

From the cooling water circuit below the interface connections towards the ACS 1000 and the raw water supply can be seen. The components shown are part of the ACS 1000 cooling unit.

Figure 7-3 Cooling Unit of the Water-Cooled ACS 1000

Space Heater forTropicalized Version

A space heater is typically required in places/countries with high ambient humidity. It is switched on automatically when the converter is not in operation in order to prevent condensation.

The heater consists of several heating elements with a rated power of 100 W each rated for 110...240 VAC supply voltage (50 / 60 Hz).

Monitored Air Filter(Air-cooled ACS 1000)

The air-cooled ACS 1000 can be supplied with air filter mats which have a finer mesh than the standard air filter mat. There are filter mats available with a 10 µm and a 12 µm fine mesh.

The optional air filter mats should be selected if the air contamination level exceeds IEC 721-3-3, Class 3C2 (for chemical gases) or IEC 721-3-3, Class 3S1 (for solid particles).

Air filter mats with finer mesh are monitored by measuring the pressure difference across the filter. An alarm is displayed if the filter is clogged.

C2

V13

L

CA

V11

M

V1 V3

V2 V4

E1

P1

P2

M

5 l/min

V14

12

PA

130 l/min

8 PA

TI

B13

QI

B12

PI

B11

V5

V81V80

S1

water to waterheat

exchanger

E2

B14

M

V82

24 l/

min

raw water inletnipple 33 mm

raw water outletnipple 33 mm

from converternipple 40 mm

to converternipple

ACS 1000 CABINET

COOLING UNIT

PressureAI 1.3

ConductivityAI 1.4

TemperatureAI 1.2

controlled by:DO 3.3DO 3.4

12 PA

12

PAOPTION

OPTION

Z2 (microfilter)

C1

Z1 (strainer)

Valve identification:

open (normal operation)

closed (normal operation)

Non-return valve

M

Control valve

B10

M11

M12

air to waterheatexchanger

make-up waterISO-R1/2

expansionvessel

ion exchangervessel


Chapter 7 - Options

The filter mat which is mounted at the converter air intake can be changed while the converter is in operation.

If the ACS 1000 is ordered with an air filter with finer mesh the derating of the drive output power needs to be considered (see Appendix B - Tech-nical Data, Environmental Aspects, page 87)

Synchronized Bypass The synchronized bypass (Figure 7-4) allows for automatic synchroniza-tion of a motor with the line after a soft start. Two versions are available:

• synchronized bypass for 1 motor

• synchronized bypass for up to 4 motors.

The bypass cabinet which is attached to the left hand side of the ACS 1000 houses the following control hardware:

• the interface for external commands and feedback signals

• the signal interface(s) for the control of motor and bypass breakers

• the control unit for synchronizing and switching coordination

• the optional voltage measuring equipment.

For dimensions and weight of the bypass cabinet see Table C-4 Dimen-sions and Weights of the ACS 1000 and Optional Equipment.

Note:The bypass switchgear is not included in the scope of this option.

Note:The ACS 1000 does not support manual or automatic bypass functions. All bypass related interlocks and the controls for the bypass switches have to be realized externally to the drive. Only an output disconnector switch can be monitored via digital inputs, if IOEC 4 board is installed. These inputs are used to interlock the drive.

7.6 Converter Isolators and Bypass


Chapter 7 - Options

Figure 7-4 Synchronized Bypass, Single Line Diagram

Input Isolator Used in addition to the main circuit breaker, the input isolator provides a visible break between the transformer and the rectifier section when the input isolator is in the open position.

The input isolator is located in an additional cabinet next to the converter.


Output Isolator The output isolator is normally used in combination with a converter bypass and provides the possibility to isolate the converter visibly from the motor.

The output isolator is located in an additional cabinet next to the converter.


=

=

MCB Transformer12 PulseRectifier

Three LevelInverter

ACS1000 Frequency ConverterOutputFilter

Sm1

ACS 1000 Control

SynchronizedBypassControls

U2

Transformer 1MCB 1

(if necessary)

(if necessary)

Mains Supply

Mains Supply

MCB 2 Transformer 2

U11

Sbp1

Sbp2

Sm2

U12

3-PhM1

M23-Ph


Chapter 7 - Options

Fieldbus AdapterModules

A fieldbus module may be used for controlling and monitoring the converter instead of using conventional hard-wired I/Os.

There are several fieldbus adapter modules available for the ACS 1000:

• Profibus DP

• Modbus

• Modbus+

• Allen-Bradley Device Net

• ABB Advant Fieldbus 100

• ABB Procontic CS31

• Interbus S

The fieldbus is connected to the adapter module via a twisted pair bus (RS 485) or via BNC-connectors (for ABB AF100). The adapter communicates with the ACS 1000 control board via a fast (4 Mbit/s) Duplex Fiber Optic Link.

All fieldbus modules require 24 VDC power. In all cases power is supplied by the ACS 1000 internal control power supply (EPS).

Spare Terminals As an option, 30 spare terminals can be provided. These terminals are not wired up. A higher number of spare terminals is available on request.

DriveWindow DriveWindow offers several advanced, yet easy-to-use tools for commissioning and control of the ACS 1000.

• The parameter and signal tool with a full set of device specific data either in online or offline mode to check, study and change the parameters

• The monitor tool as a graphic interface for monitoring digital and analog signals

• The data logger as a versatile way of tracing fast and accurate events

• The fault logger displaying a fault history

• The application tools presenting the pin values in order to debug application software and force constants

7.7 Auxiliary & Control Interfaces

7.8 PC Tools


Chapter 7 - Options

With its component structure, enhanced flexibility is achieved to allow working with several different types of products through different target and communication drivers (The look and feel of the DriveWindow program remains the same even when the product changes).

DriveSupport The DriveSupport tool offers an advanced level of servicing, maintaining and trouble shooting of a drive system. Versatile features are provided for:

• Diagnosing faults and warnings

• Testing and verifying possible causes of faults

• Locating of faulty components

• Performing step-by step replacement procedures

• Recording maintenance activities.

The DriveSupport works on-line together with the DriveWindow tool.


Chapter 8 - Selecting the Drive System

The excellent performance of the ACS 1000 makes it suitable for most variable speed drive applications.

In order to dimension and configure an ACS 1000 drive system, the driven load has to be clearly specified and an appropriate motor must be selected. The driven load together with the selected motor basically determines the size of the ACS 1000 as well as the size of the required converter input transformer.

8.2.1 Main Circuit Breaker ControlThe Main Circuit Breaker (MCB) must be controlled exclusively by the ACS 1000. This means that a closing request or command is sent from a customer’s local or remote control station to the ACS 1000. The actual closing command is then released from the converter to the MCB.

The closing command from the converter to the MCB (duration can be pre-set) can be a continuous signal or a single pulse, which is reset as soon as the status feedback MCB IS CLOSED has been received from the switchgear. If this status feedback has not arrived after a pre-set time, the closing command is reset and a trip of the MCB is initiated.

The MCB is opened by :

• an MCB OPEN command, either given from the push button on the ACS 1000 or from a remote control station via digital inputs or through a fieldbus adapter

• the hardwired tripping loop (see Tripping Loop, page 62).

The opening command from the converter to the MCB - pulse or steady state signal - is reset as soon as the status feedback MCB IS OPEN has been received. If the feedback signal has not arrived after a preset time the command MCB ORDER TRIP is initiated to open the MCB.

The MCB ORDER TRIP is a steady state true signal. When in low status it directly opens the MCB.

MCB Control Fault All opening and closing commands to the MCB are monitored for time-out An alarm or fault message comes up on the display of the CDP 312 control panel if there is something wrong in connection with the control of the MCB.

8.1 Overview

8.2 Main Circuit Breaker



8.2.2 Tripping Loop

General The tripping loop is a hardwired control circuit provided to trip the MCB directly either via the tripping coil or via the opening coil. Depending on which coil is available, the tripping coil or the opening coil has to be connected to the tripping loop.

Signals from customer devices can (but do not have to) be wired into this loop. Each of these signals is monitored by a digital input. These signals can be connected to a terminal strip in the control section of the ACS 1000. If one or several of the signals are not used a jumper must be put across the corresponding terminals.

Figure 8-1 Tripping Loop: Principle Diagram

3

2

4

56

8

910

11

1X 300

12

13

emergency off

transformer protection trip

motor protection trip

overspeed trip

supply voltage unbalance trip

MCBtripping coil

jumper when signal is not used

(one or more emergency offconnected in series)

22...250 VAC22...150 VDCcontrol voltage

provided by customer

optional IOEC board 3 required

*

*

*

*

*

*

Control section of ACS 1000Customer side



ACS 1000 TrippingLoop Signals

The following ACS 1000 contacts are wired to the tripping loop:

• the digital output "MCB ORDER TRIP"

• the emergency-off button on the ACS 1000 front door.

The digital output "MCB ORDER TRIP" is initiated:

• if the grounding isolator is closed or not not completely opened

• after an off command and there is no feedback signal within a pro-grammable time lapse

• when switching off the main circuit breaker and a signal discrepancy between off command and feedback signal is detected

• by main circuit interface board of the ACS 1000 in case of a trip.

Customer Signals The following signals from customer devices can (but do not need to) be wired to the tripping loop terminals:

• external emergency-off

• transformer protection trip

• motor protection trip

• overspeed trip

• supply voltage unbalance.

The following signals require the optional IOEC 3 board:

• overspeed trip

• supply voltage unbalance.

8.2.3 Main Circuit Breaker Features

General Requirementsfor MCB

The MCB has to be specified according to the rated primary voltage and current of the converter transformer. It should also meet the specific drive requirements (some items require proper coordination with the instrumen-tation and protection equipment). The MCB must be capable:

• to connect and maintain nominal load currents and clear short-circuit currents

• to tolerate the transformer inrush current without tripping

• to clear transformer secondary short circuits within 250 ms (the time includes the pick-up time of the protection relay and the opening time of the MCB)

• close in response to a close command

• open within 160 ms in response to an open command (signal active when high)

• open within 160 ms in response to a trip command (signal active when low)



6

• provide a status output which indicates MCB closed

• provide a status output which indicates MCB open

• provide a status output which indicates MCB not available (vacuum circuit breaker in test position or vacuum controller disconnect switch in open position).

Types of MCBs The following types of MCBs can be used:

• vacuum or gas insulated (SF6) circuit breakers

• load disconnectors with fuse

• vacuum or gas insulated (SF6) controllers / medium voltage starters.

MCB Control SignalInterface

A possible signal interface between the ACS 1000 and a vacuum controller or vacuum circuit breaker is indicated in the schematic diagrams below.

Figure 8-2 Connection Scheme with Vacuum Circuit Breaker

52

ACS 1000

5051

51N

M

CB

no

t av

aila

ble

MC

B o

pen

M

CB

clo

sed

clo

se c

om

man

d

op

en c

om

man

d

AC time residuaovercurrent rela

instantaneous / AC timovercurrent relay

trip signals

vacuum circuit breaker

trip

ping

loopl

y

e



Figure 8-3 Connection Scheme with Vacuum Controller

MCB Instrumentationand Protection

Equipment

Appropriate current transformers and protection relaying must be provided to protect transformer and transformer primary cables. The intended approach for protection is shown in Figure 8-4. As shown in the figure the protection can be considered to consist of three areas. The first area identified as Transformer Primary Fault Protection is an instantaneous trip area that protects against short circuits in the transformer primary windings or in the cables supplying the transformer primary. The lower level of the trip threshold should be adjusted high enough to insure that nuisance tripping does not occur due to transformer inrush currents. The second area identified as Transformer Secondary Fault Protection is a short delay trip area that protects against short circuits in the transformer secondary windings, the cables from the transformer secondaries to the ACS 1000, or in the input rectifier stages of the ACS 1000. The short time delay provided should be adjustable and should be set long enough to insure that the protection does not trip due to transformer inrush current. The trip level should be adjusted low enough to insure that tripping will occur within 250 ms (including MCB delay time) even if transformers with high input impedance are used. The final area identified as Overload Protection should provide long term overload protection with an inverse time characteristic. This area is intended to protect the transformer and cables from long term overload conditions.

ACS 1000

5051

51N

MC

B n

ot

avai

lab

le

MC

B o

pen

M

CB

clo

sed

clo

se c

om

man

d

op

en c

om

man

d

vacuum contactortrip signals

AC time residuaovercurrent rela

instantaneous / AC timovercurrent relay

non load-break disconnector

fast acting current lim it ing fuse

l

e

y

trip

ping

loop



The protection described can be provided with individual protection relays or with a single microprocessor based unit. Required current transformers should be sized in accordance with the rated current levels of the transformer. Basic protection configuration and connection should be as previously shown in Figure 8-2 and Figure 8-3.

Figure 8-4 Sample Protection Scheme

All ACS 1000 converters must be supplied from an isolation transformer with multiple phase-shifted secondary windings, designed in accordance with the pulse number of the input bridge. For 12-pulse systems the secondary side of the transformer has one star and one delta winding. This creates the 30° phase shift between the two 3-phase secondary windings, that is necessary to facilitate 12-pulse input bridge operation. The secondary windings of transformers for ACS 1000 converters with 24-pulse rectifier bridge are to be designed to provide a 15° phase shift.

A second purpose of the transformer is to provide sufficient impedance to limit the line harmonics to acceptable levels.

The transformer may be an oil-immersed or a dry type. Based on installation requirements of the application, the transformer may be located remote from the ACS 1000 drive equipment or nearby, even integration into the drive is possible. For requirements regarding the maximum cable length between transformer and ACS 1000 see Appendix B - Technical Data .

The transformer may be supplied from ABB or alternatively from a third party supplier in accordance with the specifications provided by ABB. The design of the transformer must take into account site-specific line conditions (voltage, short circuit capacity, existing harmonics, etc.) to

Current

TimeAdjustable Time Delay

Transformer Primary Fault Protection

Transformer Secondary Fault Protection

Overload Protection

10 ms 250 ms 1 s 10 s 100 s

x 20

x 10

x 1

8.3 Converter Input Transformer Selection



insure compliance with harmonic standards invoked by the specifications. Transformer quality is critical with respect to effecting proper limitation of harmonic currents and voltages.

When determining the power rating of the transformer, power and efficiency of the motor, power factor and efficiency of the ACS 1000 converter and harmonic loading of the transformer must all be considered.

For selecting an appropriate ABB ACS 1000 transformer or for specifiying a generic transformer, please contact your ABB representative.

The rating tables for selecting the ACS 1000 can be found in this chapter.

In general the ACS 1000 converter is selected according to the rated motor power. The rated output current of the ACS 1000 should be checked to insure that it is higher than or equal to the rated motor current.

If a motor with 6 or more poles is used, the nominal motor current usually increases as compared to a motor with fewer poles. This may result in a different output filter configuration (see ACS 1000 Output Filter below). In such cases, please contact your ABB representative for further assistance before making a final drive selection.

When determining the appropriate size of the ACS 1000 converter for a particular application the following factors need to be considered:

• ambient temperature

• temperature of the cooling media

• installation site altitude

• frostproofing of the cooling water

• the presence of a redundant cooling fan

• type of air filter.

Please refer to Appendix B - Technical Data for details on environmental aspects.

8.4.1 ACS 1000 Output FilterThe standard ACS 1000 output filter is appropriate for 2 to 6-pole motors. For higher numbers of poles a different filter configuration is sometimes needed. The modular and flexible filter design allows the ACS 1000 to be configured for 2 to 20-pole motors (and even higher numbers of poles). To determine the appropriate ACS 1000 configuration please contact your ABB representative.

8.4.2 Non Quadratic Load ApplicationsFor constant torque or constant power applications a high overloadability (start-up torque) is usually required. This overloadability, together with

8.4 Selection of the ACS 1000 Converter



possibly needed derating for low speed operation, requires some additional calculations for drive selection. To determine the appropriate ACS 1000 please contact your ABB representative.

8.4.3 ACS 1000 Selection Tables

Selection Table forAir / Water-cooled

ACS 1000 with2.3 kV Motors

ACS 1000 rated for 2.3 kV have output ratings based on horsepower (HP). Equivalent output ratings in kilowatt (kW) are approximate and listed for reference only.

Note: The load capacity (current and power) decreases if the environ-mental conditions at site do not comply with the limits given in Appendix B - Technical Data, Environmental Aspects, page 87. The resulting derating factors are specified in Appendix B - Technical Data, Derating of Drive Power, page 88.

*, ** See note at end of this Section on page 70

Table 8-1 ACS 1000 Ratings for 2.3 kV Motors, 50 Hz and 60 Hz Supply (12/24-Pulse)

MotorVoltage

(kV)Converter Type* Type of

Cooling

Max. cont. Converter

Power(kVA)

RatedMotor

Power**(HP)

Equival.Motor

Power**(kW)

RatedOutputCurrent

(A)

FrameSize

2.3 ACS10x2-A1-A0-00 Air 400 400 _ 100 A1

2.3 ACS10x2-A1-B0-00 Air 400 450 315 100 A1

2.3 ACS10x2-A1-C0-00 Air 450 500 355 113 A1

2.3 ACS10x2-A1-D0-00 Air 550 600 450 138 A1

2.3 ACS10x2-A1-E0-00 Air 650 700 500 163 A1

2.3 ACS10x2-A1-F0-00 Air 750 800 560 188 A1

2.3 ACS10x2-A1-G0-00 Air 800 900 630 201 A1

2.3 ACS10x2-A1-H0-00 Air 900 1000 710 226 A1

2.3 ACS10x2-A2-J0-00 Air 1150 1250 900 289 A2

2.3 ACS10x2-A2-K0-00 Air 1350 1500 1120 339 A2

2.3 ACS10x2-A3-L0-00 Air 1550 Please contact ABB

2.3 ACS10x2-A3-M0-00 Air 1800 Please contact ABB

2.3 ACS10x2-A3-N0-00 Air 2000 Please contact ABB





ACS 1000 rated for 3.3 kV have output ratings based on kilowatt (kW). Equivalent output ratings in horsepower (HP) are approximate and listed for reference only.

*, ** See note at end of this Section on page 70


MotorVoltage


Cooling


Power(kVA)

RatedMotor

Power**(HP)

Equival.Motor

Power**(kW)

RatedOutputCurrent

(A)

FrameSize

3.3 ACS10x3-A1-A0-00 Air 400 450 315 70 A1

3.3 ACS10x3-A1-B0-00 Air 450 500 355 79 A1

3.3 ACS10x3-A1-C0-00 Air 500 550 400 87 A1

3.3 ACS10x3-A1-D0-00 Air 550 600 450 96 A1

3.3 ACS10x3-A1-E0-00 Air 600 700 500 105 A1

3.3 ACS10x3-A1-F0-00 Air 700 750 560 122 A1

3.3 ACS10x3-A1-G0-00 Air 750 800 630 131 A1

3.3 ACS10x3-A1-H0-00 Air 850 900 710 149 A1

3.3 ACS10x3-A2-J0-00 Air 950 1000 800 166 A2

3.3 ACS10x3-A2-K0-00 Air 1100 1250 900 192 A2

3.3 ACS10x3-A2-L0-00 Air 1200 1350 1000 210 A2

3.3 ACS10x3-A2-M0-00 Air 1350 1500 1120 236 A2

3.3 ACS10x3-A2-N0-00 Air 1500 1650 1250 262 A2

3.3 ACS10x3-A2-P0-00 Air 1700 1750 1400 297 A2

3.3 ACS10x3-A3-Q0-00 Air 1900 2000 1600 332 A3

3.3 ACS10x3-A3-R0-00 Air 2150 2250 1800 376 A3

3.3 ACS10x3-W1-S0-00 Water 2400 2500 2000 420 W1

3.3 ACS10x3-W1-T0-00 Water 2700 3000 2250 472 W1

3.3 ACS10x3-W1-U0-00 Water 3000 3350 2500 525 W1

3.3 ACS10x3-W2-V0-00 Water 3350 3500 2800 586 W2

3.3 ACS10x3-W2-W0-00 Water 3750 4000 3150 656 W2

3.3 ACS10x3-W2-X0-00 Water 4250 4500 3550 744 W2

3.3 ACS10x3-W3-Y0-00 Water 4750 5000 4000 831 W3

3.3 ACS10x3-W3-Z0-00 Water 5350 6000 4500 936 W3

3.3 ACS10x3-W3-10-00 Water 5950 6700 5000 1041 W3





ACS 1000 rated for 4.0 kV have output ratings based on horsepower (HP). Equivalent output ratings in kilowatt (kW) are approximate and are listed for reference only.

* "x" stands for: "1" = 12-pulse rectifier (air / water-cooled ACS 1000)"2" = 24-pulse rectifier (air-cooled ACS 1000)

** The power ratings apply to typical 4 pole motors. For those motors theACS 1000 has a built-in overloadability of 10%. When selecting theACS 1000 it should be observed that the rated current of the ACS 1000must be higher than or equal to the rated motor current in order toachieve the rated motor power given in the table.


MotorVoltage


Cooling


Power(kVA)

RatedMotor

Power**(HP)

Equival.Motor

Power**(kW)

RatedOutputCurrent

(A)

FrameSize

4.0 ACS10x4-A1-A0-00 Air 400 400 _ 58 A1

4.0 ACS10x4-A1-B0-00 Air 400 450 315 58 A1

4.0 ACS10x4-A1-C0-00 Air 450 500 355 65 A1

4.0 ACS10x4-A1-D0-00 Air 550 600 450 79 A1

4.0 ACS10x4-A1-E0-00 Air 650 700 500 94 A1

4.0 ACS10x4-A1-F0-00 Air 750 800 560 108 A1

4.0 ACS10x4-A1-G0-00 Air 800 900 630 115 A1

4.0 ACS10x4-A1-H0-00 Air 900 1000 710 130 A1

4.0 ACS10x4-A2-J0-00 Air 1150 1250 900 166 A2

4.0 ACS10x4-A2-K0-00 Air 1350 1500 1120 195 A2

4.0 ACS10x4-A3-L0-00 Air 1550 1750 1250 224 A3

4.0 ACS10x4-A3-M0-00 Air 1800 2000 1400 260 A3

4.0 ACS10x4-A3-N0-00 Air 2000 2250 1600 289 A3

4.0 ACS10x4-W1-P0-00 Water 2300 2500 1800 332 W1

4.0 ACS10x4-W1-Q0-00 Water 2700 3000 2250 390 W1

4.0 ACS10x4-W2-R0-00 Water 3100 3500 2500 447 W2

4.0 ACS10x4-W2-S0-00 Water 3600 4000 2800 520 W2

4.0 ACS10x4-W2-T0-00 Water 4000 4500 3150 577 W2

4.0 ACS10x4-W2-U0-00 Water 4500 5000 3550 650 W2

4.0 ACS10x4-W3-V0-00 Water 4900 5500 4000 707 W3

4.0 ACS10x4-W3-W0-00 Water 5300 6000 4500 765 W3

4.0 ACS10x4-W3-X0-00 Water 5800 6700 5000 837 W3



8.5.1 Load Capacity CurvesThis chapter provides the necessary information regarding the selection criteria of the motor, to match the ACS 1000.

In the example below the rated frequency and the field weakening point for the motor are based on 50 Hz.

Figure 8-5 Load Capacity Curves

8.5 Motor Selection

Curve 1: Typical continous load capacity curve of an IEC34 self-ventilated motor, controlled by the ACS 1000.

Curve 2: Load capacity of the ACS 1000, rated for normal use (i.e.100% continous, 110% for 1 min. every 10 min.).

2.01.91.81.71.61.51.41.31.21.11.00.90.80.70.60.50.40.30.20.10.0

0 10 20 30 40 50 60 70 80 90 100

0 600 1200 1800 2400 3000 3600

0 300 600 900 1200 1500 1800 2100 2400

0 200 400 600 800 1000 1200 1400 1600

p = 2

p = 4

p = 6

f (Hz)

T/TN

n (rpm)

n (rpm)

n (rpm)

0 150 300 450 600 750 900 1050p = 8

n (rpm)

Curve 1Motor Loadability

Curve 2ACS 1000 Loadability

p = number of polesT = load torqueTN = rated motor torquen = speed f = output frequency of

ACS 1000



8.5.2 Selection Criteria Generally speaking the motor must be selected and sized as required by the load. Supplying an additional power margin to compensate for PWM inverter operation is not required with the ACS 1000 due to its sinusoidal output waveform. After the motor has been selected (or if an existing motor is being applied) the following parameters are relevant to select the converter and the transformer:

• load characteristic (the most common characteristic is square torque; for other loads like constant torque or constant power applications, please contact your ABB representative)

• overloadability requirements

• motor voltage

• number of motor poles

• shaft power (nominal)

• shaft speed (nominal)

• rated current (nominal)

• motor efficiency

• motor power factor.

Special attention must be paid to the motor cooling in variable speed applications. If the motor is self-ventilated, long-time operation at low speeds will usually require some derating to compensate for the reduced cooling.

Depending on the mechanical configuration of the motor, load, gear-box and shaft there may be some critical speeds within the operating speed range of the drive. The critical speeds have to be known and if they have to be avoided the appropriate parameter settings have to be made. Special attention has to be paid to variable speed applications using two-pole motors, since there is usually a critical motor speed below its rated speed. For more information see Chapter 6 - Standard Functions, Critical Speed.

8.5.3 RetrofitDue to its specific topology the ACS 1000 can supply standard medium voltage motors (existing or new) without applying thermal derating factors. In addition, due to its sinusoidal output waveform, standard medium voltage winding insulation is sufficient.

To avoid risk of bearing currents and related consequential damages, one motor bearing should be insulated (the one at the non-driven shaft end). This is actually a typical accessory even for most direct on-line operated motors. If, nevertheless, such a bearing is not available (e.g. for older existing motors), a grounding brush can be installed on either shaft end.



Although from an electrical point of view no restrictions exist for variable speed operation with retrofit motors, attention should be paid to possible motor and load restrictions such as insufficient lubrication or reduced cooling at low speed, critical speed areas within the targeted operating range that need to be avoided, etc. Also the maximum (i.e. rated) speed of the motor should under no circumstances be increased without authorization from the manufacturer of each component of the drive train concerned.

8.5.4 Torsional ExcitationDue to its sinusoidal output voltage and current waveforms and its superior control performance from DTC the ACS 1000 will not introduce any significant torsional excitations to the motor shaft. Therefore a torsional analysis for the sake of applying a frequency converter is not required for common applications and normal mechanical shaft arrangements.




Appendix A - Installation Guidelines

Ambient conditions may require to derate the drive due to the presence of elevated air temperature, altitude, or cooling water temperature. Sufficient air flow must be available. Other ambient factors such as relative humidity, air contamination, shock and vibration must also be in compliance with stated maximum permissible levels.

See Appendix B - Technical Data for load capacity derating factors and other requirements related to ambient conditions.

Converter Enclosure The standard IP protection classes for the converter enclosure according to IEC 529 are:

• IP21 (for air-cooled converters)

• IP31 (for water-cooled converters).

Higher IP-protection classes for the converter enclosure are optional.Please refer to Chapter 7 - Options.

Space Requirements All units must be mounted in an upright position with adequate free space provided in accordance with Table A-1.Table A-1 Required Free Space in Front and Above Converter

(The dimensions given are minimum values)

Notes:

1 Dimensions do not include space for cable entry which can be from top or from below.

2 Dimensions are above the blower hood or above the redundant fan unit.

3 This is a general recommendation to ensure proper air flow.

Ambient Conditions

Mounting

Type of Cooling

Above mm / (in.)

Belowmm / (in.)

Left / Rightmm / (in.)

Frontmm / (in.)

Backmm / (in.)

Air 500 (1)(2)(3)

(20") 0 (1)

(0")0 (5)

(0")1000 (4) (39.4")

0 (6) (0")

Water 0 / 700 (1)(2)

(0")/(27.6")0 (1)

(0")0 (5)

(0")1000 (4) (39.4")

0 (0")



4 Dimensions indicate required door swing area. Addi-tional space may be needed to meet local installation regulations and requirements.

5 Dimensions do not include space for moving the cab-inet, nor for cable and water entries (which can be from top or from below).

6 For service reasons a minimum clearance of 400 mm (15.75") is recommended but not required.

Figure A-1 ACS 1000 Free Space Requirements

For cabinet dimensions refer to Appendix C - Dimensions and Weights.

Front view

Top view

1000 mm / 39.4 in.1000 mm / 39.4 in.

Air-cooled ACS 1000 Water-cooled ACS 1000

5 400 mm / 15.75 in.00 mm / 20 in.



The foundation plans for the ACS 1000 12-pulse, air and water-cooled, are given in Figure A-2 and Figure A-3.

Figure A-2 Foundation Plan with Position of Anchoring Holes: ACS 1000 12-Pulse / 24-Pulse, Air-Cooled

Figure A-3 Foundation Plan with Position of Anchoring Holes: ACS 1000 12-Pulse, Water-Cooled

Figure A-4 Foundation Plan with Position of Anchoring Holes: ACS 1000 24-Pulse, Water-Cooled

2846

2856

800

37.5

78

78

20

12

802.52760/3260 *585.5

432

800

685

70181

38

20

50

12

1080.5



The cabinet should be fixed with anchor bolts and lock washers (recom-mended size M12, not part of supply) as shown in Figure A-5 below. The anchor holes in the base mounting channels can be accessed through the cabinet.

Figure A-5 Cabinet Mounting with Bolts and Lock Washers

Floor Levelling andCable Ducts

• The ACS 1000 cabinet must be installed in upright position.

• The maximum allowable overall unevenness is ≤ 5 mm. If the floor is uneven, it must be levelled.

• The floor must be of non-flammable material, with smooth and non-abrasive surface, protected against humidity diffusion and able to support the weight of the converter (min. 1’000 kg/m2).

• Cable ducts must be of non-flammable material, with non-abrasive surface and protected against humidity, dust and penetration of animals.

GeneralThe connection from the mains supply to the ACS 1000 drive consists of six basic elements:

• Main circuit breaker / controller

• Instrumentation and protection equipment

• Transformer primary cables

• Transformer

• Transformer secondary cables

• Cable termination - ACS 1000.

Recommendations for the installation of each of these elements are given below. All applicable manufacturer’s instructions and local regulations must be followed when installing this equipment. If any specific instruction

Anchoring Holes

Power Equipment Installation



as stated in this manual appears to be in conflict with the requirements, please contact your local ABB representative for further assistance.

For information regarding Main Circuit Breaker / Controller, Instrumentation and Protection Equipment refer to Chapter 6 - Standard Functions and Chapter 8 - Selecting the Drive System.

Transformer Primary CablesThe cables from the Main Circuit Breaker (MCB) to the Transformer primary side has no special requirements. It should carry a voltage rating consistent with the voltage present in the primary circuit. The ampacity rating should be consistent with the size of the transformer being supplied and the protection settings of the protection equipment. Derating of cable ampacity in accordance with maximum expected ambient temperature, raceway fill factors and any other factors required by local electrical codes should be applied. Installation should be in compliance with standard industrial practice for medium voltage equipment.

If required by local electrical code, an equipment safety ground wire should be supplied either separately or by including it in the 3- core cable. The ampacity of this conductor should be in accordance with the code.

Transformer Secondary CablesThe cables from the transformer secondary windings to the ACS 1000 main power input buses, are exposed to common mode voltages, resulting from normal inverter operation. For this reason it is necessary to use cables rated for insulation levels of 5 kV (phase to earth) or higher for all transformer secondary connections, regardless of the transformer secondary voltage level (1327 V, 1903 V, or 2305 V). Cables rated for 5 kV are typically used in North America, in Europe and Asia cables rated for 6kV/10 kV are common.

In order to insure compliance with EMC requirements and to provide a low impedance, high frequency path through which the common mode currents can flow, a shielded cable is recommended. Shields should be terminated and grounded at the shortest possible way at both cable termination points. The ACS 1000 includes a vertical ground bus within the cable termination section in order to facilitate above requirement.

A non-shielded cable with a continuous corrugated aluminum armor may be used as an alternative to the shielded cable described above. Steel wire armored or interlocked aluminum armored cables without extra shield should not be used. Cable terminal ends with electrical contact all around its periphery to the armor should be used to terminate the cable ends to the ground.

The ampacity rating of the cable should be in consistency with 125% of the transformer nominal output current and the settings of the protection equipment in order to allow for the harmonic content. Derating of cable ampacity in accordance with maximum expected ambient temperature, raceway fill factors and any other factors required by local electrical codes



should be applied. Installation should be in compliance with standard industrial practice for medium voltage equipment.

If required by local electrical code, an equipment safety ground wire should be supplied separately. The ampacity of this conductor shall be in accordance with the code.

For information regarding the maximum length of the transformer secondary cables see Appendix B - Technical Data.

Motor CablesThere are no special requirements to be considered for the motor cables. The maximum cable length is limited to 1000 m (3281 ft). A voltage rating consistent with the voltage present at the motor must be selected. The ampacity rating should be consistent with the size of the motor being supplied and the overload settings of the motor protection software. Derating of cable ampacity in accordance with maximum expected ambient temperature, raceway fill factors, and any other factors required by local electrical codes should be applied. Installation should comply with standard industrial practice for medium voltage equipment.

Cable screening is not required for the motor cables, since the converter output voltage and current are sinusoidal. Therefore no measures against common mode currents are needed.

If required by local electrical code an equipment safety ground wire should be supplied separately. The ampacity of this conductor shall be in accor-dance with the code.

Motor cables are terminated within the ACS 1000 cabinet in the same way as the transformer secondary cables (see Figure A-6).

Power Cable DimensionsIn order to determine the exact dimensions for a specific project, the actual situation (method of installation, voltage drop due to cable length etc.) and local regulations must be considered. Refer also to the specifications supplied by the power cable manufacturer.

Equipment GroundingIt is recommended that the ACS 1000 ground bus is connected to the plant ground bus. The recommended cross-section of the ground connection depends on the motor cable cross-section.

Auxiliary Power CablesA 3-phase cable without neutral connector is required for auxiliary power supply. Type and ratings are to be selected according to local regulations. For ratings see also Appendix B - Technical Data.



Control CablesControl cables should be in accordance with Table A-2. Cable shields should be terminated on the ACS 1000 end only. Either single or multiple twisted pair cables may be used.Table A-2 Control cable requirements

Cable Routing

Power Cables Routing of mains and motor cables must be carried out in compliance with the local regulations and according to the specifications and recommen-dations of the cable manufacturer.

• For best EMC performance, shielded three phase cables are recommended.

• If single phase cables are used, the cables with the three different phases must be grouped close together to ensure best EMC performance.

• Phase interchange must be accomplished according to local regulations.

• For high power ratings, a maximum of two cables per motor phase can be accommodated by the gland plates of the ACS 1000.

• If the cross-section of the cable shielding is less than 50% of the cross-section of one phase, an additional grounding wire should be laid along the power cables to avoid excessive heat losses in the ca-ble shieldings. Please refer to the local regulations for further details.

Cable Termination Cables must be terminated with connectors according to the cable manu-facturer’s requirements.

Grounding Wire Routing of the grounding connection must comply with local regulations.

Control Cables Control cables should not be laid in parallel to the power cables. If this cannot be avoided, a minimum distance of 30 cm (12 inches) must be maintained between control and power cables.

Control and power cables should be crossed at an angle of 90°.

Signal Type General Cable Type Cross-Section (I/O Termination)

Analog In Twisted pair(s) - Overall Shield 0.5 to 2.5 mm2 / AWG 20 to AWG 12

Analog Out Twisted pair(s) - Overall Shield 0.5 to 2.5 mm2 / AWG 20 to AWG 12

Digital In Twisted pair(s) 0.5 to 2.5 mm2 / AWG 20 to AWG 12

Digital Out Twisted pair(s) 0.5 to 2.5 mm2 / AWG 20 to AWG 12



ACS 1000 Cable Entry and TerminationAccess to the power termination section of the ACS 1000 is via the control cabinet, located on the left of the converter. A bolted access door is located behind the control swing frame. Once the access door is opened all power terminations are readily available. As an aid to interfacing the main power connections, removable bus stubs are included.

Figure A-6 shows a typical example of how transformer and motor cables are connected to the internal bus system of the ACS 1000.

Cables can be entered through the cabinet roof or from the bottom. If the cable entry is from below, the gland plates mounted on top of the cable termination section must be relocated to the bottom and the bottom cover plate must be fixed to the top of the cabinet.

Figure A-6 Principle of Power Cable Entry (Water-Cooled Type)

Front ViewSide View

Front Side of Cabinet

2U12V12W1U2V2W21U11V11W1



The figures indicated in Table A-3 are valid for transformer and motor cables. The maximum cable diameter (to fit through the gland holes) is 45 mm.

Transformer Connection Diagram for 12-Pulse ACS 1000

Figure A-7 Typical 3-Line Transformer Connection Diagram.

Table A-3 Maximum Number of Cables per Phase

2.3 kV 3.3 kV 4.0 kV

A1 1 1 1

A2 2 1 1

A3 2 2 1

W1 - 2 2

W2 - 2 2

W3 - 3 2

Transformer

ACS 1000

PE

PE

a1 c1b1 a2 c2b2

1U1 1W11V1 2U1 2W12V1

FactoryGround

FactoryGround

Shielding Armouring



Transformer Connection Diagram for 24-Pulse ACS 1000

Figure A-8 Typical 3-Line Transformer Connection Diagram

Motor Connection Diagram for 12 / 24-Pulse ACS 1000

Figure A-9 Typical 3-Line Motor Connection Diagram

Transformer

ACS 1000

PE

a1 c1b1 a2 c2b2

1U1 1W11V1 2U1 2W12V1

FactoryGround

FactoryGround

Shielding

a3 c3b3

3U1 3W13V1

a4 c4b4

4U1 4W14V1

Armouring

PE

ACS 1000

PE

FactoryGround U2 W2

V2

UV

W

PEFactoryGround

M


Appendix B - Technical Data

Primary Side Voltage Any medium voltage level can be applied to the primary side of the converter input transformer.

Secondary SideVoltage

Transformer secondary side / converter input voltages (no load) for 12 / 24-pulse ACS 1000:

• 1327 VAC, ± 10% for 2.3 kV motors



Safe operation with reduced output power is possible down to -25%.

Phase Shift Phase shift between transformer secondary windings:

• 30° for 12-pulse ACS 1000

• 15° for 24-pulse ACS 1000

Frequency Range 50 / 60 Hz

Voltage Unbalance max. ± 2% (Umax - Umin ) / Uavg

Fundamental PowerFactor

cos ϕ1 > 0.97

Total Power Factor cos ϕT > 0.95

TransformerSecondary Cables

Depending on the presence of a Common Mode Choke (CMC) in the ACS 1000, the maximum permitted length for the transformer secondary cables is as follows:Table B-1 ACS 1000 without CMC

Transformer Connection / Converter Input

ACS 1000 Types Rectifier Type Max. cable length

Air-cooled 12-pulse 30 m (98 ft)

Water-cooled 12-pulse 30 m (98 ft)





Table B-2 ACS 1000 with CMC

Nominal Voltage UNom: 2.3 kVAC, 3.3 kVAC, 4.0 kVAC

Operational Voltage UOut: 0…UNom, 3-phase, sinusoidal, symmetrical

Output Frequency 0...66 Hz (optional: 0...82.5 Hz)

Frequency Resolution 0.01 Hz

Short Term OverloadCapacity

1 min/10 min: 110% of rated current

Field Weakening Point ≥ 45 Hz

Switching Frequency 1 kHz (3-level inverter, operating at 2 x 500 Hz)

Maximum Motor CableLength

1000 m (3281 ft)

Acceleration Time 0…1800 s

Deceleration Time 0…1800 s

Efficiency Approximately 98% (with nominal input voltage and DC link under full load)

Auxiliary Voltage Level • 400 VAC, 50 or 60 Hz, 3 phase ± 10% or

• 480 VAC, 60 Hz, 3 phase ± 10% or

• 575 VAC, 60 Hz, 3 phase ± 10%

ACS 1000 Types Rectifier Type Max. cable length



Air-cooled 24-pulse Not available with CMC


Converter Output / Motor Connection

Auxiliary Supply



Auxiliary PowerConsumption

Table B-3 Auxiliary Power Consumption

*) without optional heaters / coolers

Ambient Temperature The permitted temperature range for the ACS 1000 is:

• +1…+40 °C (34…104 °F) for air-cooled types

Note: If the temperature is higher than +40 °C (+104 °F) the output power of the air-cooled ACS 1000 types decreases. For derating factors see section Derating of Drive Power, page 88.

• +1…+50 °C (34…122 °F) for water-cooled types

Contamination Levels The maximum permitted contamination levels for printed circuit boards without coating, installed in the ACS 1000, comply with the following stan-dards:

• IEC 721-3-3, Class 3C2 for chemical gases

• IEC 721-3-3, Class 3S2 for solid particles.

Installation Site Altitude The maximum possible installation site altitude for the ACS 1000 is:

• 5500 m (18045 ft) above sea level for 2.3 kV motor voltage

• 4000 m (13124 ft) above sea level for 3.3 kV motor voltage

• 3000 m (9843 ft) above sea level for 4.0 kV motor voltage.

Note: If the installation site is more than 2000 m (6562 ft) above sea level the derating of the output power needs to be considered for the air-cooled

Air-Cooled Types Water-Cooled Types Power Consumption

ACS1012-A1ACS1013-A1ACS1014-A1

5.3 kW *

ACS1012-A2ACS1013-A2ACS1014-A2ACS1012-A3ACS1013-A3ACS1014-A3

7.3 kW*

ACS1012-W1ACS1013-W1

4.3 kW *

ACS1012-W2 ACS1013-W2 ACS1013-W3 ACS1014-W2 ACS1014-W3

4.6 kW *

ACS1014-W1 4.9 kW *

Environmental Aspects



ACS 1000 types. For derating factor see section Derating of Drive Power, page 88.Water-cooled types do not have a derating for the installation site altitude.

Relative Humidity The permitted ranges for relative humidity are:

• 5…95%, no condensation is allowed

• 5…60%, if corrosive gases are present.

Vibration The ACS 1000 can be exposed to the following maximum values for vibra-tion:

• 0.3 mm (2…9 Hz)

• 1 m/s2 (2…200 Hz), sinusoidal (according to IEC 721-3-3).

Sound Pressure Level • < 75 dB (A) for air-cooled types

• < 70 dB (A) for water-cooled types.

Air-Cooled Converters

Ambient Temperature The derating factor for air-cooled converters with enclosure class IP21 is as follows:

Above +40 °C (+104 °F) the rated output current is decreased by 1.5 % for each additional 1 °C (0.85 % for each 1 °F) up to the maximum permitted temperature of +45 °C (+113 °F).

Example: If the ambient temperature is 45 °C the derating factor is calcu-lated as 100% - 1.5 %/°C · 5 °C = 92.5%. Hence, the maximum output current is 92.5% of the rated value.

Derating for Air Filters Depending on the mesh size of the filter mat the derating factors as stated in Table B-4 apply to the rated output power:Table B-4 Derating Factors for Air Filters:

Derating for RedundantCooling Fan

If a redundant cooling fan is installed the derating factor for the rated output power is 7.5 %.

Derating of Drive Power

Mesh Size Remark Derating in %

18 µm Standard 0

12 µm Option 5

10 µm Option 10



Installation Site Altitude The rated output power is reduced by 1% for each additional 100 m (330 ft) at sites higher than 2000 m (6600 ft) above sea level.

Water-Cooled Converters

Derating for Raw WaterTemperature

If the raw water temperature exceeds 27 °C (81 °F) the derating factors as stated in Table B-5 apply to the rated output power:Table B-5 Derating Factors for Raw Water Temperature

Derating forFrostproofing

If glycol is added to the make-up water, the derating factors as stated in Table B-6 apply to the rated output power:Table B-6 Derating Factors for Glycol

Storage Temperature -25…+55 °C (-13…+131 °F), class 1K4 (IEC 721-3-1)

TransportationTemperature

-25…+55 °C (-13…+131 °F), class 2K3 (IEC 721-3-2)

up to 70 °C (158 °F) for up to 24 hours

Relative Humidity(Storage)

5...95%, class 1K3 (IEC 721-3-1)

Relative Humidity(Transportation)

< 95% at +40 °C (+110 °F)

Converter Type Rated Motor Power (kW)

Cooling WaterInlet Temp. Range

Derating in % / K

ACS1013-W1 2000…2500 27°C to max. 38°C 0

ACS1013-W2 2800…4000 27°C to max. 38°C 0

ACS1013-W3 4500…5000 27°C to max. 38°C 0.4

ACS1014-W1 1800…2250 27°C to max. 38°C 0.6

ACS1014-W2 2500…3550 27°C to max. 38°C 0

ACS1014-W3 4000…5000 27°C to max. 38°C 1.35

Frostproofing Glycol Concentration Derating in %

- 10°C 20 % 4.5

- 20°C 34 % 7

- 30°C 44 % 9

- 40°C 52 % 11.5

Transportation and Storage



Vibration (Storage) Max. 0.3 mm (2..9 Hz), max.1 m/s2 (2..200 Hz), sinusoidal (IEC 721-3-1)

Vibration (Seismic) Max. 9 mm (5…35 Hz), max. 18 m/s2, sinusoidal (IEEE 344)

Shock (Storage andTransportation)

Max. 100 m/s2, 11 ms, (IEC 721-3-2 / 2M2), Spectrum I

Air-Cooled Converters

Cooling Method Air cooling with internal fan

Power Losses < 2 % of nominal output power

Cooling Air Flow • 1.7 m3/s (3600 cu ft/min) for ACS 1000 - A1

• 2.5 m3/s (5300 cu ft/min) for ACS 1000 - A2/A3

Water-Cooled Converters

Cooling Method Water-cooled closed loop system with superimposed closed circuit air cooling.

Heat Dissipation toEnvironment

approx. 1 kW

Raw WaterTemperature

+4…+27 °C (+40…+80 °F)

Raw Water Pressure 1…10 bar (14.22…144.2 lb/sq in)

Extended Raw WaterTemperature

+27…+38 °C

Raw Water Flow • ≥ 80 l/min (21.1 gal/min for ACS 1000 - W1) or

• ≥ 150 l/min (39.6 gal/min for ACS 1000 - W2/W3)

Cooling



Water Quality Table B-7 Make-up Water (Drinking Water) Quality Requirements

Table B-8 Raw Water (Industrial Water) Quality Requirements

The drive provides a wide range of protection, fault and alarm functions including:

• Motor temperature monitoring

• Motor stall

• Underload

• Overspeed

• Undervoltage

• Battery condition monitoring

• Motor phase loss

• Overvoltage

Parameter Value

pH 6 – 8.5

conductivity < 300 µS / cm

hardness 3 – 10 dH

chloride (Cl) < 100 mg/l

copper (Cu) < 0.1 mg/l

total dissolved solids (TDS) < 300 mg/l

suspended solids < 5 mg/l

Parameter Value

pH 6 – 9

conductivity < 500 µS / cm

hardness 3 – 15 dH

chloride (Cl) < 300 mg/labove 300 mg/l titanium stabilized exchanger plates are required

total dissolved solids (TDS) recommended: < 300 mg/lup to 1000 mg/l are possible, provided above limits for hardness and chloride are not exceeded

suspended solids < 10 mg/l

Protection Functions



• Short circuit in the rectifier bridge

• Charging fault

• Supply phase loss

• Overcurrent

• Short circuit of the inverter

• Measurement loss

• Communication fault

• Cooling circuit monitoring (water-cooled converters)

• Earth fault monitoring

Analog Input (AI) Floating, galvanically isolated inputs

• Signal Level: 0…20 mA / 4…20 mA or 0…10 V / 2…10 V,individually scalable by parameter setting

• Input Resistance: Rin = 100 Ω for current inputRin = 210 kΩ for voltage input

Common Mode Voltage max. 48 V

Isolation Voltage 350 VAC

Common ModeRejection Ratio

> 80 dB at 50 Hz

Resolution 0.1% (10 bit)

Accuracy ± 0.25% (Full Scale Range) at 25 °C (±30 mV offset)

Protection No internal damage up to 250 VAC/DC input voltage (for voltage inputs)

Input Updating Time 100 ms (with standard application software)

Terminal Block Size Cables 0.5…2.5 mm2 (up to AWG12)

Analog Output (AO) Floating, galvanically isolated outputs

Signal Level 0…20 mA / 4…20 mA individually scalable by parameter setting

Isolation Voltage 350 VAC

Resolution 0.03% (12 bit)

Accuracy ± 0.25% (Full Scale Range) at 25 °C (± 50 µA offset)

Analog Inputs

Analog Outputs



Max. Load Impedance 250 Ω

Protection No internal damage up to 250 VAC/DC input voltage, short circuit proof

Output Updating Time 250 ms (with standard application software)


Digital Input (DI) Floating, galvanically isolated inputs (opto-coupled)

Signal Level 22…250 VAC / 22…150 VDC

Logical Thresholds < 12 VAC/DC “0”, > 20 VAC/DC “1”

Input Current at 24 V: 13 mA at 250 V, 10 mA

Filtering Time Constant 20 ms

Isolation Individually isolated

Isolation Test Voltage (for 1minute) 2300 VAC input / input1350 VAC input / logic1350 VAC input / ground

Input Updating Time 250 ms (with standard application software)


Digital Output (DO) With switch-over contact (SPDT)

Switching Capacity • AC: 6 A switching, 4 A steady state up to 250 V

• DC: at 24 V: 8 A, at 48 V: 1A, at 120 V: 0.4 A

Contacts Encapsulated Contacts

Isolation Voltage 4 kVAC, 1 minute

Output Updating Time 250 ms (with standard application software)


Digital Inputs

Digital Outputs



Voltage 24 VDC +15% / -10%

Maximum Current 180 mA (per I/O-board)

Protection Short circuit proof


This voltage can be used for the digital inputs of ACS 1000 and / or to supply external measurement transmitters for analog inputs.An external 120 VAC / 240 VAC supply can be used instead of the internal 24 VDC supply.

Voltage 10 VDC ±10%

Maximum Current 10 mA

Protection Short circuit proof


This reference voltage can be employed to supply external potentiometers used for reference values.

High speed, DDCS protocol fiber optic serial data bus.

Connectors A pair of fiber optic connectors (transmitter and receiver)

Fiber Optic Cable Plastic core optic fiber, Ø 1 mm (0.04 in), max. length 10 m (33 ft), min. bend radius 25 mm (1 in) (short-term) or 35 mm (1.4 in) (long-term)

Standard EnclosureClasses

IP21 (for air-cooled types)

IP31 (for water-cooled types)

Auxiliary Power Output

Reference Voltage Output

DDCS Fiber Optical Link

Enclosures


Appendix C - Dimensions and Weights

Dimensions and weights of the basic ACS 1000 cabinets are given in Table C-1 to Table C-3. The dimensions and weights of additional equip-ment and converter options are given in Table C-4.

Table C-1 Dimensions and Weights of 12/24-Pulse ACS 1000 Air-Cooled and 12-Pulse ACS 1000 Water-Cooled (24-Pulse ACS 1000 Water-Cooled see Table C-4)Motor Voltage 2.3 kV

MotorVoltage

(kV)Converter Type

Typeof

CoolingDimensions and Weights

Length Depth Height Weight**

(mm) (ft/in) (mm) (ft/in) (mm) (ft/in) (kg) (lbs)

2.3 ACS1012-A1-A0-00 Air

2.3 ACS1012-A1-B0-00 Air

2.3 ACS1012-A1-C0-00 Air

2.3 ACS1012-A1-D0-00 Air

2.3 ACS1012-A1-E0-00 Air

2.3 ACS1012-A1-F0-00 Air

2.3 ACS1012-A1-G0-00 Air

2.3 ACS1012-A1-H0-00 Air 3000 9’10’’ 900 3’0’’ 2005 6’7’’ * 1600 3530

2.3 ACS1012-A2-J0-00 Air

2.3 ACS1012-A2-K0-00 Air 3000 9’10’’ 900 3’0’’ 2005 6’7’’ * 1750 3860

2.3 ACS1012-A3-L0-00 Air

Please contact ABB2.3 ACS1012-A3-M0-00 Air

2.3 ACS1012-A3-N0-00 Air

*) without air-exhaust fan cover (see Table C-4)**) approximate values



Table C-2 Dimensions and Weights of 12/24-Pulse ACS 1000 Air-Cooled and 12-Pulse ACS 1000 Water-Cooled (24-Pulse ACS 1000 Water-Cooled see Table C-4)Motor Voltage 3.3 kV

MotorVoltage

(kV)Converter Type

Typeof




3.3 ACS1013-A1-A0-00 Air 3000 900 2005 1600

3.3 ACS1013-A1-B0-00 Air 3000 900 2005 1600

3.3 ACS1013-A1-C0-00 Air 3000 900 2005 1600

3.3 ACS1013-A1-D0-00 Air 3000 900 2005 1600

3.3 ACS1013-A1-E0-00 Air 3000 900 2005 1600

3.3 ACS1013-A1-F0-00 Air 3000 900 2005 1600

3.3 ACS1013-A1-G0-00 Air 3000 900 2005 1600

3.3 ACS1013-A1-H0-00 Air 3000 9’10’ 900 3’0’’ 2005 6’7’’ * 1600 3530

3.3 ACS1013-A2-J0-00 Air 3000 900 2005 1750

3.3 ACS1013-A2-K0-00 Air 3000 900 2005 1750

3.3 ACS1013-A2-L0-00 Air 3000 900 2005 1750

3.3 ACS1013-A2-M0-00 Air 3000 900 2005 1750

3.3 ACS1013-A2-N0-00 Air 3000 ’ 900 2005 1750

3.3 ACS1013-A2-P0-00 Air 3000 9’10’ 900 3’0’’ 2005 6’7’’ * 1750 3860

3.3 ACS1013-A3-Q0-00 Air

3.3 ACS1013-A3-R0-00 Air 3000 9’10’ 900 3’0’’ 2005 6’7’’ * 2000 4410

3.3 ACS1013-W1-S0-00 Water

3.3 ACS1013-W1-T0-00 Water

3.3 ACS1013-W1-U0-00 Water 4200 13’10 902 3’0’’ 2002 6’7’ 3300 7260

3.3 ACS1013-W2-V0-00 Water

3.3 ACS1013-W2-W0-00 Water

3.3 ACS1013-W2-X0-00 Water

3.3 ACS1013-W3-Y0-00 Water

3.3 ACS1013-W3-Z0-00 Water

3.3 ACS1013-W3-10-00 Water 4700 15’5’’ 902 3’0’’ 2002 6’7 3680 8100




Table C-3 Dimensions and Weights of 12/24-Pulse ACS 1000 Air-Cooled and 12-Pulse-ACS 1000 Water-Cooled (24-Pulse ACS 1000 Water-Cooled see Table C-4)Motor Voltage 4.0 kV

MotorVoltage

(kV)Converter Type

Typeof




4.0 ACS1014-A1-A0-00 Air

4.0 ACS1014-A1-B0-00 Air

4.0 ACS1014-A1-C0-00 Air

4.0 ACS1014-A1-D0-00 Air

4.0 ACS1014-A1-E0-00 Air

4.0 ACS1014-A1-F0-00 Air

4.0 ACS1014-A1-G0-00 Air

4.0 ACS1014-A1-H0-00 Air 3000 9’10’’ 900 3’0’’ 2005 6’7’’ * 1600 3530

4.0 ACS1014-A2-J0-00 Air

4.0 ACS1014-A2-K0-00 Air 3000 9’10’’ 900 3’0’’ 2005 6’7’’ * 1750 3860

4.0 ACS1014-A3-L0-00 Air

4.0 ACS1014-A3-M0-00 Air

4.0 ACS1014-A3-N0-00 Air 3000 9’10’’ 900 3’0’’ 2005 6’7’’ * 2000 4410

4.0 ACS1014-W1-P0-00 Water

4.0 ACS1014-W1-Q0-00 Water 4200 13’10 902 3’0’’ 2002 6’7’’ 3300 7260

4.0 ACS1014-W2-R0-00 Water

4.0 ACS1014-W2-S0-00 Water

4.0 ACS1014-W2-T0-00 Water

4.0 ACS1014-W2-U0-00 Water

4.0 ACS1014-W3-V0-00 Water

4.0 ACS1014-W3-W0-00 Water

4.0 ACS1014-W3-X0-00 Water 4700 15’5’’ 902 3’0’’ 2002 6’7’’ 3680 8100




Table C-4 Dimensions and Weights of the ACS 1000 and Optional Equipment

Description Dimensions and Weights

ACS 1000Type



Air-exhaust fan cover Air-cooled 654 2’ 2"** 733 2’ 5" 278 - -

Redundant cooling fan unit Air-cooled 2000 6’ 7""* 870 2’10"" 800 300 660

Braking chopper (placed on the right side)

644 2’ 1" 902 3’ 2005/2070*

6’ 7"/6’ 10"*

460 1012

Synchronous bypass (placed on the left side)

644 2’ 1" 902 3’ 2005/2070*

6’ 7"/6’ 10"*

460 1012

24-pulse extension (placed on the left side)

Water- cooled

844 2’ 9""* 902 3’ 2005/2070*

6’ 7"/6’ 10"*

350 770

Redundant fan unit Water- cooled

650 2’ 2" 865 2’10"" 312 1’ ** 100 220

*) including lifting lugs**) approx. values


Appendix D - Applicable Codes and Standards

The ACS 1000 frequency converter is marked with a CE symbol. The CE marking indicates that the ACS 1000 complies with the basic technical requirements and conformity valuation criteria and is an essential requirement of the relevant EC Directives.

The CE marking is mainly for the benefit of authorities throughout the Common European Market.

Low Voltage DirectiveLow Voltage Directive73/23 EEC modified by 93/68 EEC.

This directive concerns all electrical equipment with nominal voltage levels of 50..1000 VAC and 75..1500 VDC.

The aim of the directive is to protect against electrical, mechanical, fire and radiation hazards. It tries to insure that safe products are placed on the market.

Compliance with theLow Voltage Directive

The ACS 1000 fully complies with the Low Voltage Directive as far as enclosure, auxiliary supply and I/O ports are concerned. The Declaration of Conformity will be enclosed in the ACS 1000 delivery.

The Low Voltage Directive is not applicable for the medium-voltage section of the ACS 1000. However, the medium-voltage section fulfills the requirements of the standard EN 50178 (Electronic equipment for use in power installations).

Machinery Directive89/392 EEC modified by 91/368; 93/44, 93/68 and 98/37EEC.

This directive concerns all combinations of mechanically joined compo-nents, where at least one part is moving.

CE Marking



Compliance with theMachinery Directive

On its own, the ACS 1000 does not have a functional value to the user: It always needs its motor coupled to the driven load before it can function effectively.

Therefore, the Machinery Directive is not applicable for the ACS 1000.

EMC Directive89/336 EEC modified by 91/263; 92/31; 93/68 and 93/97EEC.

EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other neighboring electrical equipment or system.

EmissionsThe source of high-frequency emission of frequency converters is fast switching of IGCTs and control electronics. The high-frequency emission can propagate by conduction and radiation.

ImmunityElectrical equipment should be immune to high-frequency and low-frequency phenomena. High-frequency phenomena include electrostatic discharge (ESD), fast transient burst, radiating electromagnetic field, conducting radio frequency disturbance and electrical surge. Typical low frequency phenomena are mains voltage harmonics, notches and imbalance.

Compliance with theEMC Directive

The EMC Directive applies to the ACS 1000 as far as the enclosure, the auxiliary supply and the I/O ports are concerned. The Declaration of Conformity for industrial environment signed by ABB is enclosed in the ACS 1000 delivery. The two applicable standards, EN 50081-2 (Emis-sions) and EN 50082-2 (Immunity) have been met.

As far as the medium-voltage ports are concerned the EMC Directive is not applicable. The standard IEC 1800-3: Adjustable speed electrical power drive systems - Part 3: EMC product standard including specific test methods, states: “For supply voltages higher than 1000 VAC rms, EMC requirements result from agreement between manufacturer / supplier and user.”

In order to make sure that the whole system is electromagnetically compatible within its surrounding the installation regulations have to be strictly observed. Following the grounding regulations, instructions for cable entries as well as for cable laying is extremely important.

The ACS 1000 is installed with screened control and main power supply cables that are specified in Appendix A - Installation Guidlines.

The installation of the ACS 1000 shall be performed as described in the ACS 1000 User’s Manual.



The ACS 1000 is UL and Canadian UL listed under "Power Conversion Equipment", File E176716.

The ACS 1000 Converter complies with the following codes and standards:

• IEC 22B/88/CD Draft revision of IEC 146-2: Self-commutated convertors including direct DC convertors and IEC 146-3: Semiconductors direct DC convertors DC chopper convertors

• IEC 146-1-1 Semiconductor convertors

• IEC 529 Degrees for protection provided by enclosures (IP-Code)

• IEC 664-1 Insulation coordination for equipment within low-voltage systems

• IEC 721-3-1 A1 Classification of environmental condi-tionsPart 3: Storage

• IEC 721-3-2 A2 Classification of environmental condi-tionsPart 3: Transportation

• IEC 721-3-3 A1 Classification of environmental condi-tionsPart 3: Stationary use at weatherpro-tected locations

• IEC 1000-4-2 Electrostatic immunity test- contact discharge 4 kV- air discharge 8 kV

• IEC 1000-4-4 Fast Transient immunity test- Aux-Supply Power-Ports: 2 kV, 5 kHz- Signal-Ports: 2 kV, 5 kHz

• IEC 1000-4-5 Surge immunity test- Aux-Supply Power Ports

- Line to Line 2 kV- Line to Earth 4 kV

- Signal-Ports 1 kV

UL Marking

Applicable Codes and Standards



• EN 50081-2 Electromagnetic compatibility (EMC) generic emission standard part 2: Industrial environment

• EN 50082-2 Electromagnetic compatibility (EMC) generic immunity standard part 2: Industrial environment

• EN 50178 Electronic equipment for use in power installations

• EN55011; A2 Suppression of Radio disturbances caused by electrical appliances and systems- Aux-Supply Power-Ports conducted emission 0.15 - 30 MHz Class A

• ENV 50141 Radio frequency common mode- Aux-Supply Power-Ports- Signal-Ports AM 0.15 - 80 MHz 10 V (rms)

• UL 347 High Voltage Industrial Control Equip-ment

• UL 347A Medium Voltage Power Conversion EquipmentProposed first edition of the standard

• UL 508C Power Conversion Equipment

• IEEE 519 Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems


104

Appendix E - ACS 1000 Type Code

Example: ACS 1014-A1-B0-00-F101-2…

Note: The ACS 1000 is identified by the type code which represents all stan-dard features and available options by one of the 36 digits. The type code is also printed on the name plate of each drive. Options, presently not available, are shaded on the type code sheet. The example of the type code sheet shows only a part of the type code. For the complete type code please use the soft-ware based ACS 1000 configurator tools or contact the factory.

1 A Product CategoryA = AC Drive

2/3 C S Product TypeCS = Standard xx = OEM

4 1 ACS Product Family1 = ACS 1000

5 Variation0 = Standard 1 = Non-Standard Options included (to be specified separately)

6 Input Bridge0 = 6-Pulse Rectifier 1 = 12 Pulse Rectifier 2 = 24 Pulse Rectifier3 = 12-Pulse Rect. with Integrated Transformer 4 = 24-Pulse Rect. with Integrated Transformer

7 - Voltage Rating2 = 2.3 kV 3 = 3.3 kV 4 = 4.0 kV 6 = 6.6 kV

8/9 - Frame SizeA1, A2 and A3 for Air Cooled Converters W1, W2 and W3 for Water Cooled Converters

10 Sub-Frame Size See Option SheetSee ACS 1000 rating tables

11 - Extended Ambient Air / Raw Water Temperature See Option Sheet0 = None x = extended ambient air / raw water temperature

12 Maximum Output Frequency0 = 66 Hz (Standard) 2 = 82.5 Hz x = Other options will follow later

13 - Field Weakening0 = 1 : 1.1 (Standard) 1 = max. FW 1 : 1.2 2 = max. FW 1 : 1.3 3 = max. FW 1 : 1.44 = max. FW 1 : 1.5

14 Filter EquipmentF = Sine Filter and Common Mode Choke S = Sine Filter (without Common Mode Choke)

15 Output Filter ChokeOutput Filters are motor specifically selected

16/17 - Output Filter CapacitorOutput Filters are motor specifically selected

18 Auxiliary Voltage Rating (indicated values +/- 10%)1 = 400 VAC / 50 Hz 2 = 480 VAC / 60 Hz 3 = 575 VAC / 60 Hz 4 = 400 VAC / 60 Hz


Appendix E - ACS 1000 Type Code


Documents

ACS 1000 Medium Voltage AC Drives - firstfame.co.th · ACS 1000 Medium Voltage AC Drives ... The data stated in this manual is for product description purposes and ... 2.2 Fuseless