ABB ACS1000i - User Manual

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SYSTEM DRIVES

ACS1000i air-cooled

User manual

OWNING ORGANIZATION

ABB Switzerland Ltd.

DATE

2022-03-17

STATUS

Approved

SECURITY LEVEL

Public

DOCUMENT KIND

User manual

DOCUMENT ID.

3BHS206977 E01

REV.

LANG.

PAGE

1/146

Main Page

Table of Contents3
About this Manual13
Equipment Covered by this Manual13
Structure of the User Documentation13
Terms and Definitions14
Table 1-1 Terms and Definitions14
Related Documents16
Table 1-2 Maintenance16
Table 1-3 Technical Data16
Table 1-4 Schematics16
Table 1-5 Specifications and Guidelines16
Table 1-6 Serial Communication Interfaces16
Table 1-7 Encoder16
Target Groups and Required Qualification17
Handling17
Mechanical Installation17
Electrical Installation17
Operation17
Maintenance18
User's Responsibilities18
Intended Use of Equipment18
Quality Certificates and Applicable Standards19
Table 1-8 Standards19
Items Covered by Delivery20
Identifying the Delivery20
Figure 1-1 Delivered Items20
Important Safety Information21
Safety Standards21
Safety Messages21
Product Safety Labels22
Figure 2-1 Product Warning Label Examples (Label Placement Depends on the Drive)22
General Safety Instructions23
The 7 Steps that Save Lives24
Possible Residual Risks26
Main Circuit Breaker Protection Device27
Figure 2-2 Drive System Overview27
Safety and Protection Requirements28
Minimum Requirements for MCB and MCB Control28
Figure 2-3 MCB Opening Timing Diagram29
Maintenance Recommendation30
Power Electronics and Cabinet Features31
Overview31
Figure 3-1 Acs1000I Air-Cooled31
Main Components of the Drive System32
Figure 3-2 Block Diagrams of the Drive32
Power Supply Configurations33
Main Power Supply Configurations33
Figure 3-3 Drive Overview with Power Supplies33
Auxiliary Power Supply Configurations34
Drive Topology35
Overview35
Figure 3-4 Acs1000I Air-Cooled with Combined Input Disconnector and Grounding Switch35
Figure 3-5 Acs1000I Air-Cooled with Grounding Switch36
Terminal Compartment37
Figure 3-6 Terminal Compartment with Input Disconnector (A) and Without Input Disconnector (B)37
Control Compartment and Terminal Compartment38
Figure 3-7 Control Compartment with Open Door38
Transformer and Rectifier Compartment39
Rectifier39
Figure 3-8 Transformer and Rectifier Compartment with Combined Input Disconnector (A) and with Grounding Switch (B)39
Grounding Switch40
Figure 3-9 Switchgear of the Drive40
Figure 3-10 Grounding Switch Unlocked Lamp (1)41
Figure 3-11 Grounding the Drive41
Trapped Key Interlock (Option)42
Protection Igcts42
Figure 3-12 Trapped Key Interlocking System (1)42
Inverter43
Filter43
Figure 3-13 Three-Level Voltage Source Inverter Principle43
Figure 3-14 Voltage and Current Waveforms at Drive Output43
Cooling System44
Figure 3-15 Fan Configurations and Air Flow44
Figure 3-16 Fan Groups - AC and EC Fans45
Figure 3-17 Fan Groups - EC Fans Only45
Figure 3-18 Operating Times of the AC Fan Units During Continuous Drive Operation (A) and Intermittent Drive Operation (B)46
Figure 3-19 Operating Principles of Redundant EC Fans47
Optional Braking Chopper48
Figure 3-20 Acs1000I with Braking Chopper (1)48
Figure 3-21 Principle Diagram48
Figure 3-22 Braking Chopper Design49
Table 3-1 Braking Ratings50
Cabinet Design51
Mechanical Design51
Additional Cabinets52
Figure 3-23 Acs1000I with an Additional Cabinet (1)52
Door Locking System53
Optional Cabinets53
Figure 3-24 Door Locks53
Arc Resistant Design (Optional)54
Internal Arc Classification54
Figure 3-25 IAC Label Example54
Table 3-2 ABB Arc Resistant Classes54
Power Compartment Doors55
Associated Protection Requirement55
Figure 3-26 Door Bolts55
Space Heaters56
Figure 3-27 Optional Space Heaters56
Control System57
Overview57
Figure 4-1 Block Diagram of Control System with Customer Interface (A), Control System (B) and Power Electronics (C)57
Main Components58
Local Control Panel58
Figure 4-2 Control Compartment58
AMC Circuit Board59
Figure 4-3 AMC Circuit Board59
Figure 4-4 Direct Torque Control60
Figure 4-5 PID Control Mode62
I/O Interfaces63
IOEC I/O Modules63
Figure 4-6 IOEC Interfaces Overview63
Table 4-1 IOEC Module Configuration - Analog Inputs64
Table 4-2 IOEC Module Configuration - Analog Outputs64
Table 4-3 IOEC Module Configuration - Digital Inputs64
Table 4-5 24 V Internal Voltage Supply65
Table 4-4 IOEC Module Configuration - Digital Inputs65
Figure 4-7 IOEC Module66
Figure 4-8 IOEC Module Identification67
Table 4-6 IOEC Module Identification67
Serial Communication Interface (Fieldbus)68
Pulse Encoder Interface NTAC (Option)68
Figure 4-9 NTAC-02 Pulse Encoder Interface68
Transportation, Storage and Disposal69
Safety69
Transport Conditions69
Unpacking and Inspection69
Lifting and Transportation69
General Notes on Transportation70
Using a Crane70
Figure 5-1 Transporting the Cabinet by Crane (Lift Spreader Example)71
Using Rollers72
Figure 5-2 Moving the Drive with Rollers72
Figure 5-3 Moving the Drive Backwards or Forwards72
Storage73
Storage Conditions73
Storing the Drive73
Storage and Handling of Spare Parts74
Disposal of Packaging Materials and Components74
Mechanical Installation75
Safety75
Overview of Installation Work75
General Notes on Installation75
Dimensions and Clearances75
Cabinet Roof75
Fire Protection75
Cable Duct Material75
Preparing the Floor76
Fixing the Cabinet to the Floor76
Figure 6-1 Position of Mounting Holes76
Figure 6-2 Leveling the Drive76
Installing the Fans77
Figure 6-3 Fixing the Cabinet to the Floor77
Figure 6-4 Cutouts in Drive Roof - Back (A) and Front (B)77
Figure 6-5 Standard Fan Installation78
Table 6-1 Fan Configurations78
Figure 6-6 Lifting Point Locations on Fan Unit79
Figure 6-7 Large Fan Installation80
Figure 6-8 Small Fan Installation over a Roof Cutout for a Large Fan81
Figure 6-9 Fan Installation Material81
Additional Cabinet Compartments82
Figure 6-10 Bolt Location at the Back of a Fan Unit82
Electrical Installation83
Safety83
Overview of Installation Work83
Cable Requirements83
Ground Cable Connection and Cable Shield Connections84
Figure 7-1 Grounding the Drive System84
Power Cables, Ground Cables and Equipotential Bonding Conductor85
Safety85
Determining the Cable Length85
MV Cable Entry from Top86
Figure 7-2 Top Cable Entry - Installation Material86
Figure 7-3 Bolt Locations for Cable Entry Box on Terminal Compartment Roof (a Is the Back and B Is the Front of the Compartment)87
Figure 7-4 Insulating Barrier Placement for Top Cable Entry88
MV Cable Entry from Bottom89
Figure 7-5 Bottom Cable Entry - Installation Material89
Figure 7-6 Bolt Locations on Terminal Compartment Roof for the Galvanized Steel Plate90
Figure 7-7 Bracket Location on Insulating Barrier91
Figure 7-8 Insulating Barrier Placement for Bottom Cable Entry91
Connecting the Cables92
Figure 7-9 Power Cable Terminals in a Terminal Compartment Without an Input Disconnector (A) and a Terminal Compartment with an Input Disconnector (B)92
Figure 7-10 Bolted Busbar Connections93
Auxiliary Power, Control and Serial Communication Cables94
Preparing the Cable Entry and the Cables94
Figure 7-11 Cable Entry from Top (A), from Bottom (B)94
Preparing Cables for Cable Entries with Cable Glands95
Figure 7-12 Top Entry for Auxiliary Power and Control Cables95
Figure 7-13 Preparing Control Cables for Cable Glands95
Connecting Additional Cabinets96
Final Checks96
Figure 7-14 Shield Grounding Point for Encoder Cable96
Commissioning97
Overview97
Required Qualification97
Commissioning Procedure97
Commissioning Checklist97
Customer Assistance97
Customer Acceptance97
Commissioning Checklists98
Mechanical Installation Checklist98
Electrical Installation Checklist98
Main Circuit Breaker (MCB) Checklist99
Motor Checklist99
Insulation Tests Checklist99
Power Supply Checklist99
Miscellaneous Checklist100
Operation101
Safety101
Overview101
Operating Conditions101
Local Operator Panel101
Figure 9-1 Local Operator Panel102
Status Messages103
Start Sequence of the Drive104
Stop Sequence of the Drive105
Emergency off Sequence of the Drive106
Starting the Drive106
Checks before Starting the Drive106
Starting the Drive Remotely107
Starting the Drive Locally107
Stopping the Drive109
Emergency-Off109
Initiating an Emergency-Off110
Starting the Drive after an Emergency-Off110
CDP Control Panel111
Overview111
Figure 10-1 CDP Control Panel111
CDP Control Panel Functions112
CDP Control Panel Modes112
Identification Mode112
Actual Signals Mode113
Figure 10-2 Control Panel - Actual Signals Mode115
Parameters Mode120
Table 10-1 Parameter Groups120
Figure 10-3 Control Panel - Parameters Mode122
Figure 10-4 Control Panel - Functions Mode126
Local and Remote Control128
Local Control128
Remote Control128
Operational Commands129
Setting the Direction of Rotation129
Entering a Reference Value131
Preventive and Corrective Maintenance133
General Information133
Required Qualification133
Maintenance Schedule133
Logbook133
Spare Parts133
Identifying Electrical Equipment134
Device Identification134
Cables and Wires134
Understanding Wiring Diagrams134
Figure 11-1 Device Identification134
Alarm / Fault Indications135
Messages135
Error Message Levels135
Fault Handling136
Standard Troubleshooting Procedure137
Removing the CDP Control Panel138
Leds and Switches on Circuit Boards139
AMC Circuit Board139
Figure 11-2 AMC Circuit Board139
IOEC I/O Modules140
Figure 11-3 IOEC Module140
Corrective Maintenance141
Safety141
Energizing the Drive Locally142
Grounding143
Grounding Switch Is Not Released144
Figure 11-4 Location of I/O Modules and Fuses144
Checking the Release Conditions for the Grounding Switch145
Visual Checks on the Drive147
Cleaning the Drive147
Checking Wire and Cable Connections148
Cleaning and Replacing Filter Mats148
Table 11-1 Filter Mat Specifications148
Figure 11-5 Cleaning and Replacing Filter Mats N149
Inspecting and Replacing Batteries150
Figure 11-6 Control Compartment - Battery Location150
Figure 11-7 Control Compartment - Replacing the Batteries151
Replacing a Fan Unit152
Figure 11-8 Lifting Point Locations on Fan Unit153

Brand	ABB
Model	ACS1000i
Category	Industrial Equipment
Language	English

ABB ACS1000i - User Manual

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