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1. Swing frame closed Swing frame removed for illustration swing frame is not removed in reality 4 4 of 38 3BHS102769 ACS 1000 User s Manual Rev C Pre defined Chapter 4 I O Interfaces and Application Macros In Table 4 1 Table 4 6 all predefined signals are listed in functional Signals groups I Os of the standard IOEC boards are marked with a dot 9 Table 4 1 Signals Remote Control Interface Signal Terminals Remarks Stan Signal dard Inversion DI 2 1 2 Macro specific I O e not STANDARD INPUT 1 11 1 2 possible DI 2 2 IOEC 2 Macro specific not STANDARD INPUT 2 X11 3 4 possible DI 2 3 2 Macro specific I O not STANDARD INPUT 3 X11 5 6 9 possible DI 2 4 IOEC 2 Macro specific I O not STANDARD INPUT 4 11 7 8 i possible DI 2 5 IOEC 2 Macro specific I O not STANDARD INPUT 5 X11 9 10 possible DI 2 6 2 Macro specific not STANDARD INPUT 6 12 1 2 possible DI 1 8 X301 External signal which disables local e not DISABLE LOCAL X1 2 operation via control panel possible CDP 312 DI 2 7 IOEC 2 External closing command for the e not REM ORD MCB CLOSE X12 3 4 main circuit breaker possible DI 2 13 2 External opening command for the e not REM ORD MCB OPEN X13 5 6 main circuit breaker possible DI 2 12 IOEC 2 E
2. IP 54 and cable entry from above Remove the rubber grommets from the gland plate and cut them to ade quate diameter for the auxiliary power cable To en sure proper sealing cut along the diameter marking that corresponds to the cable diameter Slide the grommet onto the cable The grommet must sit close in order to prevent water from entering the cabinet If necessary seal the junctions with silicone rubber Loosen position screws of the lead trough plate and lead the cables inside the cabinet Push the two halves of the lead through plate togeth er and tighten the screws The EMC conductive cush ions should press tightly around the bare screens 15 Connect the cable to terminals X10 U V W PE To locate the ter minals see dimensional drawings Appendix G in this manual 16 fshielded cables are used connect cable shielding to PE e g by us ing a pigtail see Figure 10 20 Figure 10 20 Auxiliary power cable connection 10 24 of 28 3BHS102769 ACS 1000 User s Manual Rev C Chapter 10 Installation Control Cable Connection Danger There can be dangerous voltages in the control cables from ex ternal circuits contact sense voltages etc even if the ACS 1000 mains power and auxiliary power are shut off Take appropriate measures when working with the unit i e deenergize any external device before you start work 17 Lead the control cables into the cabinet through
3. 6 18 of 22 3BHS102769 ACS 1000 User s Manual Rev C Chapter 6 Parameter Viewing and Editing Copying Parameters You can copy parameters from one drive to another by using the parame to Other Units ter upload and parameter download functions in the function mode Follow the procedure below 1 8 Select the correct options group 75 language and macro group 99 for each drive Set the rated values according to the name plate for each motor group 99 and perform the identification run for each motor if re quired Set the parameters in groups 10 to 97 as preferred in one ACS 1000 drive Upload the parameters from the ACS 1000 as described above Disconnect the panel and reconnect it to the next ACS 1000 unit Ensure that the target ACS 1000 is in local control L shown on the first row of the display If necessary switch to local control Download the parameters from the panel to the ACS 1000 unit as de scribed above Repeat steps 5 to 7 for all other units lt Note Parameters groups 75 99 concerning options language j macro and motor data are not copied The restriction prevents downloading of incorrect motor data group 99 In special cases it is also possible to upload and download groups 75 and 99 and the results of the motor identification run For more information please contact your local ABB representative Restoring Default 1 Settings Select the parameter
4. 690 limit until the reference is out of the crit 49 4 ical speed range The motor is acce lerted decelerated through the critical speed band according to the accelera 51 LowS1 pign S2 Low S2 High tion or deceleration ramp SADE 690547 113801360 Motor speed rpm Speed reference rpm 1 1 1 T T T T Critical speed areas are set with parameter group 34 Critical Speed For further details see Appendix K Signal and Parameter Table In some processes steady state operation at a critical shaft speed cannot be avoided Likewise solving the problem through mechanical redesign is usually an expensive and time consuming solution In such cases Reso nance Frequency Damping RFD may be used to minimize or eliminate the mechanical resonance The user can select whether RFD is enabled If selected the speed error is used as input to a resonance damping filter and the user must enter the filter parameter values Resonance Frequency the mechanical resonance frequency that needs to be eliminated Phase Shift the phase shift between the resonance frequency present and the cancellation signal generated typically somewhat less than 180 Proportional Gain the proportional gain which is used in generating the cancellation signal Resonance frequency damping is set with parameters 26 2 to 26 5 in group 26 Torque Reference Handling For further details see Appendix Signal and
5. Diode Protection Intermediate Three Level Output Squirrel Cage Rectifier IGCTs DC Link Inverter Sine Filter Induction Motor Each leg of the 3 phase inverter bridge consists of a combination of 2 IGCT s for 3 level switching operation with the IGCT s 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 3 2 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 3 2 of 30 3BHS102769 ACS 1000 User s Manual Rev C Chapter 3 Design and Functional Description Figure 3 2 Voltage and current waveforms at converter output ACS 1000 Output voltage 4 16kV Output frequency 60Hz The precharge resistors limit the current in the main DC link when the converter is energized They are bypassed with the protection IGCT s as soon the DC voltage reaches 79 The main function of these protection IGCT s is to open in case of a fault in order to prevent the rectifier to feed into the fault Common
6. Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy 2 3 amp Comments meaning of message amp 0 5 5 5 5 Tacho Supervision of tachometer Replace tachometer X Optional Possible causes If the fault cannot be eliminated Faulty tachometer call local ABB service organiza Tachometer not compatible with tion pulse encoder type TrafoTemp Transformer winding temperature Check transformer load and am X Optional or oil temperature too high bient temperature and compare Possible causes with rated figures make record Transformer load too high in logbook Refer to transformer Ambient temperature too high manual Transformer cooling disturbed Check if installation conditions Wiring in protection circuit dis are satisfactory exposure to turbed sun obstacles in air flow etc Shielding of control cables not Check cooling equipment Refer properly grounded to description of cooling circuit in transformer manual Check wiring of monitoring cir cuit input O L TEMP TRIP IOEC3 board Check if shielding of control ca bles is properly grounded If the fault cannot be eliminated call local ABB service organiza tion TrafoTemp Transformer winding temperature Check transformer load and am x x Optional or oil temperature too high bient temperature and compare Possible causes with rated figures make record Transformer load too high in logbook Refer to tran
7. service staff of ABB Industrie AG or authorized service representatives is usually part of the service contract parameter backup can be done by instructed users Drive Window soft ware is required Required Tools For maintenance tasks carried out by the owner the following tools and materials are necessary industrial vacuum cleaner with plastic tube and plastic tip compressed air oil free tool kit replacement parts Maintenance Instructions Standard Procedure n order to ensure maximum safety during maintenance activities proceed for Maintenance as follows 1 Safety measures Make sure to be familiar with and to observe all 7 4 of 12 3BHS102769 ACS 1000 User s Manual Rev C Chapter 7 Preventive Maintenance safety regulations as stated at the beginning of this chapter and in Chapter 1 Safety Instructions 2 De energize the system Danger Do not access the main power circuit nor the motor as long as the system is still energized or as long as it is not grounded After switching off the mains and after the motor has come to a stop al ways allow the intermediate circuit capacitors 5 minutes to discharge yel low indicator GND SWITCH UNLOCKED must be on before grounding and starting work on the frequency converter the transformer the motor or the cables The ACS 1000 and adjoining equipment must be properly grounded and the auxiliary supply voltage must be switched off prior to
8. ACS 1000 User s Manual Rev C 3BHS102769 10 17 of 28 Chapter 10 Installation Inserting Mains and Motor Cables Figure 10 13 Cable entries from top Power cable entries Aux power and control cable entries To locate the terminals see Figure 10 12 and drawing Power and Auxiliary Terminals see Appendix F Layout and Mechanical Drawings Connect the mains and motor cables for the ACS 1000 as described in the following section Ground the motor cable screen on the motor side as well Warning All electrical installation and maintenance work on the ACS 1000 must be carried out by qualified electricians in compliance with local regulations Any installation work must be done with mains and auxiliary power off In put and output isolators must be open and secured any adjoining ground ing device must be closed and power cables must be grounded Never apply power to the installation unless authorization is given by ABB commissioning staff For connecting the mains and motor cables to the ACS 1000 proceed as described below for installation instructions of motor transformer and other equipment please refer to the relevant manuals 1 Make sure that the ACS 1000 is disconnected from the mains and auxiliary supply network during installation main circuit breaker MCB must be open and in ser vice position i e disconnected from mains and grounded Motor is disconnected from mains and grounded 1
9. Duty of maintenance The owner must ensure that the ACS 1000 is used only under proper conditions and in a fully serviceable state Operating environment The owner must guarantee that all ambient conditions specified in Ap pendix A Technical Data are fulfilled Warning All electrical installation and maintenance work on the ACS 1000 must be carried out by qualified electricians Danger Never work on a powered ACS 1000 The main circuit breaker and the input isolators must always be opened and locked in po sition Do not access the main power circuit nor the motor as long as the system is not grounded When switching off the mains always allow the intermediate circuit capac itors to discharge before grounding and starting work on the frequency converter the motor or the motor cable The ACS 1000 and adjoining equipment must be properly grounded and the auxiliary supply voltage must be switched off prior to starting with any work Danger Some loads may apply a mechanical torque on the motor shaft If the motor can rotate due to such a load always disconnect short circuit or mechanically block the motor before you start work 1 4 of 6 3BHS102769 ACS 1000 User s Manual Rev C Chapter 1 Safety Instructions Danger There can be dangerous voltages inside the ACS 1000 from ex ternal control circuits measurement inputs from PT s etc even if the ACS 1000 mains power and auxilia
10. Inputs for external protection devices from transformer motor and pro cess control Although the ACS 1000 is safe if all interlocks and safety precautions are operating some residual danger areas remain if safety instructions are not observed 1 2 of 6 3BHS102769 ACS 1000 User s Manual Rev C Chapter 1 Safety Instructions The ACS 1000 is operating in a medium voltage environment usually consisting besides the converter of a power transformer a motor cabling the driven process and a superimposed control system The safety concept for the ACS 1000 takes into account the embedding of these components in the sense that no additional threat arises from their interaction with the ACS 1000 However the safety considerations for the individual external components and for the overall process are not part of the ACS 1000 safety concept Figure 1 1 Residual danger areas of the ACS 1000 Never remove rear cover when converter is energized or before grounding Even after pressing EMERGENCY STOP isolator is closed the converter will not be voltage free immediately Discharging will take about 5 minutes Do not attempt to close the grounding isolator by force or to open the converter doors earlier Control section Danger from auxiliary voltage when front door is open General Safety Regulations Keep air intake free from dirt Pd and obstacles Fan is coasting dow
11. 1Ut 1V1 7 cae 441 pe M l 1WA 7 N Cable lead through from top Cable lead through from below 11 Connect the shielding ends of all conductors to the grounding bar us ing pigtails 1 in Figure 10 18 12 Close the protective separation door and fasten it with the supplied screws M6 All 36 joints must be fixed 13 Fasten gland and blind plates with the supplied screws M6 joints must be fixed EN Note When closing the protective separation door and rearranging the j plates all provided screws must be mounted and tightened in order to maintain EMC performance Auxiliary Power Auxiliary power cable lead through is from below or from the roof of the Cable Connection control section Proceed as follows 14 Leadthe auxiliary power cables into the cabinet through the EMC slot of the gland plate that leads to the front area of the control section If shielded cables are used Strip cable insulation in the gland area The conductive cushions of the EMC slot should contact the stripped part of the cable See Figure 10 19 ACS 1000 User s Manual Rev C 3BHS102769 10 23 of 28 Chapter 10 Installation Figure 10 19 Auxiliary power cable lead in Base plate Side view Bottom view Lead through plate ZZ AN EMI conductive cushions gt SS Holes for position screws
12. Remote Control L in the first line of the display The motor is not stopping Local control mode can only be selected if it is not dis abled with appropriate parameter setting and if the digi tal input Disable local operation is not active The speed is not changing initial value for nref is the last actual speed but can now be changed by the CDP 312 control panel The motor is not stopping if the operational commands MCB on off Control and start stop of the remote system are correctly set The speed is changing to the actual reference value of the analog in put following the preset ramp Disabling Local f the parameter DISABLE LOCAL is set to 1 then a change from remote Operation from CDP control to local control via the LOC REM pushbutton on the CDP 312 312 Control Panel control panel on the converter front door is not possible anymore The converter has to remain in the remote control mode If the parameter DISABLE LOCAL OPERATION is set to 1 during local control the drive remains in local operation until remote control is selected via the LOC REM pushbutton on the CDP 312 control panel on the converter front door Table 5 1 Binary input Type Signal Name Terminal Type Remarks Standard DI DISABLE LOCAL IOEC 1 high Remote input to disable the e X12 5 6 active possibility for a local remote switch over from the
13. f the fault cannot be eliminated call local ABB service organiza tion TrOilLevel Transformer oil level low Check oil level and verify if a X Possible causes complete filling has been ac Incomplete filling complished Oil leaking Check oil gaskets cooler and Wiring in protection circuit dis tank for damages turbed Check wiring of monitoring cir Shielding of control cables not cuit input O L LEVEL ALARM properly grounded on IOEC3 board Check if shielding of control ca bles is properly grounded f the fault cannot be eliminated call local ABB service organiza tion Tripping Tripping loop supervision Check if a protection function X Loop Possible causes has initiated the trip Protection trip f not check external trip circuits Open contact in loop Ifthe fault cannot be eliminated Tripping loop not connected call local ABB service organiza tion Underload SW function Underload motor Verify underload curve parame X torque drops below underload ters 30 15 to 30 17 Refer to curve Appendix K Signal and Param Possible causes eter Table Underload curve parameters Check that normal load is not are not set correctly too low Motor load is too low for motor Verify that driven equipment is and converter ratings working properly Motor and converter ratings do Check whether motor and con not match verter ratings do match through out the speed range Ifthe fault cannot be el
14. 2 1 2 STRT STOP DIR STRT STOP DIR SELECTION IOEC 2 DI 9 MCB IS OPEN IOEC 2 DI 10 MCB IS CLOSED MCB IOEC 2 DI 11 CONTROL NOT SEL i LOCAL MCB IS AVAILABLI LOGIC MCB IOEC 2 DI 7 13 EXHI OPEN CLOSE COMM MODULE 4 REMOTE COMMAND Jae NOT SEL EXT2 IOEC 2 DI 7 13 COMM MODULE E 11 05 21 05 EXT1 EXT2 MCB ON MCB CONTROL MCB CONTROL CTRL MODE for further settings see Signal and Parameter Table 21 06 21 07 21 08 21 09 MCB MCB MCB MCB OPEN SIGNAL AVAILABLE CLOS TIME LIM OPEN TIME LIM 4 38 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 5 Operation Safety Instructions Introduction Conventions It is the owners responsibility to ensure that each person involved in the operation of the ACS 1000 has received the appropriate instructions and has thoroughly read and clearly understood the safety instructions in Chapter 1 Safety Instructions Danger Operation of this equipment may be dangerous if the safety in structions are not adhered to See Chapter 1 Safety Instructions Note The manufacturer declines all responsibility for possible damages caused by unauthorized personnel This chapter outlines the operation of the ACS 1000 when properly installed and commissioned All regular operation steps are described in detail Getting the ACS 1000 ready to start involves the following steps Preparatory procedures Clos
15. 4 IOEC2DI4 IOEC 1 SPEED 4 REF2 REMOTE LOOP 23 01 ma NOTSEL LOCAL SPEED REF CHO AMC BOARD see QR 12 01 ICOMM MODULE i 1 KEYPAD SPEED REF SEL CONTROLLER REF VALUE 2 i 3 09 TORQ REF 2 CTRL SIGNALS ANAL INPUTS IOEC 4 1 2 TORQUE CONTROL LOOP 26 01 TORQ SELECTOR DIG INPUTS 2 DI 1 6 DI 7 13 ACTUAL VALUE SEL 3 18 TORQ REF USED CONTROL PANEL START STOP DIRECTION COMM MODULE START STOP t DIRECTION _COMM MODULE NOTSEL IOEC 2 DI 713 COMMMODUELE 11 05 EXT2 MCB CONTROL for further settings see Signal and Parameter Table 11 04 EXT1 MCB CONTROL MCB OPEN COMMAND MCB CLOSE COMMAND NOT USED IOEC 2 DI 1 STOP ec REQUEST IOEC2 DI8 REMOTE FORWARD i REVERSE i DIRECTION i i O NOT SEL i i JoPo DIG i 11 03 16 01 DIRECTION PROCESS STOP IOEC2 DI3 i 5 11 01 11 02 12 02 EE PUSH EXT1 EXT2 EXT1 EXT2 1 1 BUTTONS STRT STOP DIR STRT STOP DIR SELECTION ON VU ACS 1000 LC lOEC2 DI9 IOEC 1 i DI 6 MCB Offline 5 OPEN D 7 MCB Online 42 IOEC2 DI 10 IS CLOSED MCB 42 2 0111 CONTROL NOT
16. For best EMC performance it is recommended to use three phase ca bles that are individually shielded and with steel armouring If single phase cables are used the cables with the three different phases must be grouped close together to ensure EMC performance Phase interchange must be accomplished according to local regula tions 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 5096 of the cross section of one phase an additional grounding wire must be laid along the power cables to avoid excessive heating losses in the cable shieldings Please refer to the local regulations for further details Cables must be terminated with connectors according to the cable manufacturer s requirements The maximum length of the transformer secondary cables is limited to 300 m 1000 ft For longer distances special design measures must be considered For the maximum length of the motor cables only the voltage drop in the cable must be taken into consideration Since the converter out put voltages and currents are nearly sinusoidal reflections which are typical for converters without output filter do not occur Routing of the grounding connection must comply with local regula tions In some countries redundant cable routing is required For grounding wire dimensions see also Equipment Grounding page 10 9 Co
17. is gt 2mA Check wiring and shielding of measuring circuit If the fault cannot be located call local ABB service organiza tion Water cooled con verters only WtrCon duct Cooling water conductivity is above alarm limit Check piping for fouling Check if all valves are in correct position Replace ion exchanger resin If the fault cannot be located call local ABB service organiza tion Water cooled con verters only WtrCon duct Cooling water conductivity is above trip limit Check piping for fouling Check if all valves are in correct position Replace ion exchanger resin If the fault cannot be located call local ABB service organiza tion Water cooled con verters only 8 32 of 38 3BHS102769 ACS 1000 User s Manual Rev C Table 8 1 Chapter 8 Trouble Shooting amp Repair Error messages and fault elimination Continued Message Possible cause meaning of message Suggested remedy uoijeoipul wely yney uedo go Comments WtrLevel Low Water level in expansion tank is low Possible causes Leakage in cooling water circuit Wiring in monitoring circuit dis turbed Shielding of cables not properly grounded Check cooling water level Check if all bleed drainage val ves are closed Check entire pipe system for leaks pump packings tube joints tubes etc If level is ok check wiring and shielding
18. Figure 5 1 Operating elements on front door grounding isolator CDP 312 control panel main circuit control buttons gnd switch unlocked indicator EMERGENCY OFF CLOSED 22 A 7 227 configuration of the mains circuit ACS 1000 User s Manual Rev C 3BHS102769 5 3 of 20 Chapter 5 Operation inputisolator is closed if applicable Output isolator is closed if applicable 8 Selectlocal or remote control mode by pressing the LOC REM key on the CDP 312 control panel Local control mode is indicated with a L in the first line of the display Local control mode can only be selected if it is not dis abled with appropriate parameter setting and if the digi tal input DISABLE LOCAL is not active For a detailed description of remote and local control please refer to the corresponding section in this chapter 9 If control mode is set to REMOTE check that remote control is ready Closing Main Circuit 10 Check that MCB is in operating position not drawn out or in test po Breaker sition 11 Check that ACS 1000 is ready No alarm or error message on CDP 312 control panel display No emergency off is active If there is still an alarm pending proceed as described in Chapter 8 Trouble Shooting amp Repair to eliminate the fault If the system is OK the CDP 312 control panel displays READY MCB ON 5 4 of 20
19. Techni cal Data If this is not the case call local ABB service organization Self Exci SW supervision detection of self Verify measured dc voltage Pa xX xX SW excitation voltage level rameters 2 02 to 2 09 Check whether mains supply voltage is within the tolerated limits See Appendix A Techni cal Data If this is not the case call local ABB service organization 8 28 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy 2 3 amp Comments meaning of message amp 0 5 5 5 5 Short Cir MI Supervision of di dt choke voltage Call local ABB service organiza Xx Possible causes tion short circuit in inverter minus pole Short Cir Supervision of di dt choke voltage Calllocal ABB service organiza PL Possible causes tion short circuit in inverter plus pole Short Cir undervoltage alarm and fault ap Check fault history buffer for cuit pear in a time window of 200us a other possibly related error short circuit in the rectifier has ap messages peared Call local ABB service organiza tion SpeedRef Speed reference signal lost Verify parameter settings of limit X x Default setting Los Possible causes parameters 13 23 minimum alarm and maintain Wrong parameter set
20. able when you call your ABB service representative 4 Try to eliminate the disturbance Note For your own safety follow exactly the instructions in Table 8 1 when identifying and correcting a disturbance and never attempt to do any repair work on the ACS 1000 beyond these instructions Before starting with trouble shooting you must read carefully the warnings stated at the begin ning of this chapter If the problem cannot be resolved always contact your ABB service representative Follow the instructions in Table 8 1 If you do not succeed with these suggestions do not try on your own Call immediately your local ABB service organization 5 Check that mains and motor connections are ok auxiliary power and control connections are ok no tools or other foreign objects are left in the cabinet All cabinet doors including protective shield and door of the control section are closed Note When closing the protective separation door all fastening screws must be mounted and tightened in order to maintain EMC performance 6 Switch on the auxiliary voltage close contactor Q1 and Q11 and Q12 in case of redundant fans Restart the converter as described in Chapter 5 Operation Reset error log clear the fault history as described in Chapter 8 Trouble Shooting amp Repair Fault Display on the CDP 312 Control 8 6 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 8 Trouble Shooting a
21. call local ABB service organiza tion ACS 1000 User s Manual Rev C 3BHS102769 8 15 of 38 Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy 2 3 amp Comments meaning of message amp 0 oP 5 5 5 FanDiffPres Alarm differential pressure su Check if doors are properly X Air cooled convert pervision in case of redundant closed ers only fans Check air filter and clean if nec Possible causes essary Fan defective If the fault cannot be eliminated Power supply for fan disturbed call local ABB service organiza tion Fil Cap Curr SW supervision Filter capacitor Check motor connections and x X overcurrent cabling Possible causes Check fault history buffer for defective capacitor other possibly related error short circuited motor messages Ifthe fault cannot be eliminated call local ABB service organiza tion Filt IDR Filter ID run is requested Carry out filter ID run x Reqst Ground SW function protection of con Check motor and motor cables X X depends on appli Fault verter equipment from ground fault Refer to motor manual cation in motor motor cable and inverter If the fault cannot be located call local ABB service organiza tion GUSP 1 Gate power supply Calllocal ABB service organiza xX tion GUSP 2 Gate power
22. gt 0 MCB open DO 2 6 IOEC 2 21 05 Command to close the MCB MCB ORD CLOSE X26 2 3 pulse gt 1 MCB close 4 22 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 4 I O Interfaces and Application Macros MOT TORQUE FILTERED X31 7 X32 7 Analog Inputs Outputs Terminal Parameter Remarks Al 2 1 IOEC 2 External reference ANALOG REFERENCE X31 2 X32 2 Al 4 1 IOEC 4 Process feedback ACTUAL VALUE X31 2 X32 2 Al 4 2 IOEC 4 Process feedback ACTUAL VALUE 31 3 32 3 AO 1 1 1 15 01 Motor frequency actual value MOTOR FREQUENCY X31 6 X32 6 4 20 mA AO 1 2 1 15 06 Motor torque actual value MOTOR TORQUE X31 7 X32 7 4 20 mA AO 2 1 IOEC 2 15 11 Motor speed actual value MOTOR SPEED X31 6 X32 6 4 20 mA AO 2 2 IOEC 2 15 16 Actual value of filtered motor torque 4 20 mA Control Signal Diagram The control signal diagram of the PID Macro in Figure 4 8 shows how the control signals i e reference value starting stopping commands MCB opening closing commands are interconnected in the application software of the ACS 1000 ACS 1000 User s Manual Rev C 3BHS102769 4 23 of 38 Chapter 4 I O Interfaces and Application Macros Figure 4 8 Control Signal Diagram of PID Control Macro ANAL INPUTS 12 06 12 03 33 33 01 EXT REF2 EXT REF1 CONSTANT CONST SPEED SELECTION SELECTION SPEEDS SELECTION
23. 3BHS102769 ACS 1000 User s Manual Rev C Chapter 5 Operation 12 Clear the fault buffer on CDP 312 control panel see section Active Fault Display page 5 17 No error message must be displayed E Charging the 13 Switch on the ACS 1000 Capacitor Bank In local control mode press the MAIN CIRCUIT ONLINE button on the control section door of the ACS 1000 remote control mode automatically via external binary input REM ORD ON LINE The CDP 312 control panel displays CHARGING The charging process lasts a few seconds ACS 1000 User s Manual Rev C 3BHS102769 5 5 of 20 Chapter 5 Operation 14 The unit is now ready The CDP 312 control panel displays READY TO START Entering Setpoint and Starting Up the ACS 1000 In Local Control Mode 15 To enter the setpoint press REF on the CDP 312 control panel 16 Input setpoint speed torque according to application macro require ments see Chapter 4 I O Interfaces and Application Macros by us ing the UP DOWN keys oo 44 The setpoint change will become active immediately 17 Press a MODE key to exit setpoint mode oo 18 Select the sense of rotation with the A or e key Warning Many processes do not permit to reverse the sense of rotation The sense of rotation can only be selected if not disabled by setting of pa ramete
24. All IOEC boards have a built in DC control voltage output which can be used for digital input signals Voltage 24 VDC 15 10 Max load current 180 mA If a higher load current is required the terminals of two boards have to be connected in parallel Terminals X13 9 24 VDC X13 10 0 V 4 2 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 4 I O Interfaces and Application Macros Potentiometer Supply There is a 10 VDC supply on each IOEC board The 10 VDC supply on IOEC 1 can be used for an external setpoint poten tiometer which is wired to Al 1 1 reference value 2 A potentiometer connected to Al 2 1 reference value 1 can be supplied by the 10 VDC output of IOEC 2 The 10 VDC supply is available at Terminals X31 1 10 VDC 32 1 0 Digital Output Home digital output is shown in its home position provided it is not inverted as Position _ illustrated in Figure 4 1 When signal HEADY is not active contact X21 1 2 is closed When signal READY is active contact X21 2 3 is closed Figure 4 1 Digital output home position example 2 DO 2 1 Terminal Signal Function X211 DO 2 1 Relay output 1 V x21 2 DO 21 DRIVE READY 59 X21 3 DO 2 1 External Connections The default I O configuration of IOEC 1 IOEC 2 IOEC and IOEC 4 be seen from the corresponding wiring diagrams in Appendix G Wiring Diagrams The wiring diagrams show the termi
25. Application Macros page 4 11 and Appendix K Signal and Parameter Table Table 3 2 Typical performance figures for torque control when Direct Torque Control is used ACS 1000 no Pulse Encoder ACS 1000 Torque Control with Pulse Encoder Linearity error 4 3 Repeatability error 3 1 Torque rise time lt 10 ms 10 ms When operated around zero frequency the error may be bigger Closing the main circuit breaker shall be possible exclusively from the converter This means that a closing request from customer side is forwarded to the ACS 1000 control software Then the actual closing command is released from the converter to the MCB Pre conditions for closing the main circuit breaker are no protection trip is active and noemergency off is active and the grounding isolator is open and the input isolator optional is closed and the output isolator optional is closed and MCB must be in operating position i e not in test position and MCB must have been open for at least 5 seconds and noalarm which causes start inhibit is active The signal from the converter to the main circuit breaker to close can be a continuous signal or a single pulse which is reset upon receiving the status feedback MCB CLOSED from the switchgear If this status feed back does not arrive after a preset time the close order is reset and a MCB trip is initiated Conditions for opening th
26. CDP 312 Control Panel Table 5 2 Binary outputs Type Signal Name Terminal Type Remarks Standard RO LOCAL MODE IOEC 3 high Local Mode Operation Status 22 1 3 active Indication set to 1 in local mode RO DRIVE READY 2 high Status Output Drive Ready e X24 1 3 active i e MCB closed DC link charged no lockout active 5 10 of 20 3BHS102769 ACS 1000 User s Manual Rev C Stopping the ACS 1000 In Local Control Mode In Remote Control Mode Chapter 5 Operation Several stop modes including ramp and coast functions can be used for normal operational stop The active stop mode is preset by adjusting the corresponding parameters One of the following stop mode is set with the parameters of group 21 START STOP MCB FUNCTION e RAMPING stop following a deceleration ramp with preset ramp time e COAST STOP torque is set to zero Please refer to Chapter 6 Parameter Viewing and Editing for further infor mation on how to set the stop mode and to display the active mode 1 Press the STOP key on the CDP 312 control panel The unit stops following the preset stop function The main circuit breaker remains closed After standstill the display shows Note You can always restart the unit by pressing the START key while the stopping sequence is still in progress Danger Do not access the main power circuit nor the motor after an operational stop The capaci
27. Hand auto 4 1 4 11 4 17 Master follower 4 1 4 11 4 34 PID control 4 1 4 11 4 22 Selection 6 11 6 13 Sequential control 4 1 4 11 4 30 Torque control 4 1 4 11 4 26 Assembly description 3 5 Automatic reset 3 27 B Battery replacement 7 11 Battery test 3 25 Cabinet design 3 5 Cable Connections 10 22 Wiring tests 10 28 Cable connection diagrams 10 10 Cable dimensions 10 8 Cable ducts 10 3 Cable routing 10 10 Cables 10 16 CDP 3123 1 Charging fault 3 24 Cleaning 7 7 Clearances 10 2 Commissioning 10 28 11 1 Acceptance 11 2 General procedure 11 2 Required customer manpower 11 2 Common mode choke 3 3 Common mode damping resistor 3 3 Communication fault 3 25 Constant speeds 3 14 Control equipment 3 1 3 9 Control functions 3 11 Control location 3 20 Control panel 3 1 3 10 8 3 B 1 Contrast 5 19 Display 5 1 keys B 4 Control system 3 4 Cooling circuit 3 8 Critical speed 3 14 D De energizing the ACS 1000 5 12 Device type B 3 Digital input 4 1 Digital output 3 19 4 1 Dimensioning of auxiliary power cable 10 9 Dimensioning of control cables 10 9 Dimensioning of power equipment 10 3 Cables 10 6 Protection Equipment 10 5 Direct torque control DTC 3 4 3 11 Direction B 3 Disabling local operation 5 10 Disassembly 9 9 Disposal 9 9 Door locks 3 8 DriveLink 3 28 DriveSupport 3 29 DriveWindow 3 28 DTC block diagram 3 4 E Electromagnetic compatibility EMC 3 5 Elementary diagram 3 2 Emergency
28. 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 Suitable for short acc dec times Motori S2 Suitable for medium acc dec times Linear S3 Suitable 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 1 125 2 t Acceleration and deceleration ramps are set with parameter group 22 Ramp Functions For further details see Appendix K Signal and Param eter Table 3 14 of 30 3BHS102769 ACS 1000 User s Manual Rev C Critical Speed Resonance Frequency Damping RFD Constant Speeds Chapter 3 Design and Functional Description 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 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 A
29. The cabinet can be entirely painted outside as an option EMC performance is further enhanced by the use of metal cable channels which are an integral part of the folded cabinet construction 3 6 of 30 3BHS102769 ACS 1000 User s Manual Rev C Chapter 3 Design and Functional Description Figure 3 4 The ACS 1000 Air cooled type _ HB LJ Rectifier Control section section Inverter section Cabinet Sections The ACS 1000 is designed with the inverter unit as one complete section including output filter capacitors and DC link capacitor This section located on the right hand side experiences maximum air flow which is advantageous for the temperature sensitive capacitors Construction allows easy exchange of IGCT s using a special tool The middle section houses the cooling fan the rectifier stack protection IGCT s and filter reactor The construction is such that the fan can be exchanged easily The third section on the left hand side includes control equipment and also provides space devoted exclusively to cable termination All control equipment with the exception of one card is located on the front of a swing frame The remaining I O card and any optional I O cards located behind and to the right of the swing frame Customer signal termi nals are al
30. The user can adjust the settings and perform the iden tification run for both motors and then save the data as two User Macros When the motor is changed only the corresponding User Macro needs to be loaded and the drive is ready to operate Warning 1 User macro load restores also the motor settings of the start up data group and the results of the motor ID run Check that the settings corre spond to the motor used 2 The user macro parameter changes are not saved when power is switched off The parameters revert to the last saved values when the power is switched on again Creating a User Macro Proceed as follows to create a user macro 1 Select the parameter mode by pressing the key The parameter mode display appears indicating the previously selected group and parameter when this mode is entered for the first time after power up the dis play will show the first parameter of the first group 2 Select parameter group 99 using the fast UP DOWN keys 3 Select parameter 99 2 APPLICATION MACRO using the slow UP DOWN keys ACS 1000 User s Manual Rev C 3BHS102769 6 21 of 22 Chapter 6 Parameter Viewing and Editing 4 Press ENTER 5 Select USER 1 SAVE or USER 2 SAVE using the slow UP DOWN keys 6 Press ENTER to save your selection Saving will take a few minutes 7 Toexitthe parame
31. close contactor Q1 and Q11 and Q12 in case of redundant fans 7 6 of 12 3BHS102769 ACS 1000 User s Manual Rev C Chapter 7 Preventive Maintenance Restart the converter as described in Chapter 5 Operation Make logbook entry Any maintenance activity must be recorded in the maintenance logbook including date and time maintenance task carried out according to mainte nance schedule any special situation or action scheduled or non scheduled replacement of parts etc Outside Cleaning Check air inlet and optional air filter for dirt clean with compressed air and if necessary replace air filter optional equipment refer to filter manual Inside Floor Cleaning Check of Connections 1 De energize the system according to Standard Procedure for Mainte nance page 7 4 After the grounding switch has been closed open the front doors Carefully clean compartment floors with the vacuum cleaner use plastic tip only to avoid damage to equipment Warning Apply special care while cleaning inside the cubicle especially do not damage the capacitor bushings In order to avoid damages do not clean any other equipment besides the floor Accomplish your maintenance job as described in Standard Proce dure for Maintenance page 7 4 De energize the system according to Standard Procedure for Mainte nance page 7 4 After the grounding switch has been closed open the front doors Check if all
32. cut along the diameter marking that corresponds to the cable diameter Slide the grom met onto the cable Figure 10 14 The grommet must sit close in order to prevent water from entering the cabinet If necessary seal the junctions with silicone rubber ACS 1000 User s Manual Rev C 3BHS102769 10 19 of 28 Chapter 10 Installation Figure 10 14Cable entry for power cables of ACS 1000 IP 20 and IP 22 Tighten the EMC sleeve on the stripped part of the cable with cable ties For IP 54 units add a rubber grommet on the ca ble J Rubber grommet Cable shielding end EMC sleeve Strip this part Mounting bracket of the cable Gland plate Base plate Cable shielding end EMC sleeve Strip this part N of the cable Cable entry from top Cable entry from below ACS 1000 User s Manual Rev C 10 20 of 28 3BHS102769 Chapter 10 Installation Figure 10 15 Cutting rubber grommets to size Grounding 7 Lead the grounding wire into the cabinet through an EMC sleeve of Connections the gland plate and fasten it to the grounding bar If there is no free gland available lead the grounding wire together with a phase con ductor into EMC sleeve Figure 10 16 Grounding wire and phase conductor combined one EMC sleeve Insulation Checks Carry out cable insulation test before connecting the cables 8 Checkinsulation of each cable with open ends when in final position and
33. meters of parameter group 99 parameter 99 12 For further details please refer to Chapter 6 Parameter Viewing and Editing Start Up Parameters page 6 7 Filter ID Run Filter ID run is used to verify output filter data It is carried out with decoupled motor Filter ID run is not required for normal operation its purpose is to facilitate trouble shooting in the output filter circuit Full Torque at Zero A motor fed by the ACS 1000 can develop short term motor nominal Speed torque at start up without any pulse encoder or tachogenerator feedback This feature is essential for constant torque applications However if long term operation at zero speed is required a pulse encoder has to be applied Enhanced Flying Start enhanced flying start function of the ACS 1000 is an improved version of the flying start and ramp start features normally found in frequency converters The ACS 1000 can detect the state of the motor within a very short time Hence rapid starting is possible under all conditions This feature allows easy starting of turbine pumps or windmill fans for example 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 motor and the drive can be improved by 1 10 depending on the load torque and speed Flux optimization is activated with parameter 27 01 Flux Control For further details see
34. see Appendix A Technical Data verter ratings Verify start up parameters 99 3 High supply voltage to 99 8 Compare with motor Incorrect motor data nameplate See Appendix K If fault occurs during accelera Parameter Description tion the acceleration time might Check if fault occurs only during be too short acceleration If this is the case Stray currents in motor cabling increase the acceleration time parameters 22 02 and 22 04 Check motor cable connections If the fault cannot be eliminated call local ABB service organiza tion ACS 1000 User s Manual Rev C 3BHS102769 8 17 of 38 Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause meaning of message Suggested remedy uoijeoipul wely yney uedo go Comments InvAirTemp Incoming cooling air above limit Check ambient temperature If ambient temperature is within limits call local ABB service or ganization Air cooled convert ers only InvAirTemp Supervision of ambient tempera ture Possible cause Ambient temperature too high Check ambient temperature If ambient temperature is within limits call local ABB service or ganization Air cooled convert ers only IOEC1Link Er Supervision of communication link Check connectors on IOEC1 AMC3 boards If the fault cannot be eliminated c
35. 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy 2 3 amp Comments meaning of message amp 0 28 78 5 5 MotHeater Alarm from converter internal con Check heater circuit resistance X Optional tactor supervision for the motor See manual for motor heater heater and Appendix G Wiring Dia Possible causes grams Fault in motor heater Check wiring and connections Wiring in monitoring circuit dis between relay and converter turbed Check relay input wiring Poor grounding connections Check cable shielding and grounding f the fault cannot be eliminated call local ABB service organiza tion Motor Stall SW function Motor stall sus Check whether actual load con X x Default setting Not tained low speed and high current ditions match motor and drive active Possible causes ratings load conditions do not match Check whether motor and con with motor and converter ratings verter ratings do match through Incorrect parameter settings out the speed range e g stall frequency limit too Check motor stall parameters high 30 02 to 30 04 Refer to Appen Motor load too high dix K Signal and Parameter Ta Disturbance in driven equipment ble Check load condition and verify that driven equipment is working properly f the fault cannot be eliminated call local ABB service organiza tion MotVibrat Alarm from external protection re Check
36. 38 Chapter 8 Trouble Shooting amp Repair 8 38 of 38 3BHS102769 ACS 1000 User s Manual Rev Chapter 9 Transportation Storage Disposal and Recycling Introduction In this chapter you will find all necessary information about proper trans portation and storage of the ACS 1000 converter unit and the spare parts as well as about disposal and recycling of materials ABB Industrie AG has determined basic requirements for transportation and storage in order not to reduce the reliability of the converter Environ mental requirements for transportation and storage are included in this chapter and must be observed For information about ambient conditions during transportation and storage refer also to Appendix A Technical Data Transportation and Storage page A 3 Environmental The packing transportation and storage conditions are defined on the Requirements basis of ABB HDST4 15 Classifications and the following norms Storage IEC 721 3 1 Code 1 5 121 125 1 1 1 62 151 1 1 Transportation 1 721 3 2 Code 2B1 2C2 281 Stationary Use 721 3 3 Code 3K4 3Z1 3Z7 3B1 3C2 3S1 3M1 For more information please contact your ABB representative Packing The converter is protected against external influences caused by either Sea air or road transportation The packing is designed to give an optimal protection against contamination by water or dust additionally for sea and air worthy packing aga
37. ACS 1000 User s Manual Rev C 3BHS102769 6 9 of 22 Chapter 6 Parameter Viewing and Editing Table 6 1 Group 99 start up parameters Continued Parameter Range Unit Description 3 MOTOR NOM 0 9000 V nominal voltage from motor VOLTAGE name plate 4 MOTOR NOM 0 Rated motor current CURRENT 5 MOTOR NOM 8 200Hz Nominal frequency from FREQ motor name plate 6 MOTOR NOM 1 18000 rpm Nominal speed from motor SPEED name plate 7 MOTOR NOM 0 9000 kW Nominal power from motor POWER name plate 8 MOTOR COS PHI 0 00 1 00 Nominal cos phi from motor name plate 9 MOTOR INSULA 1 5 Motor insulation class from TION CLASS motor name plate see Appendix K Signal and Parameter Table 10 MOTOR COOL 1 8 Type of motor cooling ING METHOD system see Appendix K Signal and Parameter Table 11 ALTITUDE A S L 0 5000 Operating altitude above sea level 12 MOTOR ID RUN NO STAN Selects the type of the DARD motor identification run REDUCED Do not set now 13 MOTOR CTRL DTC SCALAR Selects the motor control MODE mode 14 APPLIC NO YES Restores parameters to RESTORE factory setting values 15 DRIVE ID 0 32767 Drive identification number NUMBER Note Do not set parameter 99 12 MOTOR ID RUN resp make sure that this parameter is set to NO Specific instructions of how to use this parameter will follow later in this chapter see section Motor Identification R
38. C 3BHS102769 5 19 of 20 Chapter 5 Operation 5 20 of 20 3BHS102769 ACS 1000 User s Manual Rev C Chapter 6 Parameter Viewing and Editing Overview This chapter contains the necessary instructions for checking application parameters as they are programmed in the ACS 1000 When starting the ACS 1000 for the first time after a modification in the driven system or in the control circuit these application parameters should be checked and if necessary adapted Note Parameters and application macros are normally set during com 3 missioning of the process and should not need to be changed by the user afterwards except if a modification in the system configuration requires to do so The start up parameters form a special group of parameters that allow you to set up the basic ACS 1000 and motor information Start up parameters are normally set during commissioning of the driven motor and should not need to be changed afterwards Safety Instructions Itis the owners responsibility to ensure that only professionals with the appropriate education i e electrical engineers or equivalent are involved in the programming of the ACS 1000 parameter set and that each person has received the appropriate instructions and has thoroughly read and clearly understood the safety instructions in Chapter 1 Safety Instruc tions Warning Never change any parameters if you are not thoroughly familiar with the meaning of each pa
39. Local and Remote Control C0 CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO LOREM ELEC r Ea MU SEU ng ey C000 CO CO CO IO IO Local Control 3 19 Remote Control 3 19 Diagnostics 3 20 Actual Signal Monitoring 3 20 Fault History 3 20 Programmable Digital Outputs 3 20 Programmable Analog Outputs 3 20 Input Signal Source Selections and Signal Processing 3 21 Two Programmable Control Locations 3 21 Reference Signal Processing 3 21 Analog Input Processing 3 22 Offset Calibration 3 22 Standard Protection Functions 3 23 Programmable Fault Functions 3 23 Motor Winding Temperature 3 23 Motor Stall 3 23 Underload 3 24 Overspeed 3 24 Undervoltage 3 24 Preprogrammed Protection Functions 3 25 Motor Phase Loss 3 25 Short Circuit in the Rectifier Bridge 3 25 Charging Fault 3 25 Supply Phase Loss 3 25 Overcurrent 3 25 Loadability of the Inverter 3 25 Short Circuit of the Inverter 3 26 Ground Fault 3 26 2 of 10 3BHS102769 ACS 1000 User s Manual Rev C Operating System Measurement Loss Battery Test Communication Fault ID Run Fault Other Protection Functions External Motor Protection Trip External Transformer Protection Trip Process Stop External Emergency Off MCB Control Fault Other Features Limits Automatic Reset Supervision ACS 1000 Information Parameter Lock Built in PID Controller Resonance Frequency Damping RFD Customer Specific Options
40. Note all provided screws must be mounted and tightened in order to maintain EMC performance Wiring Tests 22 Carry out wiring check A functional test of the control circuits will be made during commis sioning 23 Close the control swing frame Final Work Warning Never apply power to the installation unless authorization is givn by ABB commissioning staff Preparation for See Chapter 11 Commissioning commissioning 10 28 of 28 3BHS102769 ACS 1000 User s Manual Rev C Chapter 11 Commissioning Overview Preparation of Commissioning General Preconditions High Voltage Equipment Auxiliary Voltage Supply and Control Cooling Circuit The ACS 1000 may only be commissioned by ABB staff or by their autho rized representative Functional testing commissioning and first parameter adjusting is carried out by the technicians of ABB Testing final parameter adjustment and performance tests are carried out by ABB staff with the customer present Check the following preconditions which must be fulfilled before commis sioning can be started 1 Installation of the ACS 1000 must be completed according to Chapter 10 Installation High voltage HV switchgear is connected and in operable condition Converter transformer is installed connected and ready for operation The motor is installed aligned connected and ready for operation Grounding cables of transformers converter and motor a
41. Parameter Table Once parameters have been entered operation of the resonance frequency damping function is automatic In the ACS 1000 it is possible to predefine up to 15 constant speeds Constant speeds are selected with digital inputs Constant speed activa tion overrides the external speed reference ACS 1000 User s Manual Rev C 3BHS102769 3 15 of 30 Chapter 3 Design and Functional Description Constant speed values are set with parameter group 33 Constant Speed If the sequential control application macro is used a standard set of parameter values is selected automatically For further details see Appendix K Signal and Parameter Table Speed Controller During the motor identification run the ACS 1000 speed controller is auto Tuning matically tuned However after the ID run it is possible to manually adjust the controller gain integration time and derivation action time if desired In the enhanced ID run the motor is driven through a series of movements and the speed controller is tuned based on the load and inertia of the motor and the machine Speed controller parameters are set with parameter group 24 speed control if the factory application macro is used a standard set of para meter values is selected automatically For further details see Chapter 4 Interfaces and Application Macros Application Macros page 4 11 and Appendix K Signal and Parameter Table Figure 3 10 Examples of speed respon
42. Refer to Appendix C Customer Specific Options for more details All other customer interface signals are the same for each application macro See also section Standard I O Boards 4 1 The Factory Macro is the default set macro It covers most of the common applications such as pumps fans conveyors and other industrial applications where constant speed is required The Speed Control Macro can be used for the same applications as the Factory Macro The only difference to the Factory Macro is that the motor control parameters of the ACS 1000 will not be overwritten and set to 0 when the macro is activated ACS 1000 User s Manual Rev C 3BHS102769 4 11 of 38 Chapter 4 I O Interfaces and Application Macros Hand Auto PID Control Torque Control Sequential Control Master Follower User 1 User 2 The Hand Auto Macro is suitable for applications where the speed has to be controlled automatically by a process automation system and manually by an external control panel The active control station is selected via a digital input The macro is also recommendable when two external control stations exist from where the reference value can be set and the drive can be started and stopped The active control station for the reference value is selected via a digital input The PID Macro is intended for the use with closed loop control systems such as pressure control level control and flow control For example B
43. SPEED CONTROL REF2 LOOP a e NOTSEL LOCAL spenner CHO i AMC BOARD eso 12 01 MEM KEYPAD SPEED REF SEL CONTROLLER REF V LUE i i REF2 3 09 CTRL SIGNALS TORQ REF2 DDCS LINK TORQUE CONTROL REF VALUE LOOP r i 26 01 CTRL SIGNALS SELECTOR DIG INPUTS IOEC 2 DI 1 6 i DI 7 13 313 TORQ REF USED CONTROL Y PANEL pe START DI 6 MCB Offline D 7 MCB Online IOEC 2 DI 10 MCB MCB IS CLOSED MCB OPEN COMMAND IOEC 2 DI 11 CONTROL MCB IS AVAILABLI LOGIC MCB CLOSE COMMAND f COMM MODULE NOT USED START STOP STOP EXT REQUEST 1 2 0187 nd S REMOTE FORWARD DIRECTION COMM MODULE EXT2 REVERSE DIRECTION CH NOT SEL OE e 11 08 16 01 i j CY r COMMMODUIE iem DIRECTION PROCESS STOP 1 1 e BUTTONS ON 494590022000 1 2 1 ACS 1000 IOEC2 DI9 JOEC 1 OPEN NOT SEL IOEC 2 DI 7 13 COMM MODULE NOT SEL EXT2 1OEC 2 DI 7 13 1 1 COMM MODULE bE 11 04 11 05 21 05 21 06 21 07 21 08 21 09 EXT1 EXT2 MCB ON MCB MCB MCB MCB MCB CONTROL MCB CONTROL CTRL OPEN SIGNAL AVAILABLE CLOS TIME LIM OPEN TIME LIM forfurther settings see Signal and Parameter Table 4 32 of 38 3BHS102769 ACS 1000 Use
44. User s Manual Rev C Chapter 4 I O Interfaces and Application Macros Table 4 4 O Signals Motor Continued Signal Terminals Remarks Stan Signal dard Inversion Al 3 2 wired to PT 100 External signal from a PT100 motor e possible BRG TEMP DE converter see bearing temperature sensor at the 1 Wiring Diagram driven end drive reaction is set in parameter group 35 Al 3 3 wired to PT 100 External signal from a PT100 motor e possible BRG TEMP NDE converter see bearing temperature sensor at the 1 Wiring Diagram non driven end drive reaction is set in parameter group 35 1 Standard only in water cooled ACS 1000 Table 4 5 I O Signals Process I O Signal Terminals Remarks Stan Signal dard Inversion DI 2 8 IOEC 2 External process stop signal or e not PROCESS STOP X12 5 6 run enable possible signal is active when low drive reaction is set in parameter group 21 DI 1 5 X300 External emergency off signal e not EMERGENCY x2 3 signal is active when low possible OFF wired to tripping loop in case of emergency off alarm is displayed main circuit breaker is tripped ACS 1000 User s Manual Rev C 3BHS102769 4 9 of 38 Chapter 4 I O Interfaces and Application Macros Table 4 6 I O Signals Others I O Signal Terminal Remarks Stan Signal dard Inversion DI 3 13 X300 External signal from a supply vo
45. and out put isolators must be open and secured any adjoining grounding device must be closed and power cables must be grounded Never apply power to the installation unless you have checked that mains and motor connections are ok auxiliary power and control connections are ok notools or other foreign objects are left in the cabinet All cabinet doors including protective shield and door of the control sec tion are closed Danger Never work on a powered ACS 1000 The main circuit breaker and the input isolators must always be opened and locked in po sition Do not access the main power circuit nor the motor as long as the system is not grounded When switching off the mains always allow the intermediate circuit capac itors to discharge before grounding and starting work on the frequency converter the motor or the motor cable The ACS 1000 and adjoining equipment must be properly grounded and the auxiliary supply voltage must be switched off prior to starting with any work Danger Some loads may apply a mechanical torque on the motor shaft If the motor can rotate due to such a load always disconnect short circuit or mechanically block the motor before you start work Danger There can be dangerous voltages inside the ACS 1000 from ex ternal control circuits measurement inputs from PT s etc even if the ACS 1000 mains power and auxiliary power are shut off Take appropriate measures
46. are given from the control panel To change to EXTERNAL press LOC REM key 0 50 096 I MotSpeed 1242 0 rpm Ext Controls Power 7 MotTorq 66 00 Speed ref Torque ref m MotTorq 66 00 96 CtrlLoc EXT2 The reference value is read from 2 1 if torque control is selected or AI 1 1 if speed control is selected Start stop and 3 direction commands are given through DI 2 1 and DI 2 2 Selec tion between speed and torque control is done through DI 2 3 Motor External Control Keypad Control EXT1 rpm Speed Control REF1 rpm Speed Control EXT2 Torque Control REF2 Torque Control ACS 1000 User s Manual Rev C 3BHS102769 4 25 of 38 Chapter 4 I O Interfaces and Application Macros Input and Output default I Os of the Torque Macro regarding opening closing the Signals starting stopping the drive speed control location reference and actual values are shown in the following table The corresponding parameters are listed as well For further settings refer to Appendix K Signal and Param eter Table Table 4 10 Torque Macro I O Signals Digital Inputs Outputs Terminal Parameter Remarks DI 2 1 IOEC 2 11 01 1 start START STOP X11 1 2 0 stop DI 2 2 IOEC 2 11 01 0 forward DIRECTION X11 3 4 1 reverse DI 2 3 IOEC 2 12 02 0 speed control EXT 1 2 SEL
47. as well For further settings refer to Appendix K Signal and Parameter Table Table 4 11 Sequential Macro Macro I O Signals Digital Inputs Outputs Terminal Parameter Remarks DI 2 1 IOEC 2 11 01 1 start START STOP X11 1 2 0 stop DI 2 2 IOEC 2 11 01 0 forward DIRECTION X11 3 4 1 reverse DI 2 3 IOEC 2 22 01 0 accel ramp 1 selected ACCEL DECEL 1 2 X11 5 6 1 accel ramp 2 selected SELECTION DI 2 4 IOEC 2 33 01 Selt Sel2 Sel3 Selection CONST SPEED SEL 1 X11 7 8 DI 2 5 IOEC 2 33 01 0 0 0 Analog Ref CONST SPEED SEL 2 X11 9 10 1 0 0 Const Speed 1 0 1 0 Const Speed 2 DI 2 6 IOEC 2 33 01 1 1 0 Const Speed CONST SPEED SEL3 X12 1 2 0 0 1 Const Speed 4 1 0 1 Const Speed 5 0 1 1 Const Speed 6 1 1 1 Const Speed 7 DI 1 8 X301 0 control panel is enabled DISABLE LOCAL X1 2 1 control panel is disabled DI 2 8 IOEC 2 16 01 Process stop or run enable PROCESS STOP X12 5 6 0 drive will not start or stop if run ning DI 2 7 2 11 04 pulse gt 1 command to close the REMOTE ORD MCB X12 3 4 main circuit breaker CLOSE DI 2 13 IOEC 2 11 04 pulse gt 1 command to open the REMOTE ORD MCB X13 5 6 main circuit breaker OPEN DI 2 9 IOEC 2 21 06 Feedback from MCB MCB IS OPEN X12 7 8 0 MCB is open 1 MCB is closed DO 2 5 IOEC 2 21 05 Command to open the MCB MCB ORD OPEN 26 2 3 pulse
48. be determined a trip is initiated In this case the entered data needs to be corrected and the identification run has to be repeated 3 26 of 30 3BHS102769 ACS 1000 User s Manual Rev C Chapter 3 Design and Functional Description Other Protection Functions External Motor f the customer uses an external motor protection relay it can be Protection Trip 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 motor protection is set with parameter group 35 External Motor protection For further details see Chapter 4 I O Interfaces and Applica tion Macros Standard Boards page 4 1 and Appendix K Signal and Parameter Table External Transformer f the customer uses an external transformer protection relay it can be Protection Trip 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 External transformer protection is set with parameter group 35 External Trafo Protection For further details see Chapter 4 I O Interfaces and Application Macros Standard I O Boards page 4 1 and Appendix Signal and Parameter Table Process Stop process stop button or relay can be connected to a pre defined input of the ACS 1000 The actual process stop input must be normally closed during normal ru
49. check that the results are within the specifications of the cable manufacturer ACS 1000 User s Manual Rev C 3BHS102769 10 21 of 28 Chapter 10 Installation Mains and Motor 9 Remove bus stubs from power terminals see Figure 10 17 Drill Cable Connections holes max M12 for accommodation of cable terminals according to your needs Terminal screw sizes are to be selected according to ca ble requirements Warning Do not drill inside the cabinet Make sure that dust and chips from drilling cannot enter the cabinet If necessary remove the bus stubs and drill the mounting holes outside the cabinet Electrically conducting dust may cause damage or lead to malfunction Figure 10 17 Power terminals with removable bus stubs 0 approx 60 mm x omm q 2 7 Removable Bus Stub 10 Using the bus stubs connect the phase conductors of the mains ca bles to the U1 V1 and W1 terminals and the phase conductors of the motor cable to the U2 V2 and W2 terminals See Figure 10 18 Refer to connector specifications for tightening torques 10 22 of 28 3BHS102769 ACS 1000 User s Manual Rev C Chapter 10 Installation Figure 10 18 Principle of power cable lead through ARB ABB ks S E 2U1 21 21 U2 U2 V2 V2 1U1
50. circuit disturbed shielding of control cables Shielding of control cables not If the fault cannot be located properly grounded call local ABB service organiza tion Pump 1 2 Trip pump contactor supervision Check contactor x x Water cooled con Possible cause Call local ABB service organiza verters only Pump defective tion Contactor disturbed Pump 1 2 Alarm pump contactor supervi Check contactor X Water cooled con sion in case of redundant pumps Call local ABB service organiza verters only Possible causes tion Pump defective Contactor disturbed Ride Ride through function has been Check if alarm may be caused X Through activated by a external event e g tempo Possible cause rary loss of supply voltage and Undervoltage detection record these conditions in the logbook If fault occurs repeatedly call lo cal ABB service organization Ride Ride through function has not Check if trip may be caused by a X Through been successful external event e g temporary Possible cause loss of supply voltage and Not sufficient energy record these conditions in the Time criteria exceeded logbook Restart the converter If fault occurs repeatedly call lo cal ABB service organization Self Exci HW supervision detection of self Verify measured dc voltage Pa xX xX HW excitation voltage level rameters 2 02 to 2 09 Check whether mains supply voltage is within the tolerated limits See Appendix A
51. coordination with the instrumentation and protection equipment Tolerate transformer inrush currents without tripping Clear transformer secondary short circuits within 100 ms Close in response to a close command ACS 1000 User s Manual Rev C 3BHS102769 10 3 of 28 Chapter 10 Installation Open within 60 ms in response to an open command signal active when high e Open within 60 ms in response to an trip command signal active when low Provide a status output which indicates MCB closed ure 10 3 Provide a status output which indicates MCB open Provide a status output which indicates MCB not available vacuum cir cuit breaker in test position or vacuum controller disconnect switch in open position A configuration example with vacuum circuit breaker is shown in Figure 10 2 and a configuration example with vacuum controller is shown in Fig Figure 10 2 Mains connection scheme with vacuum circuit breaker 10 4 of 28 vacuum circuit breaker s trip signals 524 o a 2 2 8 gt cic D 5515 5 5 21815 2 A residual amp co ol g overcurrent relay S 5 instantaneous AC time T Oj to e n 2 lag overcurrent relay S Solo x alalal d ao ACS 1000 y D 3BHS102769 ACS 1000 User s Manual Rev C Chapter 10 Installation Figure 10 3 Mains conne
52. critical speeds resonance frequency damping can be activated and tuned by setting the appropriate parameters To view or edit control parameters proceed as described in Verification and Modi fication of Parameters page 6 14 Additional information for determining correct parameter settings can be found in Chapter 3 Design and Functional Description and in the Engi neering Manual ACS 1000 User s Manual Rev C 3BHS102769 6 13 of 22 Chapter 6 Parameter Viewing and Editing Verification and Proceed as follows to verify or to change parameters Modification of Parameters 3 4 Before you start entering data determine the required parameter set tings for your application macro or other control features Refer to Chapter Design and Functional Description Chapter 4 I O Inter faces and Application Macros and to the Engineering Manual or to verify the application macro settings Refer to the parameter list in the appropriate application macro description All parameters that should be verified according to your application are marked with a gt Before you start entering data check each value and determine the correct settings A complete parameter list is provided in Appendix K Signal and Parameter Table where you can also find a detailed description of each parameter Select the parameter mode by pressing the key The parameter mode display appears indicating the previously selected grou
53. details see Chapter 4 I O Interfaces and Application Macros PID Macro page 4 21 and Appendix K Signal and Parameter Table Resonance Frequency Mechanical resonance frequencies within the system can be damped by Damping RFD means of an integrated algorithm of the control software If this function is enabled the control software produces a cancellation signal at the resonance frequency which minimizes or eliminates the mechanical resonance See also Hesonance Frequency Damping RFD page 3 15 Customer Specific Information on additional user specific options that are implemented in Options your ACS 1000 can be found in Appendix C Customer Specific Options PC Tools Drive Window Drive Window is an advanced yet easy to use tool for commissioning and control of your ACS 1000 Drive Window consists of several independent parts the User Interface the Target Drivers and the Communication Drivers With this component structure enhanced flexibility is achieved to enable working with several different types of products through different target and communication drivers The look and feel of the Drive Window program remains the same even when the product changes DriveLink DriveLink is the perfect tool for connecting the ACS 1000 with PC based monitoring systems such as Intouch and Genesis etc DriveLink is designed to serve as a dynamic data exchange DDE tool between the ACS 1000 User s Manual Rev C 3BHS102769 3 29 o
54. each drive Application macros are preprogrammed parameter sets that are specially adapted to a specific application Depending on the process one can select one of these macros thus enabling a quick and easy start up of the ACS 1000 With application macros the number of different parameters to be set during start up is minimized All parameters have factory set default values Leaving them unchanged a good system performance is obtained in typical situations One can either use these default values or they can be optimized individually according to your needs will be done by the ABB commissioning engineer For more infomation please refer to Chapter 4 Interfaces and Application Macros Input Output Boards page 4 1 and to the ACS 1000 Engineering Manual or ask your local ABB service organization As already mentioned good performance is achieved in an typical appli cation even if you leave the default settings unchanged However in order to optimize the ACS 1000 for your system configuration it is necessary to check whether the default settings match your requirements and to customize the settings where appropriate Initially this is done by the ABB commissioning engineer in cooperation with the owner Especially if options are added the corresponding parameters must be checked before start up A systematic guide for determining optimum parameter settings can be found in the Engineering Manual The flowchart shown in Figure
55. exit Remote setpoints are transmitted as 4 20 mA signals or via fieldbus from remote control Select the sense of rotation with the or e key Warning Many processes do not permit to reverse the sense of rotation The sense of rotation can only be selected if not disabled by setting of pa rameter 11 3 Make sure that the parameter 11 3 DIRECTION is correctly set according to the process requirements see Chapter 6 Parameter Viewing and Editing and Appendix K Signal and Parameter Table o0 If the motor is running the speed will automatically ramp to zero and the motor will reverse its sense of rotation and resume preset speed On the display the sense of rotation will be indicated with an arrow Ifthe motor is running the arrow indicates the actual 5 8 of 20 3BHS102769 ACS 1000 User s Manual Rev C In Remote Control Mode Local Remote Selection Local Control Remote Control Changing Control Mode during Operation Chapter 5 Operation sense of rotation Therefore the indication will only reverse after the motor has reached zero speed Incase of stand still the arrow indicates the prese lected sense of rotation Remote change of sense of rotation is initiated automatically via re mote control inputs see Chapter 4 Interfaces and Application Macros Input Output Boards page 4 1 Switching between local and remote contro
56. further details see Engineering Manual and Appendix K Signal and Parameter Table Automatic Heset ACS 1000 can automatically reset itself after an undervoltage A user selectable parameter determines whether this feature is implemented When the feature is activated fault reset occurs within a few milliseconds after the fault is cleared The fault has no effect on the drive or process operation however it is annunciated as a fault on the drive s panel Automatic reset can be used in case of DC undervoltage detection A reset counter tracks the number of automatic resets that occur within a set time window If an excessive number of automatic resets occur within this time window a system fault trip is initiated and drive operation ceases Automatic reset is selected with parameter group 31 Automatic Reset For further details see Appendix K Signal and Parameter Table Supervision Programmable supervision is a unique feature of the ACS 1000 which allows the drive to monitor certain user selectable signals A trigger level can be defined for each signal For example the user may set two speed limits one current limit two torque limits two reference limits and two actual value limits The digital status of the active limit appears on the control panel display and can also be supervised through relay outputs Supervision parameters are set with parameter group 32 Supervision For further details see Appendix K Signal and P
57. location reference and actual values are shown in the following table The corresponding para meters are listed as well For further settings refer to Appendix K Signal and Parameter Table Table 4 9 PID Macro I O Signals Digital Inputs Outputs Terminal Parameter Remarks DI 2 1 IOEC 2 11 01 1 start START STOP X11 1 2 0 stop DI 2 2 IOEC 2 11 01 0 forward DIRECTION X11 3 4 1 reverse DI 2 3 IOEC 2 12 02 Selection of external reference EXT 1 2 SELECTION X11 5 6 0 EXT1 1 EXT2 DI 2 4 IOEC 2 22 01 0 accel decel ramp 1 selected ACCEL DECELERATION X11 7 8 1 accel decel ramp 2 selected RAMP 1 2 DI 2 5 IOEC 2 33 01 Sel Sel2 Selection CONST SPEED SEL 1 X11 9 10 DI 2 6 IOEC 2 33 01 0 0 Analog Ref CONST SPEED SEL 2 X12 1 2 1 0 Const Speed 1 0 1 Const Speed 2 1 1 Const Speed 3 DI 1 8 X301 0 control panel is enabled DISABLE LOCAL X1 2 1 control panel is disabled DI 2 8 IOEC 2 16 01 Process stop or run enable PROCESS STOP X12 5 6 0 drive will not start or stop if running DI 2 7 IOEC 2 11 04 pulse 1 command for clos REMOTE ORD MCB X12 3 4 ing the main circuit breaker CLOSE DI 2 13 IOEC 2 11 04 pulse 1 command for open REMOTE ORD MCB X13 5 6 ing the main circuit breaker OPEN DI 2 9 IOEC 2 21 06 Feedback from MCB MCB IS OPEN X12 7 8 0 MCB is open 1 MCB is closed DO 2 5 IOEC 2 21 05 Command to open the MCB MCB ORD OPEN X25 2 3 pulse
58. mode by pressing the PAR key The parameter mode display appears indicating the previously selected group and parameter when this mode is entered for the first time after power up the dis play will show the first parameter of the first group ACS 1000 User s Manual Rev C 3BHS102769 6 19 of 22 Chapter 6 Parameter Viewing and Editing User Macros 2 Select parameter group 99 using the fast UP DOWN keys 3 Select parameter 99 11 APPLIC RESTORE using the slow UP DOWN keys 4 Press ENTER 5 Select YES using the slow UP DOWN keys 6 Press ENTER to save the selection The default settings for the active application macro are restored 9 In addition to the standard application macros it is possible to create two user macros The user macro allows the user to save the parameter settings including group 99 the results of the motor identification run and the control location selection local or external into the Flash PROM of the ACS 1000 and recall the data at a later time Example User macros make it possible to switch the ACS 1000 between 6 20 of 22 3BHS102769 ACS 1000 User s Manual Rev C Chapter 6 Parameter Viewing and Editing two motors e g main and replacement motor without having to adjust the motor parameters and to repeat the identification run every time the motor is changed
59. mode currents from the inverter are limited with the common mode choke and damped with the common mode damping resistor Due to its special construction the common mode choke provides full reac tance for the common mode currents flowing through transformer secondary cabling DC link output filter and internal grounding bus of the converter For the main DC current on the other hand the choke forms practically no reactance thus enabling the main current to pass unhin dered di dt chokes not shown in Figure 3 1 are used in the inverter to protect the inverter s free wheeling diodes from excessive rates of current drop during commutation Power Circuit Interface Input Circuit standard version of the ACS 1000 is equipped with a 12 pulse diode rectifier input see Figure 3 1 This is adequate for most supplying networks and normally the harmonic requirements as demanded by stan dards such as IEEE 519 can be met For operation in particularly sensitive networks the ACS 1000 can option ally be equipped with a 24 pulse rectifier Output Circuit 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 results
60. off 3 26 5 14 Equipment grounding 10 9 Error messages 8 8 ACS 1000 User s Manual Rev C 3BHS102769 Index 1 of 4 F Factory Macro external connections 4 10 4 15 4 20 4 24 4 28 4 32 4 36 Factory macro Operation diagram 4 13 Fan bearings replacement 7 10 Fan replacement 7 8 Fault display 8 3 Fault elimination 8 8 Fault functions 3 22 Fault handling 8 2 Fault history 3 19 5 18 8 4 clearing B 7 displaying B 7 Faults displaying B 8 resetting B 8 Filter ID run 3 12 Floor levelling 10 3 Flux optimization 3 12 Flying start 3 12 Functional Description 3 1 Functional description 3 2 G Ground fault 3 25 Grounding 10 9 Grounding connections 10 21 Grounding isolator 5 3 5 12 10 16 Grounding switch lock override 10 16 H Hand auto macro operation diagram 4 17 4 22 Humidity 9 7 I O boards 4 1 ID number B 3 ID run fault 3 25 Information 3 27 Input signal source selections 3 20 Installation 10 1 Ambient Conditions 10 2 Base dimensions and clearances 10 2 Electrical 10 16 Foundation 10 2 Mechanical 10 12 Required tools and parts 10 12 Safety 10 1 Insulation check 10 21 Intended purpose of use 1 3 Intermediate DC link voltage 3 24 Inverter Loadability 3 24 Short circuit 3 25 L Layout 3 5 Lifting arrangements 3 8 Limits 3 26 Local B 3 Local control 3 18 5 9 Main circuit breaker closing 5 4 Main circuit breaker MCB 3 17 3 26 10 3 Maintenance 7 1 Check of connections 7 7 Log
61. page 7 4 2 Afterthe grounding switch has been closed open the front door of the rectifier section 7 8 of 12 3BHS102769 ACS 1000 User s Manual Rev C Chapter 7 Preventive Maintenance 3 Unplug the supply cable 1 of the fan 4 Loosen and remove the 2 bolts 2 located to the left and right side using a 13mm wrench Warning The total weight of the fan is 100 kg 220 Ib 5 Withdraw the fan by sliding it carefully towards the front Consider the weight of 100 kg and use sufficient manpower when lifting the unit Support with a forklift if possible ACS 1000 User s Manual Rev C 3BHS102769 7 9 of 12 Chapter 7 Preventive Maintenance 6 Remove the 4 sliding blocks 3 and mount them on the replacement fan The guiding grooves must be oriented towards the back side 4 of the housing cable and nameplate are on the front side Lift the fan and slide it back onto the guiding rails Press the housing towards the gasket on the right hand side 5 in sert and tighten the 2 bolts 9 Accomplish your maintenance job as described in Standard Proce dure for Maintenance page 7 4 Check if the fan works properly when re energizing the system Replacement of Fan to follow later Bearings 7 10 of 12 3BHS102769 ACS 1000 User s Manual Rev C Chapter 7 Preventive Maintenance Replacement of 1 Open c
62. pallet Polyethylene sheet Plywood Ethylene Silicagel Disassembly and Before starting the disassembly of the ACS 1000 the unit must be de Disposal of energized and grounded according to Chapter 5 Operation De ener Equipment gizing the ACS 1000 page 5 12 The same safety precautions as described Chapter 8 Trouble Shooting amp Repair Safety Instructions page 8 1 apply None of the materials used in the ACS 1000 give rise to a special threat to the environment when disposed of correctly However special attention must be paid to the following equipment when disposed of or recycled Battery Capacitors Printed circuit boards Electronic components Proceed according to local legislation and prescriptions ACS 1000 User s Manual Rev C 3BHS102769 9 9 of 10 Chapter 9 Transportation Storage Disposal and Recycling 9 10 of 10 3BHS102769 ACS 1000 User s Manual Rev Transportation Damage Description Form ACS 1000 Company EN lec aT PT Customer s Address 00 00 0 0 resi tre irse rrse trs Reporting person Name Phone Fax Damage of packing visible oon oue orn eg oat ee uto dd ita eee t Brief description of damage at the equipment Bru P Customer s Signature Date Transport Company s Please return this form
63. should be consistent with 125 of the rat ed current of the ACS 1000 being supplied allows for harmonic content 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 industry practice for medium voltage equipment Cables must be terminated with connectors according to the cable manufacturer s requirements If required by local electrical code an equipment safety ground wire should be supplied either separately or by including it in the 3 conductor cable The ampacity of this conductor should be in accordance with the code Motor Cable There are no special requirements to be considered for the cable from the ACS 1000 to the motor It can be of any length provided that voltage drop is taken into consideration A voltage rating consistent with the voltage present in the motor circuit 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 as input to the ACS 1000 Derat ing 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 industry practice fo
64. this chapter and in Chapter 1 Safety Instructions 2 Check error log in control panel record the actual fault and the fault history as described in Fault Display on the CDP 312 Control Panel Do not clear the fault history buffer now 3 Analyze fault situation and make logbook entry Danger Never work on a powered ACS 1000 The main circuit breaker and the input isolators must always be opened and locked in po sition Do not access the main power circuit nor the motor as long as the system is not grounded When switching off the mains always allow the intermediate circuit capac itors to discharge before grounding and starting work on the frequency converter the motor or the motor cable The ACS 1000 and adjoining equipment must be properly grounded ACS 1000 User s Manual Rev C 3BHS102769 8 5 of 38 Chapter 8 Trouble Shooting amp Repair and the auxiliary supply voltage must be switched off prior to starting with any work Refer to Table 8 1 for explanation of the error messages In the table you will also find suggestions for fault remedy Any occurring alarm and fault must be recorded in the logbook including date and time of occurrence load conditions normal overload or minimum load continuous or intermittent load etc any other special situation or operating condition ambient temperature etc It is essential for an efficient fault analysis to have all these data avail
65. trough plate and lead the cables inside the cabinet Push the two halves of the lead through plate togeth er and tighten the screws The EMC conductive cush ions should press tightly around the bare screens 18 Mark each conductor with stick on tags for easy identification 19 Connect the cables to signal terminals X300 X301 and to the IOEC boards see Figure 10 22 They are located to the right hand side of the swing frame To locate the terminals see dimensional drawings Appendix G in this manual Note Control cable shields must be terminated on the ACS 1000 end only 10 26 of 28 3BHS102769 ACS 1000 User s Manual Rev C Chapter 10 Installation Figure 10 22 Control section view shows the swing frame removed The boards signal terminals and auxiliary terminals can also be seen The door covering power terminals in the rear section of the cubicle is closed ABB Customer VO Board IOEC 2 Aux Power Terminals X10 Signal Terminals X300 X 301 Access Door to Power Terminals Board IOEC 3 optional Board IOEC 4 optional ACS 1000 User s Manual Rev C 3BHS102769 10 27 of 28 Chapter 10 Installation 20 Connect the cables to the external control terminals 21 Check that the protective separation door as well as the gland and blind plates are fastened with the supplied screws M6 All joints must be fixed
66. value of motor speed AO is programmable AO 2 2 IOEC 2 Default setting e possible MOT TORQUE FILTERED X31 7 X32 7 Actual value of filtered motor torque AO is programmable 1 Standard only in water cooled ACS 1000 Table 4 2 I O Signals Main Circuit Breaker Signal Terminals Remarks Stan Signal dard Inversion DI 2 10 IOEC 2 Digital input indicating the main cir e not MCB IS CLOSED X12 9 10 cuit breaker is closed possible DI 2 9 2 Digial input indicating the main cir e not MCB IS OPEN X12 7 8 cuit breaker is open possible DI 2 11 2 Digital input indicating the main cir e possible MCB IS AVAILABLE 13 1 2 cuit breaker is not faulty drawn out or in test position DO 2 6 IOEC 2 Digital output to close the main cir e see par MCB ORD CLOSE X26 1 3 cuit breaker 21 05 pulse or maintained signal DO 2 5 IOEC 2 Digital output to open the main cir e see par MCB ORD OPEN X25 1 3 cuit breaker 21 05 pulse or maintained signal DO 1 6 X300 Digital output wired to tripping loop e not MCB ORD TRIP X12 trips the main circuit breaker when possible low 4 6 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 4 I O Interfaces and Application Macros Table 4 3 I O Signals Transformer TRAFO I O Signal Terminals Remarks Stan Signal dard Inversion DI 1 13 X300 External signal from a transformer e not EXT TRAFO PROT TRIP X4 5 protection d
67. when working with the unit i e deenergize and disconnect all such external devices auxiliary supply heaters coolers l O interfaces before you start work Prior to start working on the ACS 1000 the general safety regulations in Chapter 1 Safety Instructions must be read and understood ABB Industrie AG declines all liability for any possible damage resulting from failure or negligence to observe these warnings 7 2 of 12 3BHS102769 ACS 1000 User s Manual Rev C Maintenance Schedule Chapter 7 Preventive Maintenance Warning Do not attempt any maintenance work parts replacement or other actions on the ACS 1000 to which you are not entitled by this main tenance schedule If you have any doubts always contact your local ABB service represen tative for more information Maintenance task To be carried out Frequency Comments by Cubicle cleaning owner according to visual check cleaning if outside and floor need necessary inside atleast yearly Cubicle cleaning ABB ser yearly visual check cleaning if inside vice necessary Check of connec owner after 1 year tighten main cable con tions external then every 4 nections and terminal power and control years block connections if nec cable terminations essary Check of internal ABB ser after 1 year connections vice then every 4 years General functional ABB ser yearly According t
68. wiring Check cable shielding and grounding If the fault cannot be eliminated call local ABB service organiza tion ExtTrafProt Trip signal from external trans Inspect transformer according to X former protection the instructions in the external Possible causes protection device and transform Transformer fault er manuals Wiring in protection circuit dis Check wiring of external protec turbed tion circuit input EXT TRAFO Shielding of control cables not PROT TRIP on IOEC1 board properly grounded Check if shielding of control ca bles is properly grounded If the fault cannot be eliminated call local ABB service organiza tion 8 14 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy 2 3 amp Comments meaning of message amp 0 5 5 5 5 ExtWtrCool Alarm from external motor water Check motor temperature X Optional cooling equipment Check cooling equipment Refer Possible causes to manuals for motor and cool Fault in external motor cooling ing circuit Check with logbook if alarm oc Wiring in monitoring circuit dis curs repeatedly and record turbed alarm conditions Poor grounding connections Check wiring and connections between relay and converter Check relay input wiring Check cable shieldin
69. 0 18 of 28 3BHS102769 ACS 1000 User s Manual Rev C Chapter 10 Installation Auxiliary power supply fuse is open Any control equipment to be connected with the ACS 1000 is disconnected Open the cabinet door of the control section Open the control swing frame and the protective separation door be hind it All power terminals are now accessible 4 Totake measurement for conductor length strip the mains and motor cables and lead the conductors into the cabinet through the gland plate Warning Do not cut cables inside the cabinet Make sure that dust and chips from cable cutting and stripping cannot enter the cabinet Electrically conducting dust may cause damage or lead to malfunction 5 Markthe required conductor length and withdraw the cables Cut them to length strip conductor ends and mount connectors diameter of cable lug max M12 6 Leadthe conductors into the cabinet through the EMC sleeves of the gland plate as shown in Figure 10 14 and Figure 10 15 Strip cable insulation in the gland area Tighten the EMC sleeve on the stripped part of the cable with ca ble ties Remove the gland plate if cable entry is not possible otherwise and slide it onto the cable After the grounding connections are made fasten the gland plate P 54 Remove the rubber grommets from the gland plates and cut them to adequate diameter for the mains and the motor cable Figure 10 15 To ensure proper sealing
70. 13 IOEC 2 11 04 pulse 1 command for open REMOTE ORD MCB X13 5 6 ing the main circuit breaker OPEN DI 2 9 IOEC 2 21 06 Feedback from MCB MCB IS OPEN X12 7 8 0 MCB is open 1 MCB is closed DO 2 5 IOEC 2 21 05 Command to open the MCB MCB ORD OPEN X25 2 3 pulse gt 0 MCB is opened DO 2 6 IOEC 2 21 05 Command to close the MCB MCB ORD CLOSE X26 2 3 pulse gt 1 MCB is closed 4 14 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 4 I O Interfaces and Application Macros Analog Inputs Outputs Terminal Parameter Remarks Al 2 1 IOEC 2 Remote speed reference if EXTERNAL SPEED REF X31 2 X32 2 Const Speed Sel 1 amp Const ERENCE 1 Speed Sel 2 are set to 0 AO 1 1 IOEC 1 15 01 Actual value of motor fre MOTOR FREQUENCY X31 6 X32 6 quency AO 1 2 IOEC 2 15 06 Actual value of motor torque MOTOR TORQUE X31 7 X32 7 AO 2 1 IOEC 2 15 11 Motor speed actual value MOTOR SPEED X31 6 X32 6 4 20 mA AO 2 2 IOEC 2 15 16 Actual value of filtered motor MOT TORQUE FILTERED X31 7 X32 7 torque 4 20 mA Control Signal Diagram The control signal diagram of the Factory Macro in Figure 4 4 shows how the control signals i e reference value starting stopping commands MCB opening closing commands are interconnected in the application software of the ACS 1000 ACS 1000 User s Manual Rev C 3BHS102769 4 15 of 38 Chapter 4 I O Interfaces and Applicati
71. 14 A3 1 800 250 5 00 1 50 2 63 1 95 1014 1 2 800 389 4 09 1 95 1 62 1 240 1014 W2 4 300 597 3 23 1 185 1 99 1 300 1014 W3 5 600 777 2 59 1 300 1 94 1 400 1013 A1 800 140 4 00 1 35 4 00 1 35 1013 A2 1 400 245 4 90 1 50 2 58 1 95 1013 A3 1 800 315 4 50 1 70 2 10 1 150 1013 1 2 800 490 3 27 1 150 1 63 1 300 1013 W2 4 300 752 2 51 1 300 1 57 2 240 1013 W3 5 600 980 3 27 2 150 1 22 2 400 1012 A1 800 201 5 74 1 35 2 87 1 70 1012 A2 1 400 351 3 70 1 95 1 90 1 185 1012 A3 1 800 452 3 77 1 120 1 13 1 400 1012 W1 2 800 703 2 93 1 240 1 46 2 240 1012 W2 4 300 1 079 3 60 2 150 1 35 2 400 Comments See following page 10 8 of 28 3BHS102769 ACS 1000 User s Manual Rev C Installation Conditions Equipment Grounding Auxiliary Power Cable Control Cables Chapter 10 Installation 1 Apparent power has been taken instead of active power in order to consider the worst case situation 2 Insulation rating of the chosen cables for the transformer secondary side is 5 kV or higher 3 Allchosen cables on the transformer secondary side are shielded armoured The bending radius has to be 10 to 15 times the diameter The load factor of the cables is 100 The value for the current density is the result of the actual current and the cable cross section Ideal Worst case arrangement side by side in the free air flow max temperature 30 max conductor temperature 70 installed in a cable duct un
72. 26 2 3 pulse gt 1 MCB close 4 18 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 4 I O Interfaces and Application Macros MOT TORQUE FILTERED X31 7 X32 7 Analog Inputs Outputs Terminal Parameter Remarks Al 2 1 IOEC 2 External reference 1 in rpm REFERENCE 1 X31 2 X32 2 HAND Al 1 1 X301 External reference 2 in 96 REFERENCE 2 4 AUTO AO 1 1 IOEC 1 15 01 Motor frequency actual value MOTOR FREQUENCY X31 6 X32 6 4 20 mA AO 1 2 IOEC 1 15 06 Motor torque actual value MOTOR TORQUE X31 7 X32 7 4 20 mA AO 2 1 IOEC 2 15 11 Motor speed actual value MOTOR SPEED X31 6 X32 6 4 20 mA AO 2 2 IOEC 2 15 16 Actual value of filtered motor torque 4 20 mA Control Signal Logic control signal diagram of the Hand Auto Macro in Figure 4 6 shows how the control signals i e reference value starting stopping commands MCB opening closing commands are interconnected in the application software of the ACS 1000 ACS 1000 User s Manual Rev C 3BHS102769 4 19 of 38 Chapter 4 I O Interfaces and Application Macros Figure 4 6 Control Signal Diagram of Hand Auto Macro 12 06 12 03 33 33 01 EXT REF2 EXT REF1 CONSTANT CONST SPEED SELECTION SELECTION SPEEDS SELECTION 2 D12 REF1 SPEED 2 SPEED CONTROL n LOOP 1 EXT2 NOT SEL
73. 5 C to 55 C 23 F to 131 F Relative air humidity 5 to 85 Pay attention to always fulfill the ambient conditions during the storage period according to Appendix A Technical Data Transportation and Storage page A 3 Notice Take the following measures if you want to store the converter unit for up to one year In case of a longer storage period please contact the ABB service organization 1 Place the converter on a wooden frame or pallet 2 Cover all cable inlets and ventilation slots with a wooden panel Put an impermeable plastic or aluminum foil between the wooden cover and the slots 3 Add the desiccant of the appropriate quality 1 unit desiccant 30g ab sorbs 6g water vapor According to the used packing material you need the following quantity PEsheet 10 units sqm foil Aluminum foil 8 units sqm foil 4 Close and lock the doors of the converter unit 9 6 of 10 3BHS102769 ACS 1000 User s Manual Rev C Periodical Inspections Battery Storage Instructions for Spare Parts Transportation Ambient Conditions Humidity Temperature Chapter 9 Transportation Storage Disposal and Recycling 5 Use the below listed polyethylene sheet or combined aluminum foil as protective packing and as a protection against moisture PE sheet 0 3g sqm 24h water vapor diffusion Aluminum foil 0 01g sqm 24h water vapor diffusion 6 Attach humidity indicators e g mechanical hygrometers
74. 6 1 gives an overview on the complete parameter input procedure as it is carried out during commissioning In the remaining part of this chapter you will find detailed instructions of how to proceed when viewing and editing individual parameters in the control system of the ACS 1000 6 2 of 22 3BHS102769 ACS 1000 User s Manual Rev C Chapter 6 Parameter Viewing and Editing Figure 6 1 Application parameter programming procedure START Input start up parameters Select application macro Step Check start stop ref ramp parameters groups 11 12 13 21 22 Input speed reference parameters group 23 amp other macro related parameters depends on selected macro Check and adjust fault function parameters group 30 depending on system needs Input real time clock data parameter group 98 Any options ACS 1000 User s Manual Rev C 3BHS102769 6 3 of 22 Chapter 6 Parameter Viewing and Editing Figure 6 1 Application parameter programming procedure continued If applicable Input motor winding temperature data parameter group 30 If applicable Input external motor protection data parameter group 35 Prerequisite IOEC 3 If applicable Input external transfor mer protection data parameter group 36 Prerequisite IOEC 3 If applicable Input external inverte
75. 7 Sense of rotation 5 8 Service address 7 12 Setpoint changing 5 7 entering 5 6 Short circuit Rectifier 3 24 Signals Main circuit breaker 4 3 Motor 4 4 Others 4 5 Process 4 5 Remote control interface 4 2 Transformer 4 3 Spare parts Handling 9 8 Speed Accurate speed control 3 16 Constant speeds 3 14 controller 3 15 response 3 15 Squirrel cage induction motors 3 1 Standards fulfilled 3 1 Start operation 5 2 Start up parameters 6 1 6 7 Status row B 3 Stopping the ACS 1000 5 11 Storage 9 6 Ambient conditions 9 7 Battery 9 7 Periodical Inspections 9 7 Spare parts 9 7 Supervision 3 27 T Technical data 3 1 Temporary shut down 9 9 Torque Accurate torque control 3 16 Full torque at zero speed 3 12 ACS 1000 User s Manual Rev C 3BHS102769 Index 3 of 4 Training of personnel 1 4 Transformer protection 3 26 Transportation 9 1 Damages 9 6 Displacement to installation site 10 13 Environmental requirements 9 1 Lifting Angle 9 4 Loading 9 3 Unloading 9 3 Warning and instruction labels 9 2 Trouble shooting Safety 8 1 Standard procedure 8 5 U Underload 3 22 Undervoltage 3 12 3 23 Unpacking 9 4 User Macro 6 20 User macros 6 20 Warranty 11 2 Wiring tests 10 28 Index 4 of 4 3BHS102769 ACS 1000 User s Manual Rev C
76. AMC BOARD 12 01 i COMM MODULE KEYPAD SPEED REF SEL CONTROLLER REF VALUE gt CTRL SIGNALS CH2 DDCS LINK REF VALUE CTRL SIGNALS DIG INPUTS 2 DI 1 6 DI 7 13 CONTROL PANEL REF2 REF2 0 e REF1 rpm 3 09 TORQ REF 2 TORQUE CONTROL REMOTE LOOP LOCAL 3 13 TORQ REF USED 26 01 TORQ SELECTOR CH2 DDCS LINK TO FOLLOWER 1 1 1 1 1 1 1 1 1 1 1 1 1 i 4 T 1 START STOP DIRECTION NOT SEL i COMM MODULE IOEC 2 DI 1 2 LOCAL NOT USED START STOP EXT REQUEST IOEC2 DI8 FORWARD DIRECTION i EXTA REVERSE NOT SEL i EO ise i i 11 03 16 01 r COMMMODUI 00 DIRECTION PROCESS STOP PUSH EXT EXT2 BUTTONS SELECTION ON ff ACS 1000 IOEC2 DI9 IOEC 1 DI 6 MCB Offline MCB IS OPEN DI7 MCB Online i IOEC 2 DI 10 gt i MCB IS CLOSED MCB 2 111 CONTROL NOT SEL i LOCAL MCB IS AVAILABL LOGIC IOEC 2 DI 7 13 OPEN CLOSE COMM MODULE REMOTE COMMAND NOTSEL EXT2 Rub wd IOEC 2 DI 7 13 COMM MODULE 11 04 11 05 21 05 21 06 21 07 21 08 21 09 EXT1 EXT2 MCB ON MCB MCB MCB MCB MCB CONTROL MCB CONTROL CTRL OPEN SIG
77. After passing the fan the air is blown through the rectifier diode stacks followed by the motor filter reactor The exhaust is located on top of the cabinet and provides a natural stack effect in order to direct the air flow after the fan The exhaust is covered in order to protect the equipment inside mechanically Control and The ACS 1000 can be controlled from several control locations wid from the detachable CDP 312 Control Panel mounted on the ACS 1000 front door of the control section from external control devices e g a supervisory control system that connect to the analog and digital I O terminals on the Standard I O Boards through Fieldbus adapter modules with PC Tools Drive Window and DriveLink connected via a PC adapt er to the ACS 1000 control board Optional analog and digital I O extension modules can be used to provide extended transformer and motor protection protection for external cooling equipment e g fans chillers on line synchronization logic and other customer requirements as needed 3 10 of 30 3BHS102769 ACS 1000 User s Manual Rev C CDP 312 Control Panel Control Panel Display Control Panel Keypad Chapter 3 Design and Functional Description Figure 3 8 CDP 312 control panel Enclosure class IP54 when attached to the Control Panel Mounting Plat form e Multilingual Alphanumeric Display 4 lines x 20 characters Plain text messages in 10 available la
78. Appendix K Signal and Parameter Table Power Loss Ride If the incoming supply voltage is cut off the ACS 1000 will continue to Through 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 ACS 1000 User s Manual Rev C 3BHS102769 3 13 of 30 Chapter 3 Design and Functional Description Acceleration and Deceleration Hamps Figure 3 9 Loss of supply voltage at nominal load fout 40 Hz fut 2 f j t s 1 6 4 8 8 11 2 14 4 Upc 1000 intermediate circuit voltage fut ACS 1000 output frequency Motor torque The intermediate circuit DC voltage drops to the minimum limit The controller keeps the voltage steady as long as the main power is absent The ACS 1000 runs the motor in generator mode The motor speed falls but the drive is fully ac tive as long as the motor has enough kinetic energy Power loss ride through is set with parameter group 39 Hide Through Function For further details see Appendix K Signal and Parameter Table 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
79. C2 DIA 1 IOEC 1 SPEED 4 SPEED CONTROL REF2 LOOP SPEED CONTROLLER 3 09 TORQ REF 2 23 01 SPEED REF TORQUE CONTROL LOOP 26 01 TORQ SELECTOR 3 13 TORQ REF USED COMM MODULE REQUEST FORWARD REVERSE IOEC2 DI 8 NOT USED START STOP DIRECTION IOEC 2 DI 10 MCB IS CLOSED 2 DI 11 IS AVAILABLI MCB CONTROL LOGIC 11 03 16 01 DIRECTION PROCESS STOP 2 DI 9 MCB IS OPEN OPEN COMMAND MCB CLOSE COMMAND NOTSEL IOEC 2 DI 7 13 1 Ec 1 o E oj 2 COMMMODULE C x 11 04 11 05 21 05 21 06 21 07 2108 21 09 1 2 MCB MCB MCB MCB MCB MCB CONTROL MCB CONTROL OPEN SIGNAL AVAILABLE CLOS TIME LIM OPEN TIME LIM for further settings see Signal and Parameter Table 4 28 of 38 3BHS102769 ACS 1000 User s Manual Rev C Sequential Control Macro Description Control Overview Input Power Ext Controls NNNM 3 otor External Control EXT1 rpm Speed Control EXT2 96 Speed Control Keypad Control REF1 rpm Speed Control REF2 Speed Control Chapter 4 I O Interfaces and Application Macros The macro offers seven preset constant speeds which can be activated by DI 2 4 DI 2 5 and DI 2 6 The pa
80. CLOSED MCB OPEN COMMAND IOEC 2 DI 11 CONTROL NOT SEL i LOCAL MCB IS AVAILABL LOGIC MCB IOEC 2 DI 7 13 EXT1 ICLOSE COMMAND COMM MODULE REMOTE NOTSEL EXT2 IOEC 2 DI 7 13 1 9 9 COMMMODULE 11 04 11 05 21 05 21 06 21 07 21 09 EXT2 MCB ON MCB MCB MCB MCB CONTROL MCB CONTROL CTRL MODE OPEN SIGNAL AVAILABLE CLOS TIME LIM OPEN TIME LIM for further settings see Signal and Parameter Table 4 16 of 38 3BHS102769 ACS 1000 User s Manual Rev C Hand Auto Macro Description Chapter 4 I O Interfaces and Application Macros Start stop commands and reference settings can be given from the control panel of the ACS 1000 or from one of two external control stations EXT1 Hand or EXT2 Auto see Figure 4 5 The LOC REM key on the control panel is used to enable the control panel or the external control stations The control panel can be disabled by closing DI 1 8 The digital input can be accessed via terminals X301 1 and X301 2 The remote control station EXT1 or EXT2 is selected with 2 5 The control signals of EXT1 Hand for starting and stopping are connected to DI 2 1 Open close commands for the MCB are wired to DI 2 13 and DI 2 7 The reference value is connected to Al 2 1 The speed reference value is given in rpm The commands from EXT 2 Auto for starting and stopping are connected to DI 2 2 and for opening closing the MCB to DI 2 3 and DI 2 4 The refer ence
81. Check motor ratings load and X sum of 3 signals Temp HW high cooling Possible causes Check torque and power limits excessive load parameters 20 04 and 20 05 ACS 1000 parameters not prop Check motor temperature su erly adjusted to motor data pervision parameters parame ters 13 21 to 13 35 If the fault cannot be eliminated call local ABB service organiza tion Mot Wdg Motor winding temperature calcu Check torque and power limits X Temp SW lation by control SW parameters 20 04 and 20 05 Possible causes Check motor temperature su excessive load pervision parameters If neces ACS 1000 parameters not sary readjust the parameters erly adjusted to motor data Parameters 30 01 30 02 and Operation at low speeds 30 08 to 30 11 For details refer to Appendix K Signal and Pa rameter Table Check if parameter settings al low operation at low speeds If motor is operated continuously atlow speeds additional cooling may be necessary Check motor ratings load and cooling f the fault cannot be eliminated call local ABB service organiza tion Mot Wdg Motor winding temperature calcu Check torque and power limits X Temp SW lation by control SW parameters 20 04 and 20 05 Possible causes Check motor temperature su excessive load pervision parameters If neces ACS 1000 parameters not sary readjust the parameters erly adjusted to motor data Parameters 30 01 30 02 and O
82. Control Overview 4 34 Input and Output Signals 4 35 Chapter 5 Operation Safety Instructions 5 1 Introduction 5 1 Conventions 5 1 Start Operation of the ACS 1000 5 2 Preparatory Procedures 5 2 Prerequisites 5 2 Preparatory Steps 5 3 Closing Main Circuit Breaker 5 4 Charging the Capacitor Bank 5 5 Entering Setpoint and Starting Up the ACS 1000 5 6 In Local Control Mode 5 6 4 of 10 3BHS102769 ACS 1000 User s Manual Rev C In Remote Control Mode 5 7 Changing Setpoints 5 7 In Local Control Mode 5 7 In Remote Control Mode 5 8 Reverse Sense of Rotation 5 8 In Local Control Mode 5 8 In Remote Control Mode 5 9 Local Remote Selection 5 9 Local Control 5 9 Remote Control 5 9 Changing Control Mode during Operation 5 9 Remote gt Local Control 5 10 Local gt Remote Control 5 10 Disabling Local Operation from CDP 312 Control Panel 5 10 Stopping the ACS 1000 5 11 In Local Control Mode 5 11 In Remote Control Mode 5 11 De energizing the ACS 1000 5 12 In Local Control Mode 5 12 In Remote Control Mode 5 14 Emergency Stop 5 14 Manual Initiation 5 14 Process Monitoring 5 14 Actual Signal Display 5 15 Full Signal Name Display 5 17 Active Fault Display 5 17 Fault History Display 5 18 Other Operational Actions 5 19 Panel and Display Functions 5 19 Chapter 6 Parameter Viewing and Editing Overview 6 1 Safety Instructions 6 1 ACS 1000 Application Parameters 6 1 Parameter Groups 6 1 Start up Parameters 6 2 Application Macr
83. ECTION X11 5 6 1 torque control DI 2 4 IOEC 2 22 01 0 accel decel ramp 1 selected ACCEL DECEL 1 2 X11 7 8 1 accel decel ramp 2 selected SELECTION DI 2 5 IOEC 2 33 01 If set to 1 the predefined con CONSTANT SPEED X11 9 10 stant speed reference is SELECTION selected DI 1 8 X301 0 control panel is enabled DISABLE LOCAL X1 2 1 control panel is disabled DI 2 8 IOEC 2 16 01 Process stop or run enable PROCESS STOP X12 5 6 0 drive will not start or stop if running DI 2 7 IOEC 2 11 04 pulse 1 command for clos REMOTE ORD MCB X12 3 4 ing the main circuit breaker CLOSE DI 2 13 IOEC 2 11 04 pulse 1 command for open REMOTE ORD MCB X13 5 6 ing the main circuit breaker OPEN DI 2 9 IOEC 2 21 06 Feedback from MCB MCB IS OPEN X12 7 8 0 MCB is open 1 MCB is closed DO 2 5 IOEC 2 21 05 Command to open the MCB MCB ORD OPEN X25 2 3 pulse gt 0 MCB open 1 DO 2 6 IOEC 2 21 05 Command to close the MCB MCB ORD CLOSE X26 2 3 pulse gt 1 MCB close 4 26 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 4 I O Interfaces and Application Macros Analog Inputs Outputs Terminal Parameter Remarks Al 1 1 IOEC 1 Speed reference EXT1 SPEED REFERENCE X31 2 X32 2 Al 2 1 IOEC 2 Torque reference EXT2 TORQUE REFERENCE X31 2 X32 2 AO 1 1 IOEC 1 15 01 Motor frequency actual value MOTOR FREQUENCY X31 6 X32 6 4 20 mA AO 1 2 1 15 06 Motor torque actual value MOTO
84. Interfaces and Application Macros Overview Terms and Abbreviations Input Output Boards Standard Boards In this chapter information on boards macro specific configura tions and application macros is given Typical applications for each macro are listed as well Information regarding other customer interfaces can be found in Chapter 10 Installation on connection of mains motor and auxiliary power and in case of a water cooled ACS 1000 on cooling water supply the Fieldbus Control Adapter Start up Manual on fieldbuses i e Mod bus Profibus the Synchronized Bypass Installation and Start Up Manual the Braking Chopper Installation and Start up Manual It is recommended to have the wiring diagrams at hand when reading this chapter see Appendix G Wiring Diagrams The following terms and abbreviations are used in this chapter Input Output DI Digital Input DO Digital Output Al Analog Input AO Analog Ouput MCB Main Circuit Breaker If a reference is made to an I O for instance DI 2 1 2 refers to the board in this case IOEC 2 and 41 refers to the 1st digital input of the same board The air cooled ACS 1000 is equipped with IOEC 1 and IOEC 2 as a stan dard and the water cooled ACS 1000 is fitted with IOEC 1 IOEC 2 and IOEC 3 as a standard Optionally IOEC 3 and or IOEC 4 can be added to the air cooled ACS 1000 and IOEC 4 to the water cooled ACS 1000 W
85. LOCAL A SPEED REF CHO i AMC BOARD 2 12 01 i COMM MODULE f KEYPAD i SPEED gt REF SEL CONTROLLER REF V LUE REF2 i REMOTE REF2 i KEYPAD 3 09 CTRL SIGNALS LOCAL menda TORQ REF 2 I CH2 i i RE DDCS LINK i i gt TORQUE CONTROL REF VALUE LOOP usas i 26 01 CTRL SIGNALS j TORQ SELECTOR DIG INPUTS IOEC 2 DI 1 6 1 017 13 i 3 13 TORQ REF USED CONTROL dee e Doll gqu deu esed ui dudes START STOP DIRECTION NOT SEL COMM MODULE IOEC 2 Di 1 LOCAL A NOT USED START STOP KEYPAD EXT REQUEST IOEC2 DI 8 COMM MODULE REMOTE FORWARD DIRECTION EXTA REVERSE NOT SEL i DER 11 08 16 01 UM MODUI i DIRECTION 55 STOP COMM MODULE B IOEC2 DI5 11 01 11 02 12 02 NE PUSH EXT2 EXM EXT2 4 BUTTONS STRT STOP DIR STRT STOP DIR SELECTION ON 222 i ACS 1000 d IOEC2 DI9 IOEC 1 i DI 6 MCB Offline MCB IS OPEN DI 7 MCB Online 12 IOEC2 DI 10 MCB i MCB IS CLOSED MCB OPEN COMMAND lOEC2 DI 11 CONTROL NOT SEL LOCAL MCB IS AVAILABL LOGIC MCB IOEC 2 DI 7 13 1 CLOSE COMMAND COMM MODULE 4 lt lt REMOTE 1 24 NOTSEL EXT2 A EROS IOEC2 DI34 1 qp an d COMMMODULE TIO 11 04 11 05 21 05 21 06 21 07 21 08 21 09 EXT2 MCB ON
86. MCB MCB MCB MCB MCB CONTROL MCB CONTROL OPEN SIGNAL AVAILABLE CLOS TIME LIM OPEN TIME LIM for further settings see Signal and Parameter Table 4 20 of 38 3BHS102769 ACS 1000 User s Manual Rev C PID Macro Description Control Overview Chapter 4 I O Interfaces and Application Macros The PID Macro allows to control a process variable such as pressure or flow by adjusting the speed of the motor accordingly Start stop commands and reference settings can be given from the control panel of the ACS 1000 or from an external control station The LOC REM key on the control panel is used to enable the control panel or the external control station The control panel can be disabled by closing DI 1 8 The digital input can be accessed via terminals X301 1 and X301 2 Parameter group 40 provides the necessary settings for the PID Macro The PID Macro requires IOEC board 4 The process reference value is connected to Al 1 1 The customer termi nals for Al 1 1 are available on terminal block X301 Two process feedback signals can be used Actual value 1 is connected to Al 4 1 and actual value 2 to Al 4 2 Parameter 40 06 provides the settings regarding the number of feedback signals and their interconnection If the PID controller is part of a higher level control system and the speed of the motor is to be controlled directly the speed reference value has to be wired to Al 2 1 The internal PID c
87. NAL AVAILABLE CLOS TIME LIM OPEN TIME LIM for further settings see Signal and Parameter Table ACS 1000 User s Manual Rev C 3BHS102769 4 37 of 38 Chapter 4 I O Interfaces and Application Macros Figure 4 15 Control Signal Diagram of Follower 12 06 12 03 EXT REF2 EXT REF1 SELECTION SELECTION 33 33 01 70 17 FOLL SPEED i REFI EXT REMOTE SPEED CONTROL _ KEYPAD FOLLOWER LOOP 2 NOT SEL LOCAL 1 122 19 CHO NR AMC BOARD E ICOMM MODULE Ui KEYPAD gt REF 2 REF VALUE i REF SEL L gt KEYPAD CTRL SIGNALS CH2 DDCS LINK REF VALUE 2 CTRL SIGNALS eee DIG INPUTS NOT IN USE 2 DI 1 6 MASTER 017 13 FOLLOWER 70 18 FOLL TORQ TORQUE CONTROL FOLLOWER LOOP 122 21 MASTER TORQ REF A CONTROL v gt Z m 1 1 0 E D m d 039 y 21 Ll o t hl COMM MODULE DIRECTION PROCESS STOP eger Sra bie oiim Se ee nie ssec START START STOP DIRECTION i NOT SEL i i COMM MODULE LOCAL NOT USED START STOP pud EXT REQUEST _IOEC2 Di8 Anun MODI REMOTE FORWARD DIRECTION COMM MODULE EXT 3 SEE NOT SEL i IOEC2 DI 1 2 i KEYPAD 11 03 16 01 11 01 11 02 12 02 1
88. PC Tools DriveWindow DriveLink DriveSupport Chapter 4 I O Interfaces and Application Macros Overview Terms and Abbreviations Input Output Boards Standard I O Boards I O Ratings Control Voltage Output Potentiometer Supply Digital Output Home Position External Connections Location of IOEC Boards Pre defined Signals Application Macros Overview Macro Applications Factory Speed Control Hand Auto PID Control Torque Control 3 26 3 26 3 26 3 26 3 26 3 27 3 27 3 27 3 27 3 27 3 27 3 27 3 27 3 28 3 28 3 28 3 28 3 29 3 29 3 29 3 29 3 29 3 29 3 30 4 1 4 1 4 1 4 2 4 3 4 3 4 3 4 3 4 5 4 11 4 11 4 11 4 11 4 11 4 12 4 12 4 12 ACS 1000 User s Manual Rev C 3BHS102769 3 of 10 Sequential Control 4 12 Master Follower 4 12 User 1 User 2 4 12 Factory Macro 4 13 Description 4 13 Control Overview 4 13 Input and Output Signals 4 14 Control Signal Diagram 4 15 Hand Auto Macro 4 17 Description 4 17 Control Overview 4 17 Input and Output Signals 4 18 Control Signal Logic 4 19 PID Macro 4 21 Description 4 21 Control Overview 4 21 Input and Output Signals 4 22 Control Signal Diagram 4 23 Torque Macro 4 25 Description 4 25 Control Overview 4 25 Input and Output Signals 4 26 Control Signal Diagram 4 27 Sequential Control Macro 4 29 Description 4 29 Control Overview 4 29 Input and Output Signals 4 30 Control Signal Diagram 4 31 Master Follower Macro 4 33 Description 4 33
89. R TORQUE X31 7 X32 7 4 20 mA AO 2 1 IOEC 2 15 11 Motor speed actual value MOTOR SPEED X31 6 X32 6 4 20 mA AO 2 2 IOEC 2 15 16 Actual value of filtered motor MOT TORQUE FILTERED X31 7 X32 7 torque 4 20 mA Control Signal Diagram The control signal diagram of the Torque Macro in Figure 4 10 shows how the control signals i e reference value starting stopping commands MCB opening closing commands are interconnected in the application software of the ACS 1000 ACS 1000 User s Manual Rev C 3BHS102769 4 27 of 38 Chapter 4 I O Interfaces and Application Macros Figure 4 10 Control Signal Diagram of Torque Control Macro 12 06 12 08 33 33 01 EXT REF2 1 CONSTANT CONST SPEED KNAL INPUTS SELECTION SELECTION SPEEDS SELECTION CHO AMC BOARD ICOMM MODULE gt REF VALUE gt CTRL SIGNALS CH2 DDCS LINK REF VALUE CTRL SIGNALS DIG INPUTS 2 DI 1 6 DI 7 13 CONTROL PANEL Q DIRECTION PUSH BUTTONS ON ACS 1000 1 DI 6 MCB Offline D 7 MCB Online E gt NOT SEL IOEC2 DI 1 2 KEYPAD 11 01 STRT STO COMM MODULE 11 02 EXT2 P DIR STRT STOP DIR NOT SEL 12 01 KEYPAD REF SEL 12 02 EXT1 EXT2 SELECTION NOT SEL IOEC 2 DI 7 13 COMM MODULE LOCAL ipii CREE IOE
90. S 1000 The short time delay pro vided 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 100 ms including MCB delay time even when transformers with high input im pedance are applied The final area identified as overload protection should provide long term overload protection with an inverse time charac teristic This area is intended to protect the transformer and cables from long term overload conditions The protection described can be provided with individual protection relays or with a single microprocessor based unit Required current transformers ACS 1000 User s Manual Rev C 3BHS102769 10 5 of 28 Chapter 10 Installation Transformer Primary Cable Transformer Transformer Secondary Cable should be sized in accordance with the rated current levels of the trans former Basic protection configuration and connection should be as previ ously shown in Figure 10 2 and Figure 10 3 Figure 10 4 Sample protection scheme Current 20 Transformer Primary Fault Protection Transformer Secondary Fault Protection X10 Overload Protection LE Adjustable Time Delay x1 Time 10 ms 100 ms 1s 10s 100s The cable from the circuit breaker to the transformer primary has no spe cial requirements It s
91. SEL MCB IS AVAILABL LOGIC 2 DI 7 13 4 24 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 4 I O Interfaces and Application Macros Torque Macro Description The Torque Control Macro is used in applications requiring torque control of the motor The settings for torque reference and torque reference handling can be adjusted in parameter group 25 and 26 respectively The torque reference is given through AI 2 1 as a current signal By default O mA correspond to 0 and 20 mA to 100 of the rated motor torque The start and stop command is given through DI 2 1 and the sense of rota tion is changed by means of DI 2 2 Changing from torque control to speed control is achieved by setting DI 2 3 to low It is also possible to change the control location from external to local i e to control panel by pressing the LOC REM key When LOCAL is selected on the control panel the drive is speed controlled by default If torque control is required parameter 12 1 KEYPAD REF SELECT has to be changed to REF2 96 The control panel be disabled by closing DI 1 8 The digital input can be accessed via terminals X301 1 and X301 2 Default settings for the display of the control panel are SPEED TORQUE and CONTROL LOCATION Control Overview Figure 4 9 Torque Macro Control Overview OL 1242 0 rpm I MotSpeed 1242 0 rpm CtrlLoc LOCAL Reference value start stop and direction commands
92. Table of Contents Chapter 1 Safety Instructions General Responsibilities Safety Labels Safety Concept General Safety Regulations c c oos ONNA Chapter 2 Introduction Overview 2 1 Range of Application of the ACS 1000 2 1 Intended Audience for this Manual 2 2 What this Manual Contains 2 2 Chapter 3 Design and Functional Description Overview 3 Fuseless Design 3 Control Equipment 3 Technical Specifications 3 Technical Data 3 Standards Fulfilled 3 Description of the ACS 1000 3 Functional Description 3 2 Power Circuit Interface 3 3 Input Circuit 3 3 Output Circuit 3 3 Control System 3 4 Direct Torque Control DTC 3 4 How does DTC Differ from PWM Flux Vector Drives 3 5 Layout and Description of Assembly 3 5 Cabinet Design 3 5 Cabinet Sections 3 7 Door Locks 3 9 Lifting Arrangements 3 9 Cooling Circuit 3 9 Control and Monitoring Equipment 3 10 CDP 312 Control Panel 3 11 ACS 1000 User s Manual Rev C 3BHS102769 1 of 10 Standard Control and Monitoring Functions General Motor Control Features Motor ID Run Filter ID Run Full Torque at Zero Speed Enhanced Flying Start Flux Optimization Power Loss Ride Through Acceleration and Deceleration Ramps Critical Speed Resonance Frequency Damping RFD Constant Speeds Speed Controller Tuning Accurate Speed Control Accurate Torque Control without Speed Feedback Drive System Features Main Circuit Breaker MCB Control
93. Thanks to its outstanding performance the ACS 1000 is ideally suited for retrofit applications Figure 2 1 The ACS 1000 Air Cooled Type ACS 1000 User s Manual Rev C 3BHS102769 2 1 of 4 Chapter 2 Introduction Intended Audience for this Manual What this Manual Contains This manual is intended for electrical field professionals who are respon sible for installing commissioning and servicing the ACS 1000 frequency converter The audience is expected to have professional education in electrical installation knowledge of physical and electrical fundamentals electrical wiring practices for medium voltage MV and low voltage LV equipment electrical components and electrical schematic symbols full knowledge of safety aspects national standards and regulations hazard prevention related to work in medium voltage MV installa tions On the other hand the audience is not expected to have prior experience of ABB products prior experience of frequency converters prior experience of the ACS 1000 product family prior experience or training of installing commissioning operating and servicing the ACS 1000 Chapter 1 Safety Instructions In this chapter which is placed at the beginning of the manual the various safety instruction levels used in this manual are explained This chapter also provides general instructions o
94. a tion Aux Pwr Failure in 27 V power supply Check auxiliary input voltage xX X Fail Possible cause Terminal X10 see Appendix G Loss of auxiliary input voltage Wiring Diagrams and auxiliary power supply If the fault cannot be eliminated call local ABB service organiza tion AuxFan Contactor supervision of aux fan Call local ABB service organiza x x Water cooled con Possible causes tion verters only Fan defective Fan protection relay defective Battery Battery capacity too low Replace battery see Chapter 7 Default setting de Down Preventive Maintenance pending on applica Call local ABB service organiza tion tion Battery Battery is not connected Check battery wiring and con X x Default setting de Miss nections pending on applica Ifthe fault cannot be eliminated tion call local ABB service organiza tion Brake Chop Temperature limit of the braking Call local ABB service organiza X Optional chopper exceeded tion Possible causes Underdimensioning of braking chopper Brake Chop Temperature limit of the braking Call local ABB service organiza X X Optional chopper exceeded tion Possible causes Underdimensioning of braking chopper 8 8 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggest
95. agram nals do not corre Malfunction of isolator or isolator Check wiring and shielding of spond control isolator control circuit Wiring in isolator control circuit If the fault cannot be located disturbed call local ABB service organiza Shielding of control cables not tion properly grounded OutsAirM supervision of ambient tempera Check if analog input OUTSIDE x X Water cooled con Los ture measurement AIR TEMP on IOEC3 is gt 2mA verters only Possible causes Check wiring and shielding of Measuring circuit output lt 2 mA measuring circuit Wiring in protection circuit dis If the fault cannot be located turbed call local ABB service organiza Shielding of control cables not tion properly grounded ACS 1000 User s Manual Rev C 3BHS102769 8 25 of 38 Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy 2 3 amp Comments meaning of message amp 0 oP 5 5 5 OutsAir Supervision of ambient tempera Check ambient temperature X Water cooled con Temp ture f ambient temperature is within verters only Possible causes limits check if analog input High ambient temperature OUTSIDE AIR TEMP on External measurement device is within range defective Check limit parameter settings Parameter setting not correct 81 16 to 81 20 For details refe
96. al levels of safety instructions and notes are used in this manual to highlight a potentially dangerous situation They are marked with one of the following labels Danger This symbol indicates an imminent danger resulting from me chanical forces A non observance may lead to life threatening physical injury or death Danger This symbol indicates an imminent danger resulting from high voltage A non observance may lead to life threatening physical injury or death Warning Caution This symbol indicates a dangerous situation A non observance may lead to physical injury or cause serious damage to the converter Note This symbol emphasizes important information A non observance may cause damage to the converter The design and the specific safety devices of the ACS 1000 allow safe installation commissioning operation and maintenance of the equipment when used as intended The ACS 1000 is equipped with the following safety features see Figure 1 1 Safety grounding isolator for intermediate DC circuit Electromechanic interlocking system the safety grounding isolator cannot be closed until the main circuit breaker is open and the DC cir cuit is completely discharged Doorinterlocking system preventing access to live equipment When the drive is energized access is possible only to the control equipment Control functions to prevent from dangerous operating conditions Full converter protection
97. all local ABB service organiza tion IOEC2Link Er Supervision of communication link Check connectors on IOEC2 and AMC3 boards If the fault cannot be eliminated call local ABB service organiza tion IOEC3Link Er Supervision of communication link Check connectors on IOEC3 and AMC3 boards If the fault cannot be eliminated call local ABB service organiza tion Optional IOEC4Link Er Supervision of communication link Check connectors IOEC4 AMC3 boards If the fault cannot be eliminated call local ABB service organiza tion Optional Limit Superv Supervision if actual or reference signal is at limit Check limit settings in parame ter group 32 Supervision Link AB Lost Loss of internal communication links Check connectors in control cabinet If the fault cannot be eliminated call local ABB service organiza tion Link C Lost Loss of internal communication links Check connectors on interface board and ADCVI board If the fault cannot be eliminated call local ABB service organiza tion Link D Lost Loss of internal communication links Check connectors on interface board and ADCVI board If the fault cannot be eliminated call local ABB service organiza tion 8 18 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages an
98. arameter Table ACS 1000 Information The ACS 1000 software version test date and serial number can be displayed Information data are stored in parameter group 6 nformation For further details see Appendix K Signal and Parameter Table Parameter Lock user can prevent unwanted parameter adjustment by activating the Parameter Lock Parameter Lock is set with parameters 16 02 and 16 03 in group System Ctr Inputs For further details see Appendix K Signal and Parameter Table 3 28 of 30 3BHS102769 ACS 1000 User s Manual Rev C Chapter 3 Design and Functional Description Built in PID Controller There is a built in process PID Controller in the ACS 1000 The controller can be used to control process variables such as pressure flow or fluid level Instead of applying a speed reference to the ACS 1000 a process reference setpoint is applied via an analog input or the keypad An actual value process feedback is brought back to the ACS 1000 through Reference Level D Trans ducer one of the analog inputs Actual Value The internal PID controller of the ACS 1000 eliminates the Pump need to provide mount and wire a separate PID controller PID controller data are set in parameter group 40 P D Control Parameter group 40 can only be accessed if the PID control macro is used A stan dard set of parameter values is selected automatically in this case For further
99. ator must be able to decide whether to shut down the converter for troubleshooting or repair or to reset the fault message and restart the drive This chapter includes the safety instructions that must be complied with when installing operating and servicing the ACS 1000 If neglected phys ical injury and death may follow or damage may occur to the frequency converter the motor and the driven equipment The contents of this chapter must therefore be studied before attempting any work on or with the unit Responsibilities It is the owners responsibility to insure that each person involved in the installation commissioning operation or maintenance of the ACS 1000 has received the appropriate training or instructions and has thoroughly read and clearly understood the safety instructions in this chapter When installing the frequency converter as well as during commissioning and maintenance all personnel involved must observe the relevant general safety regulations and standards for electrical works in medium and low voltage equipment which are in force at the place of installation Furthermore personnel must make strict compliance with the instructions given in this manual ABB Industrie AG declines all liability for any possible damage resulting from failure or negligence to observe this warning ACS 1000 User s Manual Rev C 3BHS102769 1 1 of 6 Chapter 1 Safety Instructions Safety Labels Safety Concept Sever
100. ay 8 3 Fault History Display 8 4 Standard 6 of 10 3BHS102769 ACS 1000 User s Manual Rev C Procedure for Trouble Shooting 8 5 Repair Work 8 7 Error Messages and Fault Elimination 8 7 Chapter 9 Transportation Storage Disposal and Recycling Introduction 9 1 Environmental Requirements 9 1 Storage 9 1 Transportation 9 1 Stationary Use 9 1 Packing 9 1 Loading and Unloading 9 3 Lifting Angle 9 4 Center of Gravity 9 4 Unpacking 9 4 Transportation Damages 9 6 Storage 9 6 Storage Conditions 9 6 Periodical Inspections 9 7 Battery 9 7 Storage Instructions for Spare Parts 9 7 Transportation 9 7 Ambient Conditions 9 7 Humidity 9 7 Temperature 9 7 Handling Instructions for Spare Parts 9 8 Temporary Shut Down 9 9 Disposal of Packing Material 9 9 Packing Material 9 9 Disassembly and Disposal of Equipment 9 9 Chapter 10 Installation Overview 10 1 Safety Instructions 10 1 Requirements to Foundation Space and Ambient Conditions 10 2 Ambient Conditions 10 2 Base Dimensions and Clearances 10 2 Floor Levelling and Cable Ducts 10 3 Selection and Dimensioning of Power Equipment 10 3 Main Circuit Breaker Controller 10 3 Instrumentation and Protection Equipment 10 5 Transformer Primary Cable 10 6 Transformer 10 6 ACS 1000 User s Manual Rev C 3BHS102769 7 of 10 Transformer Secondary Cable 10 6 Motor Cable 10 7 Power Cable Dimensions 10 8 Comments 10 8 Installation Conditions 10 9 Equipment Grounding 10 9 Auxiliar
101. bed nected Check control panel connection terminals Replace control panel If the fault cannot be eliminated call local ABB service organiza tion Panel Lost Control panel connection is dis Check if control panel is con x Active only if con turbed nected verter is in in torque Check control panel connection control and local terminals mode Replace control panel If the fault cannot be eliminated call local ABB service organiza tion Press Stop Alarm after Filter ID run has been Press the STOP key on the completed CDP 312 control panel Process Customer system protection input Check if stop order is initiated by x x Stop Possible causes process see process control Stop order from process Check external wiring and wiring in control circuit disturbed shielding of control cables Shielding of control cables not If the fault cannot be located properly grounded call local ABB service organiza tion ACS 1000 User s Manual Rev C 3BHS102769 8 27 of 38 Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy S Comments meaning of message amp 0 5 9 5 5 Process Customer system protection input Check if stop order is initiated by X Stop Possible causes process see process control Stop order from process Check external wiring and wiring in control
102. behind the protective foil Place them for example on the front door of the convert er The storage conditions the condition of the converter unit as well as of the packing should be checked monthly during the whole storage period Pay special attention to damages caused by mechanical forces water humidity heat or fire If the packing is damaged or if you discover damages caused by water humidity heat or fire you have to unpack the converter and check its inner and outer condition Before storing the converter again all storage damages have to be repaired Store the converter as described above The battery has to be taken out of the converter unit for recharging every 6 months In order to maintain the converter spare parts in good condition after the delivery and to keep the warranty valid during the warranty period the following must be taken care of The storage place must be vibration and shock free and protected against dampness frost heat dust and sand The spare parts must be inspected immediately after receipt in order to detect possible transportation damages Any damage must be reported immediately to the forwarder and insurance company ABB does not take any responsibility for damages due to external circumstances The spare parts must be stored in their original packing in a dry vermin and insect proof room The place has to be free of corrosive gases Relative air humidity 5 to 85 The electronic boards
103. binet with M12 screws and lock washer using the mounting foot fastening plates provided as shown in Figure 10 9 These clamps can be installed either by accessing them from the ends of the cabinet structure or via the access plates that are provid ed inside the cabinet Figure 10 9 Cabinet mounting Removable access plates Fixing points 10 14 of 28 3BHS102769 ACS 1000 User s Manual Rev C Chapter 10 Installation 12 Assemble and mount the air exhaust onto the top of the control sec tion See Figure 10 10 Mounting air exhaust Use the special M6 screws with rubber coating part of supply Figure 10 10Mounting air exhaust A 13 Check that the doors be opened and locked properly If not the cabinet levelling needs improvement Check the mechanical door interlock Open the grounding switch the front doors with the exception of the control door cannot be opened Release the grounding switch lock override using a wire loop see Figure 10 11 and close the switch the front doors can be opened Re adjust the levelling if the mechanical door interlock does not work properly Note The front doors of the power sections of the ACS 1000 are mechan j ically interlocked with the ground switch and can only be opened when the ground switch is closed i e the DC circuit is grounded The ACS 1000 is shipped with closed ground switch If for any reason the ground switch should be in open
104. book 7 12 Required tools 7 4 Safety 7 1 Standard procedure 7 4 Maintenance schedule 7 3 Measurement loss 3 25 Motor ID run 3 11 6 15 Motor phase loss 3 24 Motor protection 3 26 Motor stall 3 22 Motor winding temperature 3 22 Offset calibration 3 21 Operation 5 1 Options Customer specific C 1 Overcurrent 3 24 Overspeed 3 23 Overvoltage 3 24 Index 2 of 4 3BHS102769 ACS 1000 User s Manual Rev C P Packing 9 1 Parameter Backup 7 11 Downloading 6 17 Editing 6 6 Modification 6 14 Parameter groups 6 1 programming procedure 6 3 Recalling user macro parameters 6 22 Restoring default settings 6 19 Safety 6 1 Uploading 6 16 Verification 6 14 Parameter Groups 6 1 Parameter lock 3 27 6 16 Parameters selecting B 8 phase Loss 3 24 PID controller 3 28 Power circuit interface Input circuit 3 3 Output circuit 3 3 Power loss ride through 3 12 Preparation of mounting site 10 12 Process monitoring 5 14 Process stop 3 26 Protection equipment 10 5 R Ramp functions 3 13 Reference setting B 14 value B 3 Reference signal processing 3 20 Remote B 3 Remote control 3 18 5 9 Repair work 8 7 Resonance frequency damping RFD 3 14 3 28 Run status B 3 S Safety 1 1 Commissioning 1 1 Concept 1 2 Improper behavior 1 4 Installation 1 1 10 1 Labels 1 2 Maintenance 1 1 7 1 Operation 5 1 Parameter 6 1 Residual danger areas 1 3 Responsibilities 1 1 Trouble shooting 8 1 Selection of actual signals 6
105. cal ABB Address service organization Contact them if you have any questions 7 12 of 12 3BHS102769 ACS 1000 User s Manual Rev C Chapter 8 Trouble Shooting amp Repair Overview The purpose of this chapter is to provide information and instructions on how to proceed when encountering a problem with the ACS 1000 This chapter is addressed to electrical field professionals who are responsible for servicing the ACS 1000 In order to perform the suggested actions in case of a disturbance no special training is required besides the profes sional education as indicated in Chapter 2 Introduction Intended Audi ence for this Manual page 2 2 Warning Do not attempt any measurement parts replacement or other corrective actions on the ACS 1000 which are not described in this chap ter Repair work or installation of spare parts on the ACS 1000 may only be carried out by service staff of ABB Industrie AG and by their authorized service representatives Failure to comply with this regulation will void guarantee and endanger correct operation of the installation It is strongly recommended to sign a service contract with ABB For more information please contact your local service representative Special maintenance and service training courses for professionals are offered by ABB Customer staff having successfully attended such courses will be certified to do maintenance and repair work on the ACS 1000 provided that the e
106. call local ABB service organiza tion ExtMotCool Trip from external motor cooler Check motor temperature X Optional Possible causes Check cooling equipment Refer Fault in external motor cooling to manuals for motor and cool circuit ing Wiring in monitoring circuit dis Check with logbook if fault oc turbed curs repeatedly and record trip Poor grounding connections conditions Check wiring and connections between relay and converter Check relay input wiring Check cable shielding and grounding If the fault cannot be eliminated call local ABB service organiza tion ExtMotProt External motor protection alarm Check motor and record fault to X Optional Possible causes Dueto a motor problem external motor protection relay has been actuated Wiring in protection circuit dis turbed Shielding of control cables not properly grounded gether with load conditions into logbook Check that all trip limit values are correctly set in the relay Check wiring between external protection relay and ACS 1000 input EXT MOT PROT TRIP on board Check wiring to relay inputs Check if shielding of control ca bles is properly grounded If the fault cannot be eliminated call local ABB service organiza tion ACS 1000 User s Manual Rev C 3BHS102769 8 13 of 38 Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination C
107. ck Input BRG TEMP DE on board Check power supply of monitor ing device Check wiring between external temperature measuring device and ACS 1000 Check cable shielding and grounding If the fault cannot be eliminated call local ABB service organiza tion ACS 1000 User s Manual Rev C 3BHS102769 8 9 of 38 Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy 5 3 amp Comments meaning of message 9 p d oP 5 5 5 BrgTemp Trip from temperature measure Check bearing For details refer X Optional DE ment at the driven end bearing to motor manual Possible causes Check Input BRG TEMP DE on Excessive insufficient lubrica board tion or bearing problems Check power supply of monitor Temperature measuring device ing device defective Check wiring between external Wiring in monitoring circuit dis temperature measuring device turbed and ACS 1000 Check cable shielding and grounding If the fault cannot be eliminated call local ABB service organiza tion BrgTemp Alarm from temperature measure Check bearing For details refer X Optional NDE ment at the non driven end bearing to motor manual Possible causes Check Input BRG TEMP NDE Excessive insufficient lubrica on board tion or bearing problems Check power supply of monitor Temperature measuring device in
108. connections of external power and control cables are fas tened tightly Warning Do not check the internal cabling In particular do not tighten the capacitor connections The capacitor bushings will be damaged when a excessive momentum is applied to the terminals 4 Accomplish your maintenance job as described in Standard Proce dure for Maintenance page 7 4 ACS 1000 User s Manual Rev C 3BHS102769 7 7 of 12 Chapter 7 Preventive Maintenance Replacement of Air Filters Loosen the filter frame by turning the locking bolts 4 a quarter turn counterclockwise and remove the frame 1 from the door 3 Inverter Door Air Inlet 1 2 Remove the filter mat 2 and insert the re placement mat 3 Mount the filter frame 1 and lock it by turning the locking bolts 4 a quarter turn clockwise 4 Record the date of re placement in logbook Control Door Air Inlet 1 Open control section door 7 2 2 Pulloutthe filter mat from its pocket and insert the replacement filter 3 Lockthe door and record the date of replacement in the logbook Replacement of Fan lt o Note If your system is equipped with redundant fans refer to the corre 4 sponding User s Guide for further instructions 1 De energize the system according to Standard Procedure for Mainte nance
109. ction is set in parameter group 37 1 Standard only water cooled ACS 1000 4 10 of 38 3BHS102769 ACS 1000 User s Manual Rev C Application Macros Overview Macro Applications Factory Speed Control Chapter 4 I O Interfaces and Application Macros An application macro is a pre programmed control software with specifi cally adapted parameter sets Depending on the process the appropriate macro can be selected thus enabling a quick and easy start up of the ACS 1000 All application macros have factory set parameter values These default values can be left unchanged or they can be set individually according to the needs by the ABB commissioning engineer Ask the local ABB service organization if more information is required The ACS 1000 can be operated using one of the following macros e Factory e Speed Control Hand Auto Control e Sequential Control Torque Control Master Follower User 1 e User 2 There are six digital inputs on IOEC board 2 marked STANDARD INPUT which are assigned to the application macros See Table 4 1 Signals Remote control interface The function of each digital input can change depending on the macro If I Os are used which are not located on IOEC board 2 a reference to the corresponding board is made Besides the standard and the macro specific I Os various optional I Os may be defined depending on the converter configuration
110. ction scheme with vacuum controller non load break disconnector fast acting current limiting fuse vacuum contactor ENG trip signals R VR FF 9 o 2 amp 9 E E 8 S o ELE 5 2 9 di 2 d o c AC time residual 8 overcurrent relay 700 instantaneous AC time o overcurrent relay o aaa x dl A X ACS 1000 5 D Instrumentation and Adequate current transformers and protection relaying must provide pro Protection Equipment tection for the transformer and the transformer primary cables The intend ed approach for protection is shown in Figure 10 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 wind ings 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 AC
111. d fault elimination Continued Message Possible cause Suggested remedy 5 3 amp Comments meaning of message 9 p d eprTS 5 5 Link E Lost 1055 of internal communication Check connectors on interface links board and ADCVI board If the fault cannot be eliminated call local ABB service organiza tion LS Print MI Voltage supervision across di dt Check connectors on interface Xx choke not active board and VLSD board Possible reason If the fault cannot be eliminated cabling or connection disturbed call local ABB service organiza tion LS Print PL Voltage supervision across di dt Check connectors on interface choke active board and VLSD board Possible reason If the fault cannot be eliminated cabling or connection disturbed call local ABB service organiza tion Macr User macro has been changed X Change MCB Con Converter control is unable to op Check if parameter settings are x trol erate the main circuit breaker correct and correspond with cir Possible causes cuit breaker requirements Pa Parameter setting for MCB con rameters 21 05 to 21 10 For trol not correct details refer to MCB specifica MCB tripped or in test position tions and Appendix K Signal Malfunction of MCB and Parameter Table wiring MCB control circuit dis Check MCB operation following turbed MCB user manual and circuit di Shielding of control cables not agram properly grounded Check external wiring and shiel
112. d motor identification run ID run input of nameplate data is always required a quick motor identification is automatically done the first time the Start command is given During this first start up the motor is run at zero speed for several seconds to allow a basic motor model to be created This model is sufficient to allow normal operation The unbeatable performance of direct torque control DTC is based on an accurate motor model The parameters of this model are automatically 3 12 of 30 3BHS102769 ACS 1000 User s Manual Rev C Chapter 3 Design and Functional Description determined during the enhanced ID run Basic motor nameplate data power rating speed etc must first be entered manually Then the drive is instructed to perform a motor ID run For optimum parameter determi nation the load should be disconnected from the motor during the ID run The ACS 1000 operates the motor under a predetermined set of running conditions for a few minutes For each running condition motor and inverter feedback responses are measured Based on these measure ments the motor model parameters are calculated and optimized The final result is an enhanced mathematical model of the motor which func tions to provide the DTC controller with accurate flux torque and motor speed information If no ID run is selected the converter will be stopped due to D run fault Motor ID run can be selected upon entering the so called start up para
113. der the surface max ambient temp 30 max conductor temperature 60 It is recommended that the ACS 1000 ground bus in the bottom of the cabinet is connected to the plant ground bus using a 240 mm 500 MCM cable A 3 phase cable without neutral connector is required for auxiliary power supply Type and ratings to be selected according to local regulations For ratings see als o Appendix A Technical Data Control cables should be provided in accordance with Table 10 2 Cable shields should be terminated on the ACS 1000 end only Either single or multiple twisted pair cables may be used Table 10 2 Control Cable Requirements Signal Type General Cable Type Cross Section Termination Analog In Twisted pair s Overall Shield 0 5 to 2 5 mm AWG 20 to AWG 12 Analog Out Twisted pair s Overall Shield 0 5 to 2 5 mm AWG 20 to AWG 12 Digital In Twisted pair s 0 5 to 2 5 mm AWG 20 to AWG 12 Digital Out Twisted pair s 0 5 to 2 5 mm AWG 20 to AWG 12 ACS 1000 User s Manual Rev C 3BHS102769 10 9 of 28 Chapter 10 Installation Cable Routing Power Cables Cable Termination Cable Length Grounding Wire Control Cables Mains and Motor Cable Connection Diagrams 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
114. ding of emergency stop cir cuit If the fault cannot be located call local ABB service organiza tion ACS 1000 User s Manual Rev C 3BHS102769 8 19 of 38 Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy 2 3 amp Comments meaning of message amp 0 5 5 5 5 MCB Dis One feedback signal from MCB Check if parameter settings are X Two feedback sig crep missing correct and correspond with cir nals do not corre Possible causes cuit breaker requirements Pa spond Parameter setting for MCB con rameters 21 05 to 21 10 For trol not correct details refer to MCB specifica Malfunction of MCB tions and Appendix K Signal Wiring in MCB control circuit Parameter Table turbed Check MCB operation following Shielding of control cables not MCB user manual and circuit di properly grounded agram Check external wiring and shielding of emergency stop cir cuit If the fault cannot be located call local ABB service organiza tion MCB Dis MCB opens during operation Check if parameter settings are x X x turb Possible causes correct and correspond with cir Parameter setting for MCB con cuit breaker requirements Pa trol not correct rameters 21 05 to 21 10 For MCB tripped or in test position details refer to MCB specifica Malfunction of MCB tions and Appen
115. dix K Signal Wiring in MCB control circuit Parameter Table turbed Check MCB operation following Shielding of control cables not MCB user manual and circuit di properly grounded agram Check external wiring and shielding of emergency stop cir cuit If the fault cannot be located call local ABB service organiza tion MCB Not MCB faulty drawn out in local Check MCB position and oper x Avl mode etc ating mode Check MCB operation following MCB user manual and circuit di agram Check external wiring and shielding of emergency stop cir cuit If the fault cannot be located call local ABB service organiza tion 8 20 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy 2 3 amp Comments meaning of message amp 0 egre 5 5 Mot Phase SW function motor phase loss Verify cable connections X L Possible causes Check that motor contactors Motor cabling and safety switches are in prop Current transformer malfunction positions Check if fault happens only spo radically If this is the case the trip might be caused by low speed reference Check current measurement signals Ifthe fault cannot be eliminated call local ABB service organiza tion Mot Prot Internal motor supervisio
116. e circuit capac itors to discharge before grounding and starting work on the frequency converter the motor or the motor cable The ACS 1000 and adjoining equipment must be properly grounded and the auxiliary supply voltage must be switched off prior to starting with any work Danger Some loads may apply a mechanical torque on the motor shaft If the motor can rotate due to such a load always disconnect short circuit or mechanically block the motor before you start work Danger There can be dangerous voltages inside the ACS 1000 from ex ternal control circuits measurement inputs from PT s etc even if the ACS 1000 mains power and auxiliary power are shut off Take appropriate measures when working with the unit i e deenergize and disconnect all such external devices auxiliary supply heaters coolers I O interfaces before you start work Danger The grounding isolator may become ineffective if the power cir cuit is opened The main circuit breaker and the input isolators must al ways be opened and locked in OPEN position Any external ground switch must be closed and locked Prior to start working on the ACS 1000 the general safety regulations in Chapter 1 Safety Instructions must be read and understood ABB Industrie AG declines all liability for any possible damage resulting from failure or negligence to observe these warnings If a disturbance occurs anywhere in the converter or in related equipm
117. e main circuit breaker are AMCB open command has been given either from local or remote con trol or from the fieldbus adapter or the emergency off is active manually initiated or requested by the con verter protection which activates directly the MCB tripping coil The signal from the converter to the main circuit breaker to open is a single 3 18 of 30 3BHS102769 ACS 1000 User s Manual Rev C Chapter 3 Design and Functional Description pulse signal which is reset upon receiving the status feedback MCB OPEN from the switchgear If this status feedback does not arrive after a preset time the signal MCB ORDER TRIP is initiated to open the MCB The MCB ORDER TRIP is a activated when low signal which directly acti vates the tripping coil of the MCB Several external MCB trip commands can be integrated into this hardwired tripping loop e g transformer and motor supervision relays process trips etc MCB control functions are set with parameter 11 4 and parameter group 21 Start Stop MCB Functions for control outputs Actual Signals for status inputs For further details see the Engineering Manual and Appendix K Signal and Parameter Table Local and Remote operation of the ACS 1000 is possible either by local or remote Control control The local control mode is set directly by pushing the LOC REM push button on the CDP 312 control panel On the display this is indicated by an L local control as ca
118. e rails front 8 screws Rear right 3 screws E Rear left 3 screws a 7 Move the ACS 1000 cabinet to the installation site and unpack Pro ceed as described in Chapter 9 Transportation Storage Disposal and Recycling Caution The converter has to be transported in upright position Caution Use always the lifting lugs on the top of the converter if it is moved by crane 8 Open all cabinet doors including the back side of the inverter section Check the converter and any accompanying equipment for possible transportation damages For details please refer to Chapter 9 Trans portation Storage Disposal and Recycling In case any parts are de fective or missing contact immediately your local ABB service organization and or the shipping company vg Note When re installing the back panel of the inverter section all fasten 5 ing screws must be mounted and tightened in order to maintain per formance 9 Close and lock the cabinet doors including the back side of the invert er section Mounting the Cabinet 10 Carefully move the cabinet to its final mounting position by levering it Use for example an iron bar and place a wooden lath at the bottom edge of the cabinet as shown in Figure 10 8 ACS 1000 User s Manual Rev C 3BHS102769 10 13 of 28 Chapter 10 Installation Figure 10 8 Levering cabinet to place 11 Fasten the ca
119. ed as well For further settings refer to Appendix K Signal and Parameter Table Table 4 12 Master Follower Macro I O Signals Digital Inputs Outputs Terminal Parameter Remarks DI 2 1 START STOP IOEC 2 11 01 1 start X11 1 2 0 stop DI 2 2 DIRECTION IOEC 2 11 01 1 forward X11 3 4 0 reverse DI 2 4 IOEC 2 22 01 Selection of ramp time ACCEL DECELERATION X11 7 8 0 ramp time set 1 RAMP 1 2 1 ramp time set 2 DI 2 5 IOEC 2 33 01 Sel2 Selection CONST SPEED SEL 1 X11 9 10 DI 2 6 IOEC 2 33 01 0 0 Analog Ref CONST SPEED SEL 2 X12 1 2 1 0 Const Speed 1 0 1 Const Speed 2 1 1 Const Speed 3 DI 1 8 X301 0 control panel is enabled DISABLE LOCAL X1 2 1 control panel is disabled DI 2 8 IOEC 2 16 01 Process stop or run enable PROCESS STOP X12 5 6 0 drive will not start or stop if running DI 2 7 IOEC 2 11 04 pulse 1 command for clos REMOTE ORD MCB X12 3 4 ing the main circuit breaker CLOSE DI 2 13 IOEC 2 11 04 pulse 1 command for open REMOTE ORD MCB X13 5 6 ing the main circuit breaker OPEN DI 2 9 IOEC 2 21 06 Feedback from MCB MCB IS OPEN X12 7 8 0 MCB is open 1 MCB is closed DO 2 5 IOEC 2 21 05 Command to open the MCB MCB ORD OPEN X25 2 3 pulse gt 0 MCB open 1 DO 2 6 IOEC 2 21 05 Command to close the MCB MCB ORD CLOSE X26 2 3 pulse gt 1 MCB close ACS 1000 User s Manual Rev C 3BHS102769 4 35 of 38 Chapter 4 I O Inte
120. ed control when Direct Torque Control is used Speed Control ACS 1000 ACS 1000 no Pulse Encoder with Pulse Encoder Static speed error 96 of ny 0 1 0 01 10 96 of nominal slip Dynamic speed error 0 4 sec 0 1 sec in of nominal speed Dynamic speed error depends on speed controller tuning Accurate Torque ACS 1000 can perform precise i Control without Speed torque control without any speed feed 4 Feedback back from the motor shaft With torque 100 rise time less than 10 ms at 10096 90 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 10 will maintain a specific motor torque 5 value the speed will adjust automati 20022 N que cally to maintain the required torque Tret torque reference Tact actual torque Torque control parameters are set with parameter groups 25 and 26 Torque Reference and Torque Ref Handling If the torque control macro is used a standard set of parameter values is ACS 1000 User s Manual Rev C 3BHS102769 3 17 of 30 Chapter 3 Design and Functional Description Drive System Features Main Circuit Breaker MCB Control selected automatically For further details see Chapter 4 I O Interfaces and Application Macros
121. ed remedy 2 3 amp Comments meaning of message amp 0 5 5 5 5 Brg DE Loss of analog input from temper Check Input BRG TEMP DE on X Optional Mlos ature measurement at the driven board signal must be gt Default setting pro end bearing 2mA grammable Possible causes Check power supply of monitor Temperature measuring device ing device defective Check wiring between external Wiring in monitoring circuit dis temperature measuring device turbed and ACS 1000 Check cable shielding and grounding If the fault cannot be eliminated call local ABB service organiza tion BrgNDE Loss of analog input from temper Check Input BRG TEMP NDE Xx Optional Mlos ature measurement at the non on IOEC3 board signal must be Default setting pro driven end bearing gt 2 grammable Possible causes Check power supply of monitor Temperature measuring device ing device defective Check wiring between external Wiring in monitoring circuit dis temperature measuring device turbed and ACS 1000 Check cable shielding and grounding If the fault cannot be eliminated call local ABB service organiza tion BrgTemp Alarm from temperature measure Check bearing For details refer X Optional DE ment at the driven end bearing to motor manual Possible causes Excessive insufficient lubrica tion or bearing problems Temperature measuring device defective Wiring in monitoring circuit dis turbed Che
122. eed is essential Requires shaft speed and position either measured or estimated Each inverter switching is determined separately Inverter switching based on average references to a every 25 us PWM modulator This results in delays in response and wasted switchings Torque Step Rise Time open loop is less than Torque Step Rise Time 10 msec Closed Loop 10 to 20 msec Sensorless 100 to 200 msec For more information on DTC please refer to the Technical Guide No 1 Direct Torque Control 58056685 R0025 Layout and Description of Assembly Cabinet Design riveted cabinet construction of the ACS 1000 provides extremely effective protection against electromagnetic emissions compared to tradi tional frames In addition this construction technique provides a solid yet ACS 1000 User s Manual Rev C 3BHS102769 3 5 of 30 Chapter 3 Design and Functional Description flexible and self supporting framework which avoids the need for addi tional skeletal support The design fulfils the requirements of international standards like UL 347A EMC Electromagnetic Compatibility has been achieved by minimizing the spacing between the rivets and avoiding the use of paint on the cabinet s inside walls Paint tends to reduce the effectiveness of metallic bonding which is paramount to successful EMC As standard only the front of the ACS 1000 cabinet is painted while all other walls are galvanized
123. efore grounding and starting work on the frequency converter the motor or the motor ca ble The ACS 1000 and adjoining equipment must be properly grounded prior to starting with any work The display shows 5 12 of 20 3BHS102769 ACS 1000 User s Manual Rev C Chapter 5 Operation 3 Wait approx 5 minutes until the capacitors in the main circuit are discharged to a safe level and the yellow indicator GND SWITCH UNLOCKED on the control section door is on 4 Close grounding isolator located on the central section door of the converter N CLOSED N The display shows 5 Open input and output isolators if applicable and secure the MCB by drawing it out or locking it 6 system is now dead and safe access is possible Danger The cooling water system may start automatically even if the con verter is de energized In order to shut down the cooling system the aux iliary voltage has to be switched off ACS 1000 User s Manual Rev C 3BHS102769 5 13 of 20 Chapter 5 Operation In Remote Control Mode Emergency Stop Manual Initiation Process Monitoring In remote control mode a stop is initiated when the corresponding remote order is given by external control see Chapter 4 I O Interfaces and Appli cation Macros Emergency stop is automatically initiated if the tripping loop is opened by any protection device by remote signal or i
124. ence to the corresponding page numbers 2 4 of 4 3BHS102769 ACS 1000 User s Manual Rev C Chapter 3 Design and Functional Description Overview Fuseless Design Control Equipment Technical Specifications Technical Data Standards Fulfilled The ACS 1000 is a three phase frequency converter for squirrel cage induction motors Sophisticated microprocessor circuitry is used for moni toring the motor electromagnetic status These data and Direct Torque Control enable state of the art sensorless motor control Additional pulse encoder feedback can be employed in applications where precision speed control is required or in case of long time operation near zero speed The nearly sinusoidal converter output voltage makes the ACS 1000 ideally suited for retrofit applications with existing standard induction motors without the need for derating The ACS 1000 features a fuseless protected medium voltage drive This 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 within 25 microseconds making it 1000 times faster than the operational performance of fuses The ACS 1000 is fitted with hardware and software protection features to safeguard against faults and damages due to improper operating condi tions and
125. ent it will be indicated with an error message on the CDP 312 control panel or as alternative on the Drive Window error display Two error message levels are used with the ACS 1000 Fault a fault is initiated by a serious disturbance in the converter or in related equipment transformer motor etc and always implies a con verter trip The converter will remain in tripped state with the exception of a few faults where the converter will resume operation automatically after the disturbance has disappeared 8 2 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 8 Trouble Shooting amp Repair In order to restart the system the fault must be corrected and the error message be manually reset on the CDP 312 control panel A Note Some faults require the main circuit breaker MCB to be opened The MCB handling is done by the ACS 1000 control system Therefore no external opening orders must be applied to the MCB for converter initiated trips Alarm warning an alarm is given if an irregular situation occurs that does not necessarily require a converter stop Operation is still possi ble However a persisting alarm condition can often lead to a fault if the disturbance is not cleared within a certain time e g high ambient tem perature In Table 8 1 all possible error messages are listed together with informa tion on possible causes and suggestions for remedy Please note that many of these alarm a
126. equipment malfunction The ACS 1000 frequency converter is equipped with advanced features for local and remote control Control equipment is integrated in the converter cabinet and provides fully digital and microprocessor based process control protection and moni toring functions supplemented with hardware protection circuits as a back up The CDP 312 Control Panel is the basic local user interface for monitoring adjusting parameters and controlling the ACS 1000 operation See Appendix A Technical Data See Appendix E Applicable Codes and Standards ACS 1000 User s Manual Rev C 3BHS102769 3 1 of 30 Chapter 3 Design and Functional Description Description of the ACS 1000 Functional Description Main Circuit Breaker Medium Voltage Switchgear Converter Input Transformer The 3 phase AC line voltage is supplied to the rectifier bridges through the 3 winding converter transformer see Figure 3 1 In order to obtain 12 pulse rectification a 30 phase shift is necessary between the two secondary windings of the transformer Therefore one secondary is wye connected while the other is delta connected The two fuseless rectifier bridges are connected in series such that the DC voltages are added up Therefore the full DC bus current flows through both bridges Figure 3 1 Elementary diagram ACS 1000 VA VA V AN NA NA ANN Iu EL el Eur Y ACS1000 Frequency Converter
127. ere From the fault display it is possible to switch to other displays without resetting the fault If no keys are pressed the fault or warning text is displayed as long as the fault exists Fault History Display Fault History provides information on the 40 most recent faults that occurred in your ACS 1000 The name of the fault and the date and time of occurrence are displayed Proceed as follows to view fault history 1 Enter the Actual Signal Display mode by pressing ACT on the CDP 312 control panel 2 Select the Fault History Display with the fast UP DOWN keys The most recent fault will be displayed together with the date and time of occurrence 3 Select previous UP key or next fault DOWN key 8 4 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 8 Trouble Shooting amp Repair Warning Do not clear the fault history buffer before you completely clari fied the error situation Clearing of the buffer cannot be undone 4 To clear the fault history press RESET The fault history buffer is now empty 5 Toreturn to the Actual Signal Display mode press a fast UP DOWN key Standard If a disturbance occurs in your system proceed as follows Procedure for 1 Safety measures Make sure to be familiar with and to observe all Trouble Shooting safety regulations as stated at the beginning of
128. evice possible signal active when low wired to tripping loop in case of trip alarm is displayed main circut breaker is tripped DI 3 1 3 External signal for alarm indication e possible OIL LEVEL ALARM X11 1 2 of transformer oil level 1 DI 3 2 IOEC 3 External signal for alarm indication e possible TRAFO TEMP ALARM X11 3 4 of transformer oil or winding tem 1 perature DI 3 3 IOEC 3 External signal from a transformer e not TRAFO TEMP TRIP X11 5 6 oil or winding temperature monitor 1 possible trips the drive DI 3 4 IOEC 3 Signal from Buchholz relay for e possible BUCHHOLZ ALARM X11 7 8 alarm indication 1 DI 3 5 IOEC 3 Signal from Buchholz relay trips e not BUCHHOLZ TRIP X11 9 10 the drive 1 possible AI 3 1 IOEC 3 Signal from transformer oil or wind e possible TRAFO TEMP X31 2 X32 2 ing temperature monitor for alarm 1 indication drive reaction is set in parameter group 36 1 Standard only in water cooled ACS 1000 ACS 1000 User s Manual Rev C 3BHS102769 4 7 of 38 Chapter 4 I O Interfaces and Application Macros Table 4 4 I O Signals Motor Signal Terminals Remarks Stan Signal dard Inversion DI 1 14 X300 External signal from a motor pro e not EXT MOT PROT TRIP X6 7 tection device possible wired to tripping loop signal active when low in case of trip alarm is displayed main circuit breaker is tripped DI 3 11 IOEC 3 Exter
129. f 30 Chapter 3 Design and Functional Description DriveSupport Target Driver and most of the DDE supporting Windows applications such as MS Excel The DriveLink does not need any other ABB tool to perform its actions The DriveLink consists of several independent parts the User Interface the Target Driver and the Communication Driver With this component structure enhanced flexibility is achieved to enable working with several different types of products through different target and communication drivers The look and feel of the DriveLink program remains the same even when the product changes The DriveSupport is a multimedia based diagnostics tool which identifies faults and warnings based on the signal values from the converter It provides expert knowledge for troubleshooting and servicing of the converter Actual pictures and step by step replacement procedures are available within the tool The DriveSupport is fully configurable for ABB drive products and or projects The user language can be customized and special faults and warnings can be added based on experience In addition the Drive Support keeps a record of all service activities that have been performed on any part of the converter since start up Spare part numbers and contract information can be added to the tool The DriveSupport works on line together with the Drive Window tool 3 30 of 30 3BHS102769 ACS 1000 User s Manual Rev C Chapter 4 I O
130. f control cables not If the fault cannot be located properly grounded call local ABB service organiza tion Ready MCB Converter ready to energize none normal operating status on indication Ready to System ready DC link charged none normal operating status Run no faults pending indication Running System running none normal operating status indication 8 36 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 8 Trouble Shooting amp Repair Table 8 2 Indication messages Continued Message Possible cause Suggested remedy 5 3 Comments meaning of message amp 0 oP 5 5 5 Stopping System stopping none normal operating status indication Test se Test after exchange of faulty part none X quence Trip Summarized signal Check fault history display on X control panel and proceed ac cording to the specific fault de scription Voltage Above upper or below lower limit Check fault history buffer for X control other possibly related error messages Wait Time Will be displayed if after a trip 3a Check fault history buffer for X out restart will be tried before the time other possibly related error for the zero voltage switching is messages over Write Pro Will be displayed if it is tried to none X tec write over a protected parameter ACS 1000 User s Manual Rev C 3BHS102769 8 37 of
131. f the local EMERGENCY OFF button is pressed 1 Foran emergency stop press the red EMERGENCY OFF button on the control section door of the ACS 1000 see Figure 5 1 The trip ping loop opens the converter will be stopped by coast stop and the MCB will be opened The display shows Danger Do not access the main power circuit nor the motor as long as the system is not grounded After switching off the mains always allow the intermediate circuit capacitors 5 minutes to discharge yellow indicator GND SWITCH UN LOCKED must be on before grounding and starting work on the frequen cy converter the motor or the motor cable The ACS 1000 and adjoining equipment must be properly grounded prior to starting with any work For process monitoring in actual signal display mode two displays can be selected on the CDP 312 control panel the actual signal display and the fault history display Actual signal display mode is selected by pressing the ACT key When in actual signal display mode the fast UP DOWN keys allow to 5 14 of 20 3BHS102769 ACS 1000 User s Manual Rev C Chapter 5 Operation toggle between actual signal display and fault history display Actual Signal Display Actual signals are used to monitor ACS 1000 functions and do not affect the performance of the drive Actual signal values are measured or calcu lated internally and they cannot be set o
132. fect Signals the performance of the drive Their values are measured or calculated internally and they cannot be set or altered by the user Actual signals can be selected by activating the corresponding parame ters in groups 1 to 9 For detailed instructions on how to select and monitor actual signals please refer to Chapter 5 Operation Actual Signal Display page 5 15 A complete list of the selectable actual signals can be found in Appendix K Signal and Parameter Table Start Up Parameters The start up parameters form a special set of parameters that allow you to set up the basic ACS 1000 and motor information Start up parameters are normally set during commissioning and should not need be changed afterwards Before the system can be started the start up parameter set must be entered Warning Running the motor and the equipment being driven with incor rect data can result in improper operation reduction in control accuracy and damage to equipment ACS 1000 User s Manual Rev C 3BHS102769 6 7 of 22 Chapter 6 Parameter Viewing and Editing To access the start up parameters proceed as follows 1 Checkthatthe main circuit breaker is open and the grounding isolator is closed 2 Select the parameter mode by pressing the PAR key The parameter mode display appears indicating the previously selected group and parameter When this mode is entered for the first time after power up the display will show t
133. from analog input AI 2 1 Start stop and direction commands are given through digital inputs DI 2 1 and DI 2 2 ACS 1000 User s Manual Rev C 3BHS102769 4 13 of 38 Chapter 4 I O Interfaces and Application Macros Input and Output default I O signals of the Factory Macro regarding opening closing the Signals MCB starting stopping the drive speed control location reference and actual values are shown in the following table The corresponding para meters are listed as well For further settings refer to Appendix K Signal and Parameter Table Table 4 7 Factory Macro I O Signals Digital Inputs Outputs Terminal Parameter Remarks DI 2 1 START STOP IOEC 2 11 01 1 start X11 1 2 0 stop DI 2 2 DIRECTION IOEC 2 11 01 0 forward X11 3 4 1 reverse DI 2 4 IOEC 2 22 01 0 accel decel ramp 1 selected ACCEL DECELERATION X11 7 8 1 accel decel ramp 2 selected RAMP 1 2 DI 2 5 IOEC 2 33 01 Sel2 Selection CONST SPEED SEL 1 X11 9 10 DI 2 6 IOEC 2 33 01 0 0 Analog Ref CONST SPEED SEL 2 X12 1 2 1 0 Const Speed 1 0 1 Const Speed 2 1 1 Const Speed 3 DI 1 8 X301 0 control panel is enabled DISABLE LOCAL 1 2 1 control panel is disabled DI 2 8 IOEC 2 16 01 Process stop or run enable PROCESS STOP X12 5 6 0 drive will not start or stop if running DI 2 7 IOEC 2 11 04 pulse 1 command for clos REMOTE ORD MCB X12 3 4 ing the main circuit breaker CLOSE DI 2
134. g and grounding f the fault cannot be eliminated call local ABB service organiza tion ExtWtrCool Trip from external motor water Check motor temperature X Optional cooling equipment Check cooling equipment Refer Possible causes to manuals for motor and cool Fault in external motor cooling ing circuit Check with logbook if fault oc Wiring in monitoring circuit dis curs repeatedly and record trip turbed conditions Poor grounding connections Check wiring and connections between relay and converter Check relay input wiring Check cable shielding and grounding f the fault cannot be eliminated call local ABB service organiza tion Fan 1 2 Trip fan contactor supervision Check contactor x x Air cooled convert Possible causes Replace fan ers only Overload If the fault cannot be eliminated Fan defective call local ABB service organiza Contactor defective tion Fan 1 2 Alarm fan contactor supervision Check contactor X Air cooled convert in case of redundant fans Replace fan ers only Possible causes f the fault cannot be eliminated Overload call local ABB service organiza Fan defective tion Contactor defective FanDiffPres Trip differential pressure supervi Check if doors are properly X X Air cooled convert sion closed ers only Possible causes Check air filter and clean if nec Fan defective essary Power supply for fan disturbed Ifthe fault cannot be eliminated
135. g device defective Check wiring between external Wiring in monitoring circuit dis temperature measuring device turbed and ACS 1000 Check cable shielding and grounding If the fault cannot be eliminated call local ABB service organiza tion BrgTemp Trip from temperature measure Check bearing For details refer X Optional NDE ment at the non driven end bearing to motor manual Possible causes Check Input BRG TEMP NDE Excessive insufficient lubrica on board tion or bearing problems Check power supply of monitor Temperature measuring device ing device defective Check wiring between external Wiring in monitoring circuit dis temperature measuring device turbed and ACS 1000 Check cable shielding and grounding If the fault cannot be eliminated call local ABB service organiza tion 8 10 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy 5 3 amp Comments meaning of message amp 0 28 68 5 5 Buchholz Alarm signal from external Buch Inspecttransformer according to X Optional holz protection the instructions in the transform Possible causes er manual Gas or air bubble generation in Check wiring of Buchholz pro transformer oil circuit tection circuit input BUCH Wiring in protection circu
136. g or box and components in an enclosure or tube Notice Handle a printed circuit board as if it were a rare collector s pho nograph record Hold the card by its edges Avoid touching the card s ter minals components and folios Notice Put the card or component down only on a grounded working sur face that is protected against electrostatic discharges Notice Handle a faulty card just as carefully as a new one and transport it or send it in a package that is protected against electrostatic discharges 9 8 of 10 3BHS102769 ACS 1000 User s Manual Rev C Chapter 9 Transportation Storage Disposal and Recycling Temporary Shut When shutting down the ACS 1000 temporarily the unit must first be de Down energized and grounded according to Chapter 5 Operation De ener gizing the ACS 1000 page 5 12 The same safety precautions as described Chapter 8 Trouble Shooting amp Repair Safety Instructions page 8 1 apply The directions in Storage page 9 6 to be observed when placing the unit in storage Disposal of Packing The packing is designed for minimum environmental impact Parts of it are Material reusable Dispose of packing material as prescribed by local legislation If in doubt ask your local environmental specialist or contact the local authorities Packing Material Listed below is the packing waste arising from unpacking and installing the ACS 1000 Wooden frame Wooden
137. gt 0 MCB open 4 30 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 4 I O Interfaces and Application Macros Table 4 11 Sequential Macro Macro I O Signals Continued MOT TORQUE FILTERED X31 7 X32 7 DO 2 6 IOEC 2 21 05 Command to close the MCB MCB ORD CLOSE X26 2 3 pulse gt 1 MCB close Analog Inputs Outputs Terminal Parameter Remarks Al 2 1 IOEC 2 External reference ANALOG REFERENCE X31 2 X32 2 AO 1 1 IOEC 1 15 01 Motor frequency actual value MOTOR FREQUENCY X31 6 X32 6 4 20 mA AO 1 2 IOEC 1 15 06 Motor torque actual value MOTOR TORQUE X31 7 X32 7 4 20 mA AO 2 1 IOEC 2 15 11 Shaft speed actual value SHAFT SPEED X31 6 X32 6 4 20 mA AO 2 2 IOEC 2 15 16 Actual value of filtered motor torque 4 20 mA Control Signal Diagram control signal diagram of the Sequential Macro in Figure 4 12 shows how the control signals i e reference value starting stopping commands MCB opening closing commands are interconnected in the application software of the ACS 1000 ACS 1000 User s Manual Rev C 3BHS102769 4 31 of 38 Chapter 4 I O Interfaces and Application Macros Figure 4 12 Control Signal Diagram of Sequential Control Macro 12 06 12 03 33 33 01 EXT REF2 EXT REF1 CONSTANT CONST SPEED KNAL INPUTS SELECTION SELECTION SPEEDS SELECTION REF2 IOEC 2 Alt REF1 IOEC 1 i
138. have to be stored in antistatic bags or boxes The air must be free of corrosive gases salt or other impurities that could damage electronic equipment and boards No water condensation is allowed If you are in doubt whether the maximum allowed humidity is exceeded you should protect the spares by an external heater for example The storage temperature range for spare parts is 5 C to 55 23 F to 131 F the same as for the converter unit Should you store any batteries the air temperature should not exceed ACS 1000 User s Manual Rev C 3BHS102769 9 7 of 10 Chapter 9 Transportation Storage Disposal and Recycling Handling Instructions for Spare Parts 30 86 F For more information about the warranty period and the condition of the spare parts please consult the commercial terms in the purchasing agree ment Should you have further questions please consult your local ABB office or the manufacturer ABB Industrie AG Dept IA CH 5300 Turgi SWITZERLAND Tel 41 56 299 22 05 Fax 41 56 299 34 00 Spare parts must be handled carefully and protected against electrostatic discharges always when taken out of the original factory packing Improper handling may cause damage to sensitive components The following handling instructions must be followed carefully Notice Even over short distances the spare parts must be transported in packages that are protected against static electricity cards in a ba
139. he first parameter of the first group parameter 11 1 3 Select parameter group 99 using the fast UP DOWN keys 4 Selectthe first parameter to be entered 99 1 LANGUAGE using the slow UP DOWN keys Please refer to Table 6 1 with a list of the start up para meters A detailed description of each start up parame ter can be found in Appendix K Signal and Parameter Table 5 Press to access edit mode 6 8 of 22 3BHS102769 ACS 1000 User s Manual Rev C Chapter 6 Parameter Viewing and Editing 6 Change the parameter using fast for numeric values only and slow UP DOWN keys oo 414 7 Press ENTEH to save the changed value Start up parameters can be entered only if the ACS 1000 is de energized If this precondition is not ful filled the following message will appear To cancel the selection and keep the original value press any of the mode keys without pressing ENTER The display will change to the selected keypad mode 8 Repeat steps 4 to 7 for parameters 99 2 to 99 11 and 99 13 to 99 15 according to Table 6 1 Table 6 1 Group 99 start up parameters Parameter Range Unit Description 1 LANGUAGE Languages Display language selec tion 2 APPLICATION Application Application macro selec MACRO macros tion see also next section
140. hen an optional IOEC board is installed in the drive the corresponding manual is attached in Appendix C Customer Specific Options Each board provides the following number of I Os Digital Inputs 14 ACS 1000 User s Manual Rev C 3BHS102769 4 1 of 38 Chapter 4 I O Interfaces and Application Macros VO Ratings Control Voltage Output Digital Outputs 6 Analog Inputs 4 Analog Outputs 2 1 is mainly used for internal control signals and the I Os cannot be accessed by the customer except for the following DI 1 8 Disable Local accessible via terminal block X301 Al 1 1 Ref Value 2 accessible via terminal block X301 AO 1 1 programmable analog output AO 1 2 programmable analog output If an output of an board is not predefined for a standard function a macro or an option the output can be assigned to a binary status signal of the ACS 1000 by setting the corresponding parameter s accordingly In general all l Os marked PROGRAMMABLE can be used Digital inputs marked FREE in the wiring diagrams cannot be programmed by parameters All analog and digital I Os are floating galvanically isolated with the following ratings Analog Input 0 20 mA 4 20 mA or 0 10 V 2 10 V scalable by DIP switches Analog Output 0 20 mA 4 20 mA scalable by parameter Digital Input Opto coupled rated for 22 250 VAC or 22 150 VDC Digital Output two way contact rated for 250 VAC 4 A
141. hould carry a voltage rating consistent with the volt age present in the primary circuit The ampacity rating should be consistent with the size of the transformer being supplied and the protec tion settings of the protection equipment Derating of cable ampacity in ac cordance 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 industry prac tice 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 conductor cable The ampacity of this conductor should be in accordance with the code All ACS 1000 drives must be supplied from an isolation transformer with multiple phase shifted secondary windings designed in accordance with the pulse number of the input bridge 12 or 24 This transformer may be supplied from ABB with the ACS 1000 or may be supplied through another source in accordance with the specification provided by ABB The design of the transformer must take into account user line conditions voltage short circuit capacity existing harmonics etc to insure compliance with harmonic standards invoked by the specification Transformer quality is critical with respect to effecting proper limitation of harmonic currents and voltages For more information concerning the transformer consult the doc
142. ia DI 2 2 if parameter 11 03 has been set to REQUEST before master and follower Three constant speeds can be selected via DI 2 5 and DI 2 6 when the drive is in remote control Furthermore the Master Follower Macro offers two preset acceleration deceleration ramps which can be selected via DI 2 4 ACS 1000 User s Manual Rev C 3BHS102769 4 33 of 38 Chapter 4 I O Interfaces and Application Macros Control Overview Figure 4 13 Master Follower Macro Control Overview Input Input Pose POWER 1 L gt 600 0 rpm 1 Status Running Ext Controls Drive Link MotSpeed 600 00 rpm MotCurr 75 0 Reference value start stop and direction commands are given from the control panel To change to EXTERNAL press LOC REM key WM p 1 7 1 gt 600 0 rpm 1 Status Running MotSpeed 600 00 rpm MotCurr 75 0 The reference value is read from Al 2 1 Start stop and direction com mands are given through DI 2 1 and DI 2 2 Motor Motor MASTER FOLLOWER 4 34 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 4 I O Interfaces and Application Macros Input and Output default I O signals of the Master Follower Macro regarding opening Signals closing the MCB starting stopping the drive speed control location refer ence and actual values are shown in the following table The corre sponding parameters are list
143. igital outputs 6 on each board are available For further details on output allocation refer to the Engineering Manual ACS 1000 offers two programmable current outputs Analog output signals can be inverted and filtered The minimum level can be adjusted to 0 mA 4 mA or 10 mA Depending on parameter selection the analog output signals can repre sent motor speed process speed scaled motor speed output frequency output current motor torque motor power DC bus voltage output 3 20 of 30 3BHS102769 ACS 1000 User s Manual Rev C Chapter 3 Design and Functional Description voltage application block output the process PID controller output the active reference or reference deviation difference between the reference and the actual value of the process PID controller Also the output can be proportional to the process PID controller actual value of the ACS 1000 The process PID controller actual values can be scaled inverted and filtered For further details on output allocation refer to the Engineering Manual Input Signal Source Selections and Signal Processing Note ACS 1000 is a speed controlled device If you need to convert frequency to speed use the following formula FREQUENCY Hz NUMBER OF POLES SPEED rpm 120 Pole pairs 1 2 3 Number of poles 2 4 6 Two Programmable ACS 1000 with no optional devices can receive Start Stop Direction Control Location
144. ill find step by step instructions of how to proceed when editing parameters of the ACS 1000 With these instructions you should be able to understand the programming procedure to check the parameters of your system and to make minor adjustments that might be necessary when operating the ACS 1000 Major parameter readjustments should only be necessary in case of modifications in the driven system and must be prepared according to the instructions in the Engineering Manual Warning Never change any parameters if you are not thoroughly familiar with the meaning of each parameter and with the consequences resulting from the modification Running the ACS 1000 the motor and the equipment being driven with in correct data can result in improper operation reduction in control accuracy and damage to equipment All instructions which require actions from your side are numbered You are requested to carry out these steps exactly in the prescribed sequence Any steps that require actions on the CDP 312 control panel or that can be monitored on the display are complemented with a diagram indicating the keys to be activated on the control panel and the resulting information on the display Example Press Key CDP 312 Display e fthere are several keys in the Press Key field you are requested to select one of them Depending on your choice there might be different reactions Ifthe UP DOWNkeys are shown you can scroll
145. iminated call local ABB service organiza tion ACS 1000 User s Manual Rev C 3BHS102769 8 31 of 38 Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause meaning of message Suggested remedy uoipeoipul wely yney uedo go Comments Undervolt age Detection of temporary undervolt age in the DC circuit Check if alarm may be caused by a external event e g tempo rary loss of supply voltage and record these conditions in the logbook Check fault history buffer for other possibly related error messages If fault occurs repeatedly call lo cal ABB service organization Ride through func tion is activated Undervolt age Trip due to detection of undervolt age in the dc circuit Check if trip may be caused by a external event e g temporary loss of supply voltage and record these conditions in the logbook Check fault history buffer for other possibly related error messages If fault occurs repeatedly call lo cal ABB service organization Wrong EPLD Software version mismatch WtrCondM Los Water conductivity sensor loss of analog input Possible causes Measuring circuit output 2 mA Wiring in protection circuit dis turbed Shielding of control cables not properly grounded Check if analog input WATER CONDUCTIVITY on
146. in many important benefits Harmonic heating is virtually eliminated The drive may be used to sup ply standard medium voltage motors existing or new without applying ACS 1000 User s Manual Rev C 3BHS102769 3 3 of 30 Chapter 3 Design and Functional Description Control System Direct Torque Control DTC thermal derating factors Voltage reflection and the associated occurrence of voltage doubling at the motor input terminals is no longer an issue the causal high frequen cy content does not exist Therefore any standard medium voltage winding insulation system existing or new is compatible Motor cables of any length may be utilized without concern normal voltage drop issues as found in any electrical installation still applys Motor bearing failures attributable to capacitively coupled high frequen Cy current are no longer an issue the causal high frequency common mode voltage is eliminated Motor insulation is not subjected to the common mode voltage typical for other drive topologies 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 with the reference va
147. ing the main circuit breaker and charging the capacitor bank The unit is then ready to start e Setpoint selection Run up to pre set operating point In this chapter you will find step by step instructions of how to proceed when operating the ACS 1000 All instructions which require actions from your side are numbered You are requested to carry out these steps exactly in the prescribed sequence Any steps that require actions on the CDP 312 control panel or can be monitored on the display are complemented with a diagram indicating the keys to be activated on the control panel and the resulting information on the display Example Press Key CDP 312 Display 9 ACS 1000 User s Manual Rev C 3BHS102769 5 1 of 20 Chapter 5 Operation Start Operation of the ACS 1000 Preparatory Procedures Prerequisites fthere are several keys in the Press Key field you are requested to select one of them Depending on your choice there might be different reactions Ifthe UP DOWNkeys are shown you can scroll using these keys alternately Always keep keys pressed for some time 0 5 1 sec in order to avoid misinterpretation Actual signals appear with their short name 8 characters and their current value 1 Press and hold the ACT key to view the full signal names HOLD 2 Release the ACT key to return to normal display To prepare the ACS 1000 for operation
148. ing the slow UP DOWN keys Please refer to Table 6 2for a list of all available applica tion macros 6 Press ENTEH to save your selection The new application macro with all its related parameter settings default settings is now active in the system Warning Once you save the application macro selection even if the same as before the actual parameter settings will be overwritten by the default settings of the macro Consequently some of your individual settings might get lost To cancel the selection and keep the original application macro press any of the mode keys without pressing ENTER The display will 6 12 of 22 3BHS102769 ACS 1000 User s Manual Rev C Chapter 6 Parameter Viewing and Editing change to the selected Keypad Mode 7 To exit the parameter mode press of the mode keys or to check and if necessary to modify the parameters proceed as de scribed in section Verification and Modification of Parameters page 6 14 Table 6 2 Application macro selection Macro Select Factory 1 FACTORY Hand Auto 2 HAND AUTO PID Control 3 PID CTRL Torque Control 4 T CTRL Sequential Control 5 SEQ CTRL Master Follower 10 M F CONTROL Selection of Motor Additional motor control features such as acceleration and deceleration ramps e power loss ride through
149. inst mechanical forces extreme climatic conditions The packing is labeled with all relevant warnings and instructions for packaging handling and storage ACS 1000 User s Manual Rev C 3BHS102769 9 1 of 10 Chapter 9 Transportation Storage Disposal and Recycling Table 9 1 Warning and instruction labels on the converter packing Label Meaning Application A This way up Marked on all cases and open shipped components 2 B Fragile handle with Marked on cases containing fragile or care sensitive to shock material C P Keep dry Marked on cases plywood cases and a d a cartons that are to be kept dry Do not put on crates or cases meant for long term storage outdoors D Center of gravity Marked on cases and components that are shipped unprotected open and require the indication of the center of gravity E Sling here Marked on all cases and open compo 2 nents where ropes and chains are slung 9 2 of 10 3BHS102769 ACS 1000 User s Manual Rev Chapter 9 Transportation Storage Disposal and Recycling The following symbol has become widely used and generally understood Various customer packing specifications require a marking on the outside of the case if the inner packing of the goods requires the application of a desiccant Label Meaning Application F packing with desiccant On all cases requiring the application of ndis a desiccant Symbol p
150. ion of fault codes and messages on the CDP 312 control panel as well as explanations of all alarm messages and trip functions is included The procedure for restarting the converter is described Chapter 9 Transportation Storage Disposal and Recycling provides information about environmental conditions to be maintained during trans portation and storage together with instructions for packing unpacking lifting and moving It includes special requirements for storage and conservation together with instructions for periodical inspections In addi tion information on disposal and recycling of material as well as on tempo rary shut down and decommissioning of the ACS 1000 is given Chapter 10 Installation specifies the mechanical and electrical require ments to the foundation cabling and other equipment gives instructions for mounting drawings and descriptions cable routing and termination for power auxiliary and signal connections incl EMC requirements Chapter 11 Commissioning includes an installation checklist and and preconditions for commissioning In addition the various commisioning steps are described Appendix A Technical Data lists the ACS 1000 technical specifications Appendix B The CDP 312 Control Panel explains all panel push buttons and all panel functions Appendix C Customer Specific Options is a documentation of all customer specific options including descriptions and drawings Appendix D Q
151. ion macros Therefore part of the functions described in this chapter will automatically be configured by selecting an application macro In the remainder of this chapter you will find the description of the standard control monitoring and protection functions with references to the related parameters A description of the basic devices and the application macros of the ACS 1000 you will find in Chapter 4 I O Interfaces and Ap plication Macros This and the following chapter are intended to be used as a reference for obtaining quick information on a specific function A sys tematic guide for determining the parameter settings and I O allocation for commissioning you will find in the ACS 1000 Engineering Manual Configuring the ACS 1000 is a task that requires a professional back ground going far beyond the knowledge needed for system operation Therefore parameters and application macros are set during commission ing of the converter by ABB commissioning engineers based on the in formation received by the owner and should normally not be changed afterwards by the user Warning Never change any parameters if you are not thoroughly familiar with the meaning of each parameter and with the consequences resulting from the modification Running the ACS 1000 the motor and the driven equipment with incorrect data can result in improper operation reduction in control accuracy and damage to equipment With the standar
152. ir contamination and shock and vibration must also be in compliance with stated maximum permissible levels Base Dimensions and Drive unit dimensions are shown in drawing Dimensions and floor mount Clearances ing see Appendix F Layout and Mechanical Drawings All units must be mounted with adequate free space provided in accordance with Figure 10 1 e Provisions for access to installation site clearances of passageways etc and availability of transportation aids must be ensured prior to installation Figure 10 1 ACS 1000 free space requirements Dimensions are given in mm with equivalent inches in parenthesis Above 1 Below Left Right Front 9 Back 500 20 2 9 0 0 0 0 1000 39 4 0 0 500 mm 20 in 1000 mm 39 4 in 10 2 of 28 3BHS102769 ACS 1000 User s Manual Rev C Chapter 10 Installation Notes 1 Dimensions listed do not include space for cable en try which can be from top or from below Dimensions listed are above the blower hood 3 Thisis a general recommendation to insure proper air flow actual site conditions may allow this dimension to decrease or force it to increase 4 Dimensions listed indicate maximum necessary door swing area Additional space may be needed to meet local code requirements Floor Levelling and ACS 1000 cabinet must be installed in upright position Cable Ducts The floor must be of non flammable material with smo
153. ist of all available signals parameter groups 1 to 9 5 Select a signal using the UP DOWN keys 6 Toacceptthe selection and to return to the actual signal display Mode press ENTER 2 To cancel the selection and keep the original selection press any of the mode keys without pressing ENTER The display will change to the selected Keypad Mode 5 16 of 20 3BHS102769 ACS 1000 User s Manual Rev C Chapter 5 Operation Full Signal Name Actual signals appear with their short name 8 characters and their Display current value 1 Press and hold the ACT key to view the full signal names HOLD 2 Release the ACT key to return to normal display Active Fault Display f a fault or an alarm is generated in the drive it will be displayed imme diately with a flashing text except if you are in the drive selection mode 1 You can always view any active fault by selecting the actual signal display mode 2 Toresetthe fault press RESET After a reset the fault message will not appear anymore in Actual Signal Display mode However the fault is still stored in the fault history and can be viewed there From the fault display it is possible to switch to other displays without ACS 1000 User s Manual Rev C 3BHS102769 5 17 of 20 Chapter 5 Operation reset
154. it dis HOLZ ALARM on turbed board Shielding of control cables not Check if shielding of control ca properly grounded bles is properly grounded Ifthe fault cannot be eliminated call local ABB service organiza tion Buchholz Trip signal from external Buchholz Inspect transformer according to x Optional protection the instructions in the transform Possible causes er manual Gas or air bubble generation in Check wiring of Buchholz pro transformer oil circuit tection circuit input BUCH Wiring in protection circuit dis HOLZ TRIP on board turbed Check if shielding of control ca Shielding of control cables not bles is properly grounded properly grounded f the fault cannot be eliminated call local ABB service organiza tion CalibNot Offset calibration of IOEC boards x Done was not successful CHO LinkEr Communication time out internal Check fibre optic connections X x Default setting Not comm on AMC 3 board active Call local ABB service organiza tion CH2 LinkEr Communication time out internal Check fibre optic connections X x Default setting Not comm on AMC 3 board active Call local ABB service organiza tion Charge Circ Charging circuit disturbed Call local ABB service organiza tion Charging Charging of intermediate dc circuit Verify measured dc voltage Pa X x failed rameters 2 02 to 2 09 Possible causes Check whether mains supply Mai
155. l is possible without the need to stop the ACS 1000 Local control mode is set directly by pushing the LOC REM pushbutton on the CDP 312 control panel as described earlier in this chapter On the display this is indicated by an L local control as you can see on the figure below T2 1 L 1 0 rpm 0 Status row of CDP 312 Control Panel Local Control Remote control is indicated by an empty field 1 i 0 rpm 0 Status row of CDP 312 Control Panel Remote Control If the converter is switched to local local operation from the pushbuttons on the converter front door and from the CDP 312 control panel is enabled In local operation mode no remote control command will be accepted If the converter is switched to remote local operation from the pushbut tons on the converter front door except for the emergency off button and from the CDP 312 control panel is disabled In remote control mode commands like close open main circuit breaker or start stop are initiated by binary inputs or via fieldbus The reference value for controlling the speed is determined from an analog input signal or via fieldbus 1 If the control mode is to be set to remote check that remote control is ready 2 Selectlocal or remote control mode by pressing the LOC REM key on the CDP 312 control panel Local control mode is indicated with a ACS 1000 User s Manual Rev C 3BHS102769 5 9 of 20 Chapter 5 Operation Remote Local Local
156. le lifting the converter unit Figure 9 1 Lifting Angle Center of Gravity X n Front View Od H y Top View 2 x 1505 mm y 926 mm z 469mm Unpacking For unpacking the converter following steps have to be followed 1 Check the packing condition Pay attention to damages by mechanical forces water humidity heat or fire 9 4 of 10 3BHS102769 ACS 1000 User s Manual Rev Chapter 9 Transportation Storage Disposal and Recycling 2 case the packing has been damaged please proceed as described in section Transportation Damages page 9 6 3 Remove all packing material carefully see Figure 9 2 Do not use sharp edged or pointed devices to open the packing in order not to damage the converter casing 4 Check the condition of the converter unit Pay especially attention to bent doors and side walls loose electric cables unassembled parts damaged parts dust layers water or humidity indicator color on side of the box must be blue if the color is red the converter has been exposed to excessive humidity damages by insects or vermin 5 Open the back panel of the inverter section and check the inside con dition 6 Check the condition of any accompanying equipment such as trans former motor Please refer to the corresponding manuals 7 Compare the complete deli
157. lication Macros Description All drive commands and reference settings can be given from the CDP 312 control panel or from an external control station The control station is selected with the LOC REM key on the control panel The control panel can be disabled by closing DI 1 8 The digital input can be accessed via terminals X301 1 and X301 2 In remote control the following default signal interface applies The reference value is connected to Al 2 1 The start stop command is wired to DI 2 1 The sense of rotation can be changed with DI 2 2 The default setting is FORWARD It can be changed to REVERSE either by setting parameter 11 03 to REVERSE or via DI 2 2 if parameter 11 03 has been set to REQUEST before Three constant speeds can be selected via DI 2 5 and DI 2 6 when the drive is in remote control Two preset acceleration deceleration ramps can be selected via DI 2 4 When the Factory Macro is active the drive is speed controlled Control Overview Figure 4 3 Factory Macro Control Overview Input Power Ext 25 Controls NNNM NN j Motor 1 L gt 600 0 rpm 1 Status Running MotSpeed 600 00 rpm MotCurr 75 0 Reference value start stop and direction commands are given from the control panel To change to EXTERNAL press LOC REM key 1 gt 600 0 rpm 1 Status Running MotSpeed 600 00 rpm MotCurr 75 0 Reference value is read
158. ling system of the ACS 1000 is available The commissioning procedure will last 1 to 2 days excluding any waiting time During the whole commissioning period the customer must provide 1 qualified electrical professional who is familiar with medium and low voltage equipment and with the local safety regulations familiar with the driven process authorized to operate the associated medium and low voltage equip ment MCB other MV and LV switchgear etc authorized to operate the driven process for testing purposes When commissioning is completed the commissioning report will be signed by the customer as sign of acceptance and by the ABB commis sioning engineer One copy of this report will be handed out to the customer the second copy will be sent to ABB Headquarters The customer will then receive a confirmation from ABB Headquarters including a record of all parameter settings as they were set during commissioning Warranty will start on the date of acceptance i e upon signing of the commissioning report by both parties and will last 1 year 11 2 of 2 3BHS102769 ACS 1000 User s Manual Rev C Index A ABB service address 7 12 Active fault 5 17 8 3 Actual signal 3 19 Actual Signals B 5 Actual signals 5 15 6 2 Full signal name display 5 17 Air filters replacement 7 8 Alarm handling 8 2 Analog input 3 21 4 1 Analog output 3 19 4 1 Application macros 4 11 6 2 Factory 4 1 4 11 4 13
159. lt Electronic power supply fault Call local ABB service organiza tion ExtRef1 External reference signal 1 lost Check origin of reference signal X Default setting Lost see also process control alarm Check external wiring and shielding of reference circuit f the fault cannot be located call local ABB service organiza tion ExtRef2 External reference signal 2 lost Check origin of reference signal X Default setting Lost see also process control alarm Check external wiring and shielding of reference circuit f the fault cannot be located call local ABB service organiza tion 8 12 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy 2 3 amp Comments meaning of message amp 0 5 5 5 5 ExtMotCool Alarm from external motor cooler Check motor temperature X Optional Possible causes Check cooling equipment Refer Fault in external motor cooling to manuals for motor and cool circuit ing Wiring in monitoring circuit dis Check with logbook if alarm oc turbed curs repeatedly and record Poor grounding connections alarm conditions Check wiring and connections between relay and converter Check relay input wiring Check cable shielding and grounding f the fault cannot be eliminated
160. lt e not SUPPL VOLT UNBAL X10 11 age relay 1 possible ANCE signal is active when low wired to tripping loop in case of trip alarm is indicated main circuit breaker is tripped DI 4 1 IOEC 4 External signal from a cooling water possible EXT WTR COOLING X11 1 2 monitor for alarm indication ALARM DI 4 2 IOEC 4 External signal from a cooling water not EXT WTR COOLING TRIP X11 3 4 monitor indicating a trip possible signal is active when low in case of trip alarm is displayed drive is tripped DI 4 3 IOEC 4 External signal from a cooling fan or not BRAKE CHOP FAN PUMP X11 5 6 pump for braking resistors indicating possible ALARM a alarm signal is active when low DI 4 4 IOEC 4 External signal from a temperature not BRAKE CHOP TEMP X11 7 8 monitor for braking resistors indica possible ALARM ting an alarm signal is active when low DI 4 5 IOEC 4 External signal indicating the output not OUTPUT ISOL IS OPEN X11 9 10 isolator is open possible DI 4 6 IOEC 4 External signal indicating the output not OUTPUT ISOL IS CLOSED X12 1 2 isolator is closed possible DI 4 7 IOEC 4 External signal indicating the input not INPUT ISOL IS OPEN X12 3 4 isolator is open possible DI 4 8 IOEC 4 External signal indicating the input not INPUT ISOL IS CLOSED X12 5 6 isolator is closed possible Al 3 4 IOEC 3 External actual value of an outside e possible OUTSIDE AIR TEMP X31 5 X32 5 air temperature 1 drive rea
161. lues produced by the torque and flux refer ence controllers Depending on the outputs from the hysteresis control lers the pulse selector directly determines the optimum inverter switch positions Typical performance figures for the speed and torque control are given in Standard Control and Monitoring Functions page 3 12 3 4 of 30 3BHS102769 ACS 1000 User s Manual Rev C Chapter 3 Design and Functional Description Figure 3 3 DTC block diagram Speed controller acceleration compensator Internal torque Torque Control Switch position reference status signals commands Torque DC bus Torque reference Torque _ jl comparator Optimum reference pulse Flux i selecto Speed reference Flux Actual torque _ Status ASIC Flux Actual flux Switch reference positions controller Adaptive Internal flux reference Actual speed DC bus voltage Inverter current 4 measurements Filter current M 8 measurements 95 How does DTC Differ DTC every switching is determined separately based on the values of from PWM Flux Vector flux and torque rather than switching in a predetermined pattern as in Drives conventional PWM flux vector drives DTC Flux Vector Switching based on core motor variables Flux and Switching based on separate control of magnetising Torque and torque producing components of current Shaft speed and position not required Mechanical sp
162. meaning of message 28 8 5 5 Alarm Summarized signal Check fault history display on X control panel and proceed ac cording to the specific alarm de scription Charging DC voltage charging state none normal operating status indication Defect A fault cannot be reset because of Call local ABB service organiza x a defect tion Discharg DC discharging state after switch none normal operating status ing ing off MCB indication Earthlso Grounding isolator is closed none normal operating status clos indication ID Run ID run is requested Calllocal ABB service organiza x Req tion ID Run If ID run is selected none X Selec Magnetiz Magnetization in progress also in none normal operating status ing dicating flying start indication MCB not Will be displayed if a start is tried Proceed as described Chap x when the MCB is not closed ter 5 Operation MotWillRun Before during ID run none X No ID Run Will be displayed if a start without Carry out ID run X preceding ID run is tried f you need assistance call local ABB service organization Param Lock Parameter is locked and can t X modified Process Customer system protection input Check if stop order is initiated by x x Stop Possible causes process see process control Stop order from process Check external wiring and wiring in control circuit disturbed shielding of control cables Shielding o
163. motor and bearings For X Optional lay motor vibration level too high details refer to motor manual Possible causes Check vibration monitoring de Excessive motor vibrations due vice to unbalance or overheated Check power supply of monitor bearing ing device Vibration measuring device de Check wiring between external fective temperature measuring device Wiring in monitoring circuit dis and ACS 1000 Check input turbed wiring of measuring device Check cable shielding and grounding f the fault cannot be eliminated call local ABB service organiza tion 8 22 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy 2 3 amp Comments meaning of message amp 0 28 78 3 5 MotVibrat Trip from external protection relay Check motor and bearings For X Optional motor vibration level too high details refer to motor manual Possible causes Check vibration monitoring de Excessive motor vibrations due vice to unbalance or overheated Check power supply of monitor bearing ing device Vibration measuring device de Check wiring between external fective temperature measuring device Wiring in monitoring circuit dis and ACS 1000 Check input turbed wiring of measuring device Check cable shielding and grounding If the fa
164. mp Repair Panel page 8 3 Repair Work During warranty any repair work is to be done exclusively by ABB service personnel After expiration of the warranty period repair work with the exception of replacement of parts specifically mentioned in Chapter 7 Preventive Maintenance is to be done only by ABB service personnel or by authorized persons having attended the maintenance and service training as mentioned at the beginning of this chapter Adequate docu mentation will be handed out during these courses Error Messagesand See Table 8 1 and Table 8 2 Fault Elimination ACS 1000 User s Manual Rev C 3BHS102769 8 7 of 38 Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Message Possible cause Suggested remedy 5 x amp Comments meaning of message amp 0 5 5 5 5 AirFiltSupv differential pressure supervi Replace air filter X Optional sion f the fault cannot be located Air cooled convert Possible causes call local ABB service organiza ers only Air filter is dirty tion AninpCalib Automatic input calibration of Disconnect analog inputs and X IOEC boards not successful retry f the fault cannot be eliminated call local ABB service organiza tion AninpCalib Automatic input calibration of Disconnect analog inputs and X IOEC boards not successful retry f the fault cannot be eliminated call local ABB service organiz
165. n Check motor for excessive heat X SW If the fault persists call local ABB service organization MotCooler Alarm from converter internal con Check motor temperature X Optional tactor supervision for the motor Check cooling equipment Refer cooler to manuals for motor and cool Possible causes ing Fault in external motor cooling Check with logbook if alarm oc circuit curs repeatedly and record Wiring in monitoring circuit dis alarm conditions turbed Check wiring and connections Poor grounding connections between relay and converter Check relay input wiring Check cable shielding and grounding Ifthe fault cannot be eliminated call local ABB service organiza tion MotCooler Trip from converter internal con Check motor temperature X Optional tactor supervision for the motor cooler Possible causes Fault in external motor cooling circuit Wiring in monitoring circuit dis turbed Poor grounding connections Check cooling equipment Refer to manuals for motor and cool ing Check with logbook if fault oc curs repeatedly and record trip conditions Check wiring and connections between relay and converter Check relay input wiring Check cable shielding and grounding If the fault cannot be eliminated call local ABB service organiza tion ACS 1000 User s Manual Rev C 3BHS102769 8 21 of 38 Chapter 8 Trouble Shooting amp Repair Table 8
166. n safety which must be respected during all work on the ACS 1000 Chapter 3 Design and Functional Description contains a short technical overview of the ACS 1000 and a short description of its features and control functions Chapter 4 Interfaces and Application Macros describes standard control configuration using application macros Factory Hand Auto PID Control Torque Control Sequential Control Master Follower together with the macro specific and indicates typical applications for each macro Chapter 5 Operation describes safety considerations preconditions for energizing and operation of the ACS 1000 Furthermore remote and local control starting and stopping changing setpoints monitoring of actual process values de energizing the ACS 1000 and the emergency stop function are described Chapter 6 Parameter Viewing and Editing describes how to view and modify start up data how to select application macros and edit other parameters using the CDP 312 control panel Some ancillary parameter and macro editing features are described as well Chapter 7 Preventive Maintenance includes the maintenance schedule and specific descriptions of all preventive maintenance procedures Chapter 8 Trouble Shooting amp Repair explains what to do upon an alarm message and how to proceed in case of an alarm or a converter trip A list 2 2 of 4 3BHS102769 ACS 1000 User s Manual Rev C Chapter 2 Introduct
167. n after shut down Do not attempt to open doors by force when drive is ener gized or before grounding isolator is closed The safety instructions in this chapter generally apply when working on the ACS 1000 You will find additional instructions and warnings related to particular topics or actions throughout the manual where relevant The following regulations must be strictly observed Intended purpose of use The technical specifications see Appendix A Technical Data and the intended purpose of use see Chapter 2 Introduction must be strictly adhered to ACS 1000 User s Manual Rev C 3BHS102769 1 3 of 6 Chapter 1 Safety Instructions Training of personnel Only well trained personnel are allowed to install operate maintain or service the ACS 1000 This personnel must be specially instructed about the dangers that can be caused by this equipment Improper behavior Working in a way that could cause dangers to persons or the ACS 1000 is strictly prohibited Access for untrained and Unauthorized Personnel The owner is responsible for making sure that untrained personnel do not have access to the ACS 1000 frequency converter and cannot op erate the ACS 1000 and adjoining equipment Modifications without authority Modifications and constructional changes in the ACS 1000 are not al lowed Always contact ABB Industrie AG
168. n be seen on the figure below 1 1 0 rpm O Status row of CDP 312 Control Panel Local Control Remote control is indicated by an empty field nM Status row of CDP 312 Control Panel 1 ws 0 rpm 0 L Remote Control Local Control If the converter is switched to local control local operation from the push button on the converter front door and from the CDP 312 control panel is possible In local operation mode no remote control command will be accepted Remote Control If the converter is switched to remote control local operation from the push button on the converter front door and from the CDP 312 control panel is not possible Instead all commands like close open main circuit breaker or start stop are received through the remote control interface The reference value for controlling the speed is given as an analog input signal Alternatively all remote control signals can be exchanged via a fieldbus interface optional The switch over from local to remote and vice versa can be disabled by setting the digital input DISABLE LOCAL see Chapter 4 Customer ACS 1000 User s Manual Rev C 3BHS102769 3 19 of 30 Chapter 3 Design and Functional Description Diagnostics Actual Signal Monitoring Fault History Programmable Digital Outputs Programmable Analog Outputs Interfaces and Application Macros Table 4 1 90 Actual Signals are available The most significant ones are ACS 1000 output freque
169. nal signal from a motor pro e possible EXT MOT PROT ALARM 13 1 2 tection device for alarm indication 1 DI 3 6 IOEC 3 External signal from motor cooling e possible MOT COOLING ALARM 12 1 2 for alarm indication 1 DI 3 7 IOEC 3 External signal from motor cooling e not MOT COOLING TRIP X12 3 4 trips the drive 1 possible DI 3 8 IOEC 3 External signal from a motor vibra e possible VIBRATION SV ALARM X12 5 6 tion monitor for alarm indication 1 DI 3 9 IOEC 3 External signal from a motor vibra e not NIBRATION SV TRIP X12 7 8 tion monitor 1 possible trips the drive DI 3 10 X300 External signal from a motor over e not OVERSPEED TRIP X8 9 speed monitor 1 possible signal is active when low wired to tripping loop in case of trip alarm is displayed main circuit breaker is tripped Al 2 2 wired to PT 100 External signal from a 100 motor e possible MOT WDG TEMP PH U converter see winding temperature sensor in Wiring Diagram phase U drive reaction is set in parameter group 30 Al 2 3 wired to PT 100 External signal from a PT100 motor e possible MOT WDG TEMP PH V converter see winding temperature sensor in Wiring Diagram phase V drive reaction is set in parameter group 30 Al 2 4 wired to PT 100 External signal from a PT100 motor e possible MOT WDG TEMP PHW converter see winding temperature sensor in Wiring Diagram phase W drive reaction is set in parameter group 30 4 8 of 38 3BHS102769 ACS 1000
170. nals for all inputs and outputs together with the corresponding signal name All contacts are shown in their home de energized position The default I O configuration of IOEC 2 depends on the selected applica tion macro Refer to paragraph Application Macros page 4 11 Location of IOEC IOEC boards are installed in the control section of the ACS 1000 as Boards shown in Figure 4 2 IOEC 1 is located in the center area of the swing frame The terminal block X301 which is connected to DI 1 8 DISABLE LOCAL and AI 1 1 REFER ENCE VALUE 2 is fitted on the right hand side of the control section IOEC 2 IOEC 3 and IOEC 4 are located on the right hand side of the control section The terminals on the IOEC boards are accessible when the swing frame is open ACS 1000 User s Manual Rev C 3BHS102769 4 3 of 38 Chapter 4 I O Interfaces and Application Macros Figure 4 2 Location of IOEC Boards Swing frame Electronic power supply EPS board AMC 3 control board IOEC 1 77 standard IOEC 2 standard Terminal block X301 IOEC standard for water cooled converters IOEC 4 optional
171. ncy 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 Operating time counter h kWh counter e Digital I O and analog I O status PID controller actual values if the PID Control Macro is selected Three signals can be displayed simultaneously on the control panel Actual signals to be displayed can be selected from parameter group1 to 5 Actual Signals For further details see Chapter 5 Operation Actual Signal Display page 5 15 The Fault History contains information on the forty most recent faults detected by the ACS 1000 Faults are displayed in words For further details see Chapter 5 Operation Fault History Display page 5 18 Four programmable digital outputs are at the user s disposition They can be used as floating change over contacts Each output can be selected via parameter setting ready running fault warning motor stall motor temperature alarm trip ACS 1000 temperature alarm trip reversed selected external control selected preset speed limits 2 pcs interme diate circuit voltage limits preset motor current limit reference limits 2 pcs loss of reference signal ACS 1000 started motor operating at reference speed process PID controller actual value limits low high etc By choosing the two optional boards IOEC 3 and IOEC 4 12 additional d
172. nd fault messages are related to the specific equip ment in use e g transformer type cooling system or to external protec tion devices provided by the user For that reason some of the messages might never appear in your system since they are not relevant for your application For your own safety follow exactly the instructions in Table 8 1 when iden tifying and correcting a disturbance and never attempt to do any repair work on the ACS 1000 beyond these instructions Before starting with trouble shooting you must read carefully the warnings stated at the begin ning of this chapter Fault Display on the The following section gives a concise description of how to display error CDP 312 Control messages on the CDP 312 control panel For further details please refer Panel to Appendix B The CDP 312 Control Panel and to Chapter 5 Operation Active Fault Display f a fault or an alarm is generated in the drive it will be displayed immedi ately with a flashing text except if you are in the Drive Selection Mode 1 Youcan always view any active fault by selecting the Actual Signal Display mode ACS 1000 User s Manual Rev C 3BHS102769 8 3 of 38 Chapter 8 Trouble Shooting amp Repair 2 Toresetthe fault press RESET 9 After a reset the fault message will not appear anymore in Actual Signal Display mode However the fault is still stored in the fault history and can be viewed th
173. ng amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy 2 3 amp Comments meaning of message Qm M w oP 5 5 WtrTemp Water temperature above alarm Check flow in the main water cir X Water cooled con level cuit verters only Check temperature and pres sure in the raw water circuit check the heat exchanger for fouling f the cooling circuit is leaky or if the fault cannot be located call local ABB service organization WtrTemp Water temperature above trip level Call local ABB service organiza X Water cooled con tion verters only WtrTempM Water temperature measurement Check if analog input COOL x Water cooled con Los loss of analog input ING WATER TEMP on IOEC1 is verters only Possible causes gt 2 Measuring circuit output 2 mA Check wiring and shielding of Wiring in protection circuit dis measuring circuit turbed f the fault cannot be located Shielding of control cables not call local ABB service organiza properly grounded tion 8 34 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 8 Trouble Shooting amp Repair ACS 1000 User s Manual Rev C 3BHS102769 8 35 of 38 Chapter 8 Trouble Shooting amp Repair Table 8 2 Indication messages Message Possible cause Suggested remedy S Comments 2 gt m
174. nguages Act FUNC DRIVE Control Panel Mode Selection keys Double Up Arrow Up Arrow Enter Double Down Arrow Down Arrow keys Local Remote Reset Reference and Start keys Forward Reverse and Stop keys Using the panel it is possible to enter start up data into the drive control the drive with a reference signal and with Start Stop and Direc tion commands display actual values three values can be read simultaneously display and adjust parameters display information on the most recent forty fault events upload and download complete parameter sets from one drive to an other this greatly simplifies the start up procedure of several identical drives For further details please refer to Appendix B The CDP 312 Control Panel ACS 1000 User s Manual Rev C 3BHS102769 3 11 of 30 Chapter 3 Design and Functional Description Standard Control and Monitoring Functions General Motor Control Features Motor ID Run The ACS 1000 control and protection system is configured and custom ized through a set of application parameters These parameters can be programmed by the user either with the CDP 312 control panel supplied with the converter or with a PC and the Drive Window software package Parameters can be defined by setting them one by one or by invoking a predefined set of parameters which is optimized for a particular applica tion Such predefined parameter sets are called applicat
175. nning If the process stop input opens the drive control initiates a stop order The type of stop torque limit ramp or coast is parameter selectable Process stop is set with parameter 16 01 in group System Ctr Inputs and parameters 21 03 and 21 04 in group Start stop Functions For further details see Chapter 4 Interfaces and Application Macros Standard O Boaras page 4 1 and Appendix K Signal and Parameter Table External Emergency If the customer wants to use an External Emergency Off button it can be Off connected to a pre defined protection input of the ACS 1000 The External Emergency Off input is integrated into the tripping loop by a normally closed NC contact For further details see Chapter 4 I O Interfaces and Application Macros Standard I O Boards page 4 1 MCB Control Fault All opening and closing commands to the main circuit breaker are supervised for time out If the MCB does not change its status within a pre set time the MCB trip loop signal active when low is activated MCB time out supervision is set with parameters 21 08 and 21 09 in group Start stop Functions For further details see Appendix K Signal and Parameter Table Other Features Limits ACS 1000 offers adjustable limits for speed current max and ACS 1000 User s Manual Rev C 3BHS102769 3 27 of 30 Chapter 3 Design and Functional Description torque max and protects itself against overvoltage For
176. ns voltage low voltage is within the tolerated limits See Appendix A Techni cal Data Verify stiffness of mains supply f the fault cannot be eliminated call local ABB service organiza tion CoSens Cooling water conductivity sensor Call local ABB service organiza Water cooled con Dirty is dirty tion verters only ACS 1000 User s Manual Rev C 3BHS102769 8 11 of 38 Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy 5 3 Comments meaning of message amp 0 28 78 5 5 Discharg Discharging failure DC link maxi Call local ABB service organiza X X ing mum discharging time exceeded tion Danger Intermedi ate DC circuit is still charged Doing F IDR Filter ID run is in progress gt X Doing ID ID run is in progress X Run Earthlso Feedback signal from earth isola Call local ABB service organiza Xx Ctrl tor is lost during operation tion EmergStop External or internal emergency Check origin of Emergency stop X x stop order order see also process control Possible causes Check external wiring and Emergency stop order shielding of emergency stop cir External wiring in emergency cuit stop circuit disturbed If the fault cannot be located Shielding of control cables not call local ABB service organiza properly grounded tion EPS Fau
177. ntrol cables should not be laid in parallel to the power cables If this cannot be avoided a minimum distance of 30 cm 12 in must be maintained between control and power cables Control and power cables should be crossed at an angle of 90 Figure 10 5 shows a typical mains cable connection The actually applied connecting scheme must comply with local regulations 10 10 of 28 3BHS102769 ACS 1000 User s Manual Rev C Chapter 10 Installation Figure 10 5 Typical mains connection 3 line diagram Transformer Factory Ground Shielding Armouring Factory Ground ACS 1000 Figure 10 6 shows a typical motor cable connection The actually applied connecting scheme must comply with local regulations Figure 10 6 Typical motor connection 3 line diagram ACS 1000 Factory Ground Factory Ground ACS 1000 User s Manual Rev C 3BHS102769 10 11 of 28 Chapter 10 Installation Mechanical Installation Required Tools and Parts Preparation of Mounting Site This chapter provides instructions for moving the ACS 1000 cabinet to the mounting position fastening it on the floor and preparing it for electrical connection For the installation the following tools are required Basic set of tools e Setof wrenches Drilling machine with concrete drill for M12 bolts with dowels Knife Megger e and Ohmmeter e Special to
178. o instructions and visual inspec vice in service documentation tion service tool Cleaning replace owner on occurrence optional equipment ment of air filter alarm FanDiff Pres Cleaning replace owner on occurrence ment of control alarm FanDiff door air filter Pres Replacement of fan owner ABB 30 000 hours check parameter 5 05 bearings service running time Replacement of fan owner ABB 30 000 hours check parameter 5 05 service running time depending on fan condition Replacement of owner ABB upon alarm batteries service ACS 1000 User s Manual Rev C 3BHS102769 7 3 of 12 Chapter 7 Preventive Maintenance Maintenance task To be carried out Frequency Comments by Parameter backup ABB ser upon any param and software ver vice eter modifica sion check tion atleast every 5 years Measurement of ABB ser after 3 year capacitors vice then every 2 years Insulation test ABB ser every 2 years According to instructions vice in service documentation service tool Inspection of motor owner ABB ser according to the see relevant mainte transformer and vice relevant mainte nance instructions MCB nance instructions Spare parts check ABB ser yearly check stock according to Appendix I Recom mended Spare Parts List Check of optional ABB ser According to instructions equipment vice in service documentation service tool
179. of measuring circuit If the cooling circuit is leaky or if the fault cannot be located call local ABB service organization Water cooled con verters only WtrPresM Los Water pressure measurement loss of analog input Check if analog input WATER PRESSURE on IOEC1 is gt 2 Check wiring and shielding of measuring circuit If the fault cannot be located call local ABB service organiza tion Water cooled con verters only WtrPres sure Cooling water pressure below alarm level Check water level in the expan sion vessel Check if all bleed drainage val ves are closed Check entire pipe system for leaks pump packings pipe joints pipes etc If level is ok check wiring and shielding of measuring circuit If the cooling circuit is leaky or if the fault cannot be located call local ABB service organization Water cooled con verters only WtrPres sure Cooling water pressure below trip level Check water level in the expan sion vessel Check if all bleed drainage val ves are closed Check entire pipe system for leaks pump packings pipe joints pipes etc If level is ok check wiring and shielding of measuring circuit If the cooling circuit is leaky or if the fault cannot be located call local ABB service organization Water cooled con verters only ACS 1000 User s Manual Rev C 3BHS102769 8 33 of 38 Chapter 8 Trouble Shooti
180. offset calibra tion signal cables must be disconnected first from the analog inputs Analog inputs are calibrated by setting the appropriate parameters Auto Offset Calib in parameter groups 15 81 and 86 Offset of the internal current and voltage measurement inputs will be calculated automatically if the grounding isolator is opened after de ener gization of the converter 3 22 of 30 3BHS102769 ACS 1000 User s Manual Rev C Chapter 3 Design and Functional Description Standard The ACS 1000 offers six programmable fault functions and several other Protection non user adjustable preprogrammed protection functions Functions Programmable Fault Functions Motor Winding motor can be protected from overheating by activating the motor Temperature winding temperature supervision The calculation of the motor temperature is user adjustable The tempe rature supervision is based either on a load curve or on a thermal constant set by the customer or given by the automatically integrated function The load curve should be adjusted in case the ambient temperature exceeds 30 C Alternatively the ACS 1000 offers as standard three analog inputs for motor winding temperature measurement If this measurement is connected the calculation model is disabled The values for alarm and trip levels must be set in either case Motor temperature protection is set with parameters 30 01 to 30 11 in group Fault Functions For furthe
181. ols as prescribed by cable manufacturer Fork lift crane or other means for moving the ACS 1000 1 Before you proceed with the mechanical installation make sure that all preconditions as described in Section Requirements to Founda tion Space and Ambient Conditions are fulfilled Note The following mounting instructions apply for normal mounting con ditions in industrial surroundings In case of special site conditions such as ships cranes etc contact your ABB representative for further information on the installation procedure 2 Checkthe floor levelling with a spirit level The maximum allowable overall unevenness is x 5mm If the floor is uneven it must be levelled 3 If power cables are to be installed from the bottom provide floor cut outs according to the arrangement of the cable glands as shown in drawing Dimensions and floor mounting see Appendix F Layout and Mechanical Drawings 4 Dril mounting holes for M12 screws according to the drilling plan in drawing Dimensions and floor mounting see Appendix F Layout and Mechanical Drawings 5 Insert dowels 10 12 of 28 3BHS102769 ACS 1000 User s Manual Rev C Chapter 10 Installation Displacement to 6 Ifthe ACS 1000 has to be moved by crane mount the crane rails on Installation Site the front and rear top edge of the converter see Figure 10 7 Rails and screws size M8 8 8 length 25mm are part of the supply Figure 10 7 mounting cran
182. on Macros Figure 4 4 Control Signal Diagram of Factory Macro 12 06 12 03 33 33 01 EXT REF2 EXT REF1 CONSTANT CONST SPEED SELECTION SELECTION SPEEDS SELECTION IOEC 2 DI 5 6 SPEED CONTROL LOOP KEYPAD 23 01 EXT2 NOTSEL LOCAL SPEED REF AMC BOARD Aedes 12 01 i ICOMM MODULE KEYPAD SPEED REF SEL CONTROLLER REF2 i i T REF V LUE KEYPAD CERE 3 09 LOCAL RER 2 DDCS LINK i cem f i i TORQUE CONTROL REF VALUE LOOP C gt i 26 01 CTRL SIGNALS TORQ SELECTOR DIG INPUTS i IOEC 2 DI 1 6 i DI 7 13 i 3 18 i TORQ REF USED CONTROL i PANEL i sled eee eos e sue EH ds e START STOP DIRECTION COMM MODULE NOT SEL IQEC 2 DI 1 2 NOT USED START STOP KEYPAD REQUEST 2 8 REMOTE FORWARD j DIRECTION MM MODULE oe EKTE REVERSE NOT SEL IOEC2 DI 1 2 11 03 16 01 KEYPAD DIRECTION jp PROCESS STOP COMM MODULE EXT CTIO OCESS STO aue 11 01 11 02 12 02 PUSH 2 EXT1 EXT2 BUTTONS STRT STOP DIR STRT STOP DIR SELECTION ON 9 9 BB IL ACS 1000 IOEC 2 DI 9 IOEC 1 DI 6 MCB Offline MCB IS OPEN DI 7 MCB Online i IOEC 2 DI 10 MCB i MCB IS
183. onding parameters are listed as well For further settings refer to Appendix K Signal and Parameter Table Table 4 8 Hand Auto Macro 1 0 Signals Digital Inputs Outputs Terminal Parameter Remarks DI 2 1 IOEC 2 11 01 1 start START STOP HAND X11 1 2 0 stop DI 2 6 IOEC 2 11 02 1 start START STOP AUTO X124 2 0 stop DI 2 7 IOEC 2 11 04 1 request for closing the main REMOTE ORD MCB X12 3 4 circuit breaker CLOSE HAND DI 2 13 IOEC 2 11 04 1 request for opening the main REMOTE ORD MCB X13 5 6 circuit breaker OPEN HAND DI 2 3 IOEC 2 11 05 pulse 1 command for clos REMOTE ORD MCB X11 5 6 ing the main circuit breaker CLOSE AUTO DI 2 4 2 11 05 pulse 1 command for open REMOTE ORD MCB X11 7 8 ing the main circuit breaker OPEN AUTO DI 2 5 IOEC 2 12 02 0 hand selected EXT1 EXT2 SELECTION X11 9 10 1 auto selected DI 2 2 IOEC 2 33 01 If set to 1 a predefined constant CONSTANT SPEED 1 X11 3 4 speed reference is selected DI 1 8 X301 0 control panel is enabled DISABLE LOCAL X1 2 1 control panel is disabled DI 2 8 IOEC 2 16 01 Process stop or run enable PROCESS STOP X12 5 6 0 drive will not start or stop if running DI 2 9 IOEC 2 21 06 Feedback from MCB MCB IS OPEN X12 7 8 0 MCB is open 1 MCB is closed DO 2 5 IOEC 2 21 05 Command to open the MCB MCB ORD OPEN X25 2 3 pulse gt 0 MCB open 1 DO 2 6 IOEC 2 21 05 Command to close the MCB MCB ORD CLOSE X
184. ontinued Message Possible cause Suggested remedy 2 3 amp Comments meaning of message amp 0 5 5 5 5 ExtMotProt External motor protection trip Check motor and record fault to X Possible causes gether with load conditions into Dueto a motor problem external logbook motor protection relay has been Check that all trip limit values actuated are correctly set in the relay Wiring in protection circuit dis Check wiring between external turbed protection relay and ACS 1000 Shielding of control cables not input EXT MOT PROT TRIP on properly grounded board Check wiring to relay inputs Check if shielding of control ca bles is properly grounded If the fault cannot be eliminated call local ABB service organiza tion ExtOver External motor overspeed protec Check parameter settings of ex X X Optional speed tion ternal relay Check that settings Possible causes are not in conflict with converter Wrong parameter settings parameter settings Loss of parameter settings or check power supply of external power supply in external relay relay Motor is forced to overspeed by Check motor loading especially driven equipment if driven equipment is dimen Wiring in protection circuit dis sioned correctly and functioning turbed properly Check with logbook if Poor grounding connections fault occurs repeatedly and record trip conditions Check wiring and connections between relay and converter Check relay input
185. ontrol section door Batteries Disconnect the batteries Loosen the rubber belt 1 around the batteries and remove the bat teries Place the new batteries and fasten the rubber belt Reconnect the cables to both batteries Make sure that the polarity is set correctly according to the markings on the batteries and on the la bels of the cables see Figure 6 Make a polarity check see figure below onthe EPS board unplug the cable 1 2 connect the terminal of the unplugged cable to the test pin 3 The LED 4 must light up if the polarity is correct Plug the cable 2 back to the pin 4 1 E 1 2 7 Lock the door and record the date of replacement the logbook Parameter Backup See Drives Windows user manual ACS 1000 User s Manual Rev C 3BHS102769 7 11 of 12 Chapter 7 Preventive Maintenance Inspection of Motor See corresponding manuals Transformer and MCB Maintenance A maintenance logbook with a complete record of any maintenance Logbook activity must be kept Any entry must include date and time maintenance task carried out according to mainte nance schedule any special situation or action scheduled or non scheduled replacement of parts etc ABB Service Please ask your ABB sales representative for the address of the lo
186. ontroller is bypassed if external control station EXT1 is selected DI 2 3 is open Then the ACS 1000 no longer controls the process variable but the speed of the motor directly Default actual signals shown on the control panel are MOTOR SPEED ACTUAL VALUE1 and CONTROL DEVIATION Figure 4 7 PID Macro Control Overview Input Power OL 1242 0rpm I MotSpeed 1242 0 rpm Actual Valuel 52 00 96 EU 1 0 1 ef E PID Reference value start stop and direction Actual value EXT commands are given from the control panel To START STOP EXT1 change to EXTERNAL press the LOC REM key oS ee im peed Process 0 52 1 I MotSpeed 1242 0 rpm Run Enable M rp Const Speed Actual Valuel 52 0 CtrlDev 0 1 External Control r EXT1 rpm Direct Speed Control Reference is read from analog input AI 1 1 Start 2 96 Process PID Control M stop command is given through DI 2 1 when in direct speed control EXT1 or through digital Keypad Control input DI 2 6 when in Process Control EXT2 REF1 rpm Direct Speed Control Motor REF2 96 Process PID Control ACS 1000 User s Manual Rev C 3BHS102769 4 21 of 38 Chapter 4 I O Interfaces and Application Macros Input and Output default I O signals of the PID Macro regarding opening closing the Signals MCB starting stopping the drive speed control
187. oors includes an electrome chanical interlock system that operates in conjunction with the safety grounding switch and electrical interlocks from the main circuit breaker external This interlock system insures that none of the power cabinets can be opened until the main source of power is disconnected the safety grounding switch is closed and the DC link capacitors are discharged 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 The control section can always be opened Lifting Arrangements cabinets are fitted with lifting lugs as standard Channels are provided at the base of the unit for lifting by forklift vehicles Cooling Circuit ACS 1000 ACS1014 A2 is equipped with forced air cooling as mentioned above The air intake is located in the front door of the inverter section The standard grid can optionally be equipped with an air filter ACS 1000 User s Manual Rev C 3BHS102769 3 9 of 30 Chapter 3 Design and Functional Description system to minimize air pollution in the converter The air filter can be replaced from outside while the system is running Figure 3 7 Cooling fan inside the converter cabinet standard From the front door intake the air flows through the heat sinks of the vertical inverter stacks and is then routed to the central section where the fan is located
188. ooster pumps of municipal water supply systems Automatic level control of water reservoirs Booster pumps of district heating systems Speed control of different types of material handling systems where the material flow has to be regulated The Torque Control Macro is set up for processes requiring torque control e g mixers and slave drives The torque reference comes from a process automation system or a control panel The Sequential Control Macro is typically used in processes requiring different constant speed settings and or different acceleration decelera tion settings in addition to an adjustable speed reference value Up to seven constant speed settings and two acceleration deceleration settings are possible The selection of the different settings can be automized by a process control system or can be made manually by selector switches which are connected to the corresponding digital inputs The Master Follower Macro is designed for applications with several ACS1000 drives 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 at some adjustable other ratio which depends on the process Each of these two macros allows to save a complete customized para meter set and to recall it at a later instant 4 12 of 38 3BHS102769 ACS 1000 User s Manual Rev C Factory Macro Chapter 4 I O Interfaces and App
189. or speed user adjustable a trip is initiated In addition an input for connection of an external motor overspeed trip is available A converter trip is also initiated if the external motor overspeed trip is activated signal active when low For further details refer to the Engineering Manual In order to detect a loss of the net supply the levels of the positive and negative DC link voltage levels are supervised If these voltage levels drop below 709 of their nominal levels an undervoltage alarm is initiated and 3 24 of 30 3BHS102769 ACS 1000 User s Manual Rev C Chapter 3 Design and Functional Description power loss ride through is activated provided it is selected If the DC link voltage levels drop below 65 of their nominal levels an undervoltage trip is initiated For further details refer to the Engineering Manual Preprogrammed Protection Functions Motor Phase Loss phase loss function monitors the status of the motor cable connec tions 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 supervises 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 Overvoltage The levels of the positive and negative DC link voltage are su
190. os 6 2 Application Parameter Editing Overview 6 2 Parameter Editing with the CDP 312 Control Panel 6 6 General 6 6 Conventions 6 6 Prerequisites 6 7 Selection of Actual Signals 6 7 Start Up Parameters 6 7 Selection or Verification of Application Macro 6 11 ACS 1000 User s Manual Rev C 3BHS102769 5 of 10 Selection of Motor Control Features 6 13 Verification and Modification of Parameters 6 14 Motor Identification Run 6 15 Miscellaneous Functions 6 16 ACS 1000 Information 6 16 Parameter Lock 6 16 Uploading Parameters 6 16 Downloading Parameters 6 17 Copying Parameters to Other Units 6 19 Restoring Default Settings 6 19 User Macros 6 20 Creating a User Macro 6 21 Recalling User Macro Parameters 6 22 Chapter 7 Preventive Maintenance Introduction 7 1 Safety Instructions 7 1 Maintenance Schedule 7 3 Required Tools 7 4 Maintenance Instructions 7 4 Standard Procedure for Maintenance 7 4 Outside Cleaning 7 7 Inside Floor Cleaning 7 7 Check of Connections 7 7 Replacement of Air Filters 7 8 Inverter Door Air Inlet 7 8 Control Door Air Inlet 7 8 Replacement of Fan 7 8 Replacement of Fan Bearings 7 10 Replacement of Batteries 7 11 Parameter Backup 7 11 Inspection of Motor Transformer and MCB 7 12 Maintenance Logbook 7 12 ABB Service Address 7 12 Chapter 8 Trouble Shooting amp Repair Overview 8 1 Safety Instructions 8 1 Alarm and Fault Handling 8 2 Fault Display on the CDP 312 Control Panel 8 3 Active Fault Displ
191. oth and non abrasive surface protected against humidity diffusion levelled and able to support the weight of the converter min 1 000 kg m Cable ducts must be of non flammable material with non abrasive sur face and protected against humidity dust and penetration of animals Selection and The connection from the mains supply to the ACS 1000 drive consists of Dimensioning of six basic elements Power Equipment Wain circuit breaker controller nstrumentation and protection equipment Transformer primary cable Transformer Transformer secondary cable Cable termination ACS 1000 Recommendations for the dimensioning and 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 as stated in this manual appears to be in conflict with the requirements please contact your local ABB representative for further assistance Main Circuit Breaker main circuit breaker controller can be either a vacuum or gas insu Controller lated circuit breaker or vacuum controller medium voltage starter In ei ther case it should carry basic voltage and current ratings in accordance with the rated primary voltage and current levels of the transformer which is supplied In addition to the basic electrical characteristics it must also meet specific drive requirements some items require proper
192. out according to the maintenance schedule on time in the described sequence and by authorized personnel Unless agreed otherwise in a service contract it is the owner s responsi bility to verify that all necessary maintenance work is carried out according to the maintenance plan and tocall up the local ABB service organization when maintenance work is due In order to maintain safe and reliable operation of the ACS 1000 it is strongly recommended to sign a service contract with the local ABB service organization For more information please contact your local service representative Special maintenance and service training courses for professionals are offered by ABB Customer staff having successfully attended such courses will be certified to do maintenance and repair work on the ACS 1000 provided that the equipment is not under warranty anymore For further information please contact your local service representative The ACS 1000 is a high voltage device and when misused it can cause damage to personnel and property When located installed and connected in accordance with the instructions given in this manual the device is safe Warning All electrical work on the ACS 1000 must be carried out by ACS 1000 User s Manual Rev C 3BHS102769 7 1 of 12 Chapter 7 Preventive Maintenance qualified electricians in compliance with local regulations Any work must be done with mains and auxiliary power off Input
193. p and parameter when this mode is entered for the first time after power up the dis play will show the first parameter of the first group Select a parameter group using the fast UP DOWN keys Select a parameter to be entered using the slow UP DOWN keys 6 14 of 22 3BHS102769 ACS 1000 User s Manual Rev C Chapter 6 Parameter Viewing and Editing 5 Press ENTER B 6 Change the parameter using fast for numeric values only and slow UP DOWN keys oo 00 7 Press ENTER to save the changed value To cancel the selection and keep the original value press any of the Mode keys without pressing ENTER The display will change to the selected Keypad Mode Repeat steps 3 to 7 for all remaining parameters 9 To exit the parameter mode press any of the mode keys Or to select another parameter group and to continue with parameter in put use the fast UP DOWN keys Motor Identification follow later For a short description see Chapter Design and Func Run tional Description Motor ID Run page 3 12 Please contact your ABB service representative if you need to change the motor parameters ACS 1000 User s Manual Rev C 3BHS102769 6 15 of 22 Chapter 6 Parameter Viewing and Editing Miscellaneous Functions ACS 1000 Information ACS 1000 software version test da
194. pened through more than 90 The design is such that the swing frame can be opened without danger ously exposing the power terminals The standard ACS 1000 cabinet is rated IP21 Higher IP ratings are optionally available The ACS 1000 cabinet system provides the flexibility to add cabinet sections to the drive at any time Sections can be added in widths of 600 800 and 1000 mm resp 24 32 and 39 Inches 3 8 of 30 3BHS102769 ACS 1000 User s Manual Rev C Chapter 3 Design and Functional Description Figure 3 6 Hear view of ACS 1000 Clamp resistors Rs di dt chokes Ls Inverter stacks Power terminals Door Locks doors are hinged and locked using carriage key locks The power section of the drive multiple d
195. peration at low speeds 30 08 to 30 11 For details refer to Appendix K Signal and Pa rameter Table Check if parameter settings al low operation at low speeds If motor is operated continuously at low speeds additional cooling may be necessary Check motor ratings load and cooling If the fault cannot be eliminated call local ABB service organiza tion 8 24 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy 2 3 amp Comments meaning of message amp 0 5 5 5 5 No Cur Offs to start the converter be De energize converter X x fore the current offsets have been close grounding isolator accord checked ing to Chapter 5 Operation De energizing the ACS 1000 page 5 12 offset will be calculated automatically when grounding isolator is closed Danger When MCB is open wait 5 minutes before closing grounding switch No Filt Data Filter data missing Call local ABB service organiza Xx tion Offset Offset calibration was not suc x cessful OS Fault Operating system failure Calllocal ABB service organiza tion OutplsolDis Output isolator feedback discrep Check isolator operation follow Optional ancy ing isolator user manual and cir Two feedback sig Possible causes cuit di
196. pervised 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 imple mented 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 excita tion voltage that is causing the DC link voltage levels to rise To provide ultimate reliability the second overvoltage trip is implemented both in soft ware and redundantly in hardware 140 Short Circuit in the short circuit in the rectifier bridge is detected by supervising the DC link Rectifier Bridge voltage If a short circuit is detected a trip is initiated and the drive is disconnected from the supply voltage MCB opening time 100 ms Charging Fault The intermediate DC link voltage is supervised while charging If the voltage does not reach a certain level after a pre set time a trip will be initi ated Supply Phase Loss If the voltage ripple in the intermediate dc link rises above a pre set level a supply phase may be lost A trip is initiated Overcurrent The overcur
197. position and the doors cannot be opened it is possible to override the door interlocking ACS 1000 User s Manual Rev C 3BHS102769 10 15 of 28 Chapter 10 Installation system Proceed as described in Step 13 and Figure 10 11 Figure 10 11 Grounding switch lock override Warning as soon as the installation is terminated the cover plate must be re mounted Electrical Installation Mains and Motor The mains and motor cables are connected to the ACS 1000 in the left Cable Lead In hand section control section of the cabinet as illustrated in Figure 10 12 10 16 of 28 3BHS102769 ACS 1000 User s Manual Rev C Chapter 10 Installation Figure 10 12 Principle of power cable lead through BBB j EE e E 2U1 C 2201 SEP 2v SETE 21 f Nr U2 Nso V2 1U1 101 1V1 1 1 1W1 1 1 SLT ILPTELTATE TE Cable lead through from top Cable lead through from below Mains and motor cable lead through is from below or from the roof The gland plates mounted on top of the control section must be relocated to the base of the cabinet if the cables are led in from below The maximum conductor diameter is 45 mm
198. ps 75 OPTION MODULES and 99 START UP DATA 9 will not be uploaded Proceed as follows for parameter uploading 6 16 of 22 3BHS102769 ACS 1000 User s Manual Rev C Chapter 6 Parameter Viewing and Editing 1 Select the Function mode by pressing the FUNC key 2 Select UPLOAD using the slow UP DOWN keys 3 Press to start uploading 4 During the uploading process only the STOP command can be given To exit the function mode after completion press any of the mode keys Downloading Parameter downloading might be necessary following the replacement of Parameters control equipment such as the board or the Flash PROM The drive must be stopped during downloading ACS 1000 User s Manual Rev C 3BHS102769 6 17 of 22 Chapter 6 Parameter Viewing and Editing Downloading can only be started following a successful upload Otherwise the following warning will appear e 2 8 Note Parameter groups 75 OPTION MODULES 99 START UP DATA 3 will not be downloaded Proceed as follows for parameter downloading 1 Select the function mode by pressing the FUNC key 2 Select DOWNLOAD using the slow UP DOWN keys 4 During the downloading process only the STOP command can be given To exit the function mode after completion press any of the mode keys
199. quipment is not under warranty anymore For further information please contact your local service representative Safety Instructions ACS 1000 is a high voltage device and when misused it can cause damage to personnel and property When located installed and connected in accordance with the instructions given in this manual the device is safe Warning All electrical work on the ACS 1000 must be carried out by qualified electricians in compliance with local regulations Any work must be done with mains and auxiliary power off Input and out put isolators must be open and secured any adjoining grounding device must be closed and power cables must be grounded Never apply power to the installation unless you have checked that mains and motor connections are ok auxiliary power and control connections are ok notools or other foreign objects are left in the cabinet Allcabinet doors including separation door behind the swing frame and ACS 1000 User s Manual Rev C 3BHS102769 8 1 of 38 Chapter 8 Trouble Shooting amp Repair gt PP B Alarm and Fault Handling door of the control section are closed Danger Never work on a powered ACS 1000 The main circuit breaker and the input isolators must always be opened and locked in po sition Do not access the main power circuit nor the motor as long as the system is not grounded When switching off the mains always allow the intermediat
200. r Step VII protection data parameter group 37 Prerequisite 3 amp 4 If applicable Activate external motor heater cooler parameter group 38 Prerequisite IOEC 3 For motor cooler only If applicable Activate external speed measurement 75 03 and input data parameter group 50 If applicable Activate fieldbus APC2 communication 75 04 and input data param groups 90 to 95 6 4 of 22 3BHS102769 ACS 1000 User s Manual Rev C Chapter 6 Parameter Viewing and Editing Figure 6 1 Application parameter programming procedure continued Activate I O board configuration IOEC 3 IOEC 4 Step VIII parameters 75 01 amp 75 02 According to selected options Set I O parameters parameter groups 80 to 89 A Start ACS 1000 If first start initiate ID run then start ACS 1000 Adjust speed controller parameter group 24 and other control parameters depending on selected macro If required Set critical and constant speeds ride through and supervision parameters groups 32 to 34 39 Step XII If required Set pass code parameter group 16 ACS 1000 User s Manual Rev C 3BHS102769 6 5 of 22 Chapter 6 Parameter Viewing and Editing Parameter Editing with the CDP 312 Control Panel General Conventions In this chapter you w
201. r wiring in monitoring circuit dis to MCB specifications and Ap turbed pendix K Signal and Parameter Shielding of cables not properly Table grounded Check wiring and shielding of measuring circuit f the fault cannot be located call local ABB service organiza tion OutsAir Supervision of ambient tempera Check ambient temperature X Water cooled con Temp ture f ambient temperature is within verters only Possible causes limits check if analog input High ambient temperature OUTSIDE AIR TEMP on External measurement device is within range defective Check limit parameter settings Parameter setting not correct 81 16 to 81 20 For details refer wiring in monitoring circuit dis to MCB specifications and Ap turbed pendix K Signal and Parameter Shielding of cables not properly Table grounded Check wiring and shielding of measuring circuit f the fault cannot be located call local ABB service organiza tion Overspeed SW function Motor overspeed Check all parameters start up supervision of rotation frequency data of group 99 particularly Possible causes the nominal speed setting and Wrong parameter settings compare with the motor name Motor is forced to overspeed by plate driven equipment Check parameters in group 12 reference select and 20 lim its Refer to Appendix K Signal and Parameter Table Check motor loading especially if driven equipment is dimen sioned correc
202. r s Manual Rev C Chapter 4 I O Interfaces and Application Macros Master Follower Macro Description All drive commands and reference settings for a master follower drive configuration can be given from the control panel of the master drive or from an external control station connected to the master drive The follower drive s receive s the control signals via a fibre optic link from the master drive Connect all control signals to the master drive only Do not control the follower s with its their own control panel s Disable the control panels of all follower drive s by setting parameter 16 02 PA RAMETER LOCK to LOCKED to prevent accidental use Do not control the follower through a fieldbus system Parameter settings and further information regarding the Master Follower Macro can be found in Appendix K Signal and Parameter Table para meter group 70 The active control station control panel or external control station is selected by the LOC REM key on the control panel of the master The control panel can be disabled by closing DI 1 8 The digital input can be accessed via terminals X301 1 and X301 2 In remote control the reference value is connected to Al 2 1 the start stop command is wired to DI 2 1 and the sense of rotation can be changed with DI 2 2 The default setting for the sense of rotation parameter 11 03 is FORWARD It can be changed to REVERSE either by setting parameter 11 03 to REVERSE or v
203. r 11 3 Make sure that the parameter 11 3 DIRECTION is correctly set according to the process requirements see Chapter 6 Parameter Viewing and Editing 5 6 of 20 3BHS102769 ACS 1000 User s Manual Rev C Chapter 5 Operation On the display the selected sense of rotation will be in dicated with an arrow 19 Start the unit by pressing the key In the first place magnetization takes place After a few seconds the motor is driven up to reference speed following a preset ramp In Remote Control Remote setpoint transmission and remote start are initiated automat Mode ically via remote control inputs see Chapter 4 I O Interfaces and Ap plication Macros Input Output Boards page 4 1 Changing Setpoints Setpoint changes on the operating system can be made at any time from the active control location local or remote control In Local Control Mode 1 Press REF on the CDP 312 control panel ACS 1000 User s Manual Rev C 3BHS102769 5 7 of 20 Chapter 5 Operation In Remote Control 1 Mode Reverse Sense of Rotation In Local Control Mode 1 Input setpoint speed torque according to application macro require ments see Chapter 4 I O Interfaces and Application Macros Input Output Boards page 4 1 by using the UP DOWN keys gt 14 The setpoint change will become active immediately Press the ACT key to
204. r altered by the user In the actual signal display mode the CDP 312 display continuously shows the actual values of three preselectable signals The actual signal display appears first when the actual signal display mode is selected However if the drive is in a fault condition the fault display will be shown instead The panel will automatically return to actual signal display mode from other modes if no keys are pressed within one minute exceptions status display and common reference display in drive selection mode and fault display mode In the actual signal display mode you can monitor three actual signals at a time Depending on the selected application macro a default set of 3 signals will be displayed A complete list of selectable actual signals parameter groups 1 9 can be found in Appendix K Signal and Parameter Table Proceed as follows to change any of the displayed signals can be done when system is running 1 Enter the actual signal display mode by pressing ACT on the CDP 312 control panel 2 Selectarow by using the UP DOWN keys a blinking cursor indicates the selected row ACS 1000 User s Manual Rev C 3BHS102769 5 15 of 20 Chapter 5 Operation 3 activate the actual signal selection option press ENTER 4 Select a parameter group using the fast UP DOWN keys Please refer to Appendix K Signal and Parameter Table for a l
205. r details see Engineering Manual and Appendix K Signal and Parameter Table Motor Stall ACS 1000 protects the motor if a stall condition is detected The supervision 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 of the following conditions are fulfilled simultaneously Figure 3 12Stall region of the motor Torque egion 1 The output frequency is below the set stall frequency 2 Thedrive is in torque limit The torque limit level can be set by the user The Stall f Hz TP i Frequency torque limit level is a basic setup pa rameter that sets maximum drive output torque Although it indirectly ef fects 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 Motor stall protection is set with parameters 30 12 to 30 14 in group Fault Functions For further details see Engineering Manual and Appendix K Signal and Parameter Table ACS 1000 User s Manual Rev C 3BHS102769 3 23 of 30 Chapter 3 Design and Functional Description Underload Loss of motor load may indicate a process malfunction ACS 1000 provides an underload function to protec
206. r medium voltage equipment Cable screening is not required for the motor cables since converter out put 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 either separately or by including it in the 3 conductor cable The ampacity of this conductor should be in accordance with the code Motor cables are terminated within the ACS 1000 in the same way as transformer secondary cables See Electrical Installation page 10 16 for further details ACS 1000 User s Manual Rev C 3BHS102769 10 7 of 28 Chapter 10 Installation Power Cable Dimensions Table 10 1 lists the recommended cross sections for mains and motor cables In orderto determine the exact dimensions for your application the actual situation method of installation voltage drop due to cable length etc and local regulations must be considered Refer also to the specifica tions of the cable manufacturer Table 10 1 Recommended cable cross section for power cables for the ACS 1000 Type Motor amp PEE Ideal installation conditions Worst case d usd current o Cross Current T Cross ACS ensiy Sabies PRA LA xd A mm mm A mm mm 1014 A1 800 111 4 44 1 25 3 17 1 35 1014 A2 1 400 194 5 55 1 35 2 78 1 70 10
207. rameter and with the consequences resulting from the modification Running the ACS 1000 the motor and the equipment being driven with in correct data can result in improper operation reduction in control accuracy and damage to equipment ACS 1000 The control configuration and the application parameters of the ACS 1000 Application are programmable Configuring the ACS 1000 includes basically the input Parameters of a set of parameters by the commissioning engineer Some of these parameters are determined automatically by the control system i e the motor characteristic by performing the motor ID run and cannot be altered by the user Parameter Groups In order to simplify programming parameters in the ACS 1000 are orga nized in groups Typical parameter groups are e Start up parameters Reference selection e Analog binary inputs or output definition parameters all inputs and ACS 1000 User s Manual Rev C 3BHS102769 6 1 of 22 Chapter 6 Parameter Viewing and Editing Start up Parameters Application Macros Application Parameter Editing Overview outputs are programmable e Actual signals A complete list of all parameters can be found in Appendix K Signal and Parameter Table The start up parameters form a special set of parameters defining the basic system characteristics such as nominal mains voltage rated current and other main data of the motor They must be determined and entered individually for
208. rameters assigned for constant speed settings are in group 33 Two preset acceleration deceleration ramps are selectable via DI 2 3 The start stop command is connected to DI 2 1 and the sense of rotation can be changed via DI 2 2 An external speed reference value can be wired to Al 2 1 It is active if DI 2 4 DI 2 5 and DI 2 6 are low Operational commands and reference value can also be given using the control panel if set to local The control panel can be disabled by closing DI 1 8 The digital input can be accessed via terminals X301 1 and X301 2 Default actual values shown on the Control Panel are FREQUENCY CURRENT and POWER Figure 4 11 Sequential Macro Control Overview Speed Speed 3 Stop with deceleration ramp Speed2 Speed 1 Accel1 Accel1 Accel2 Decel2 hm Accelt Deceli T Speed 1 Speed 2 Accel2 Decel2 a Speed 3 PF llc NN Example of sequential control using constant speeds and different acceleration and deceleration times ACS 1000 User s Manual Rev C 3BHS102769 4 29 of 38 Chapter 4 I O Interfaces and Application Macros Input and Output The default I O signals of the Sequential Macro regarding opening closing Signals the starting stopping the drive speed control location reference and actual values are shown in the following table The corresponding parameters are listed
209. re connected All cable screens are connected Oo BR C Insulation of cables transformers and motor has been tested and com plies with the specification insulation test of the converter will be per formed by the commissioning engineer An official test report is available 8 Mains voltage supply is available 9 The driven load pump fan compressor etc is ready for coupling and for operation under nominal conditions 10 auxiliary cables are connected 11 Auxiliary voltage switchgear is connected and operable 12 Control cables are connected MCBoontrol cables are connected directly to the con verter Tripping loop Remote control cabling Cabling of options Transformer and motor protec tion tachometer etc 13 Auxiliary voltage supply is available 14the plate of the grounding switch lock override is attached and secured 15 Raw water circuit connected to the converter if applicable ACS 1000 User s Manual Rev C 3BHS102769 11 1 of 2 Chapter 11 Commissioning Miscellaneous Commissioning Procedure Required Customer Manpower Acceptance Warranty 16 Raw water according to Chapter 10 Installation is available if applica ble 17 All spare parts are available 18 All necessary process information has been handed over to your ABB sales representative For details please contact ABB 19 For water cooled converters only Sufficient deionized water for filling the coo
210. referably above 2 777 DESICCANT gt gt the swivel cover of the inspection hole Color of the label is black ABB s Quality Management assures that the packing of the converter unit corresponds to specific requirements regarding safety and cost efficiency The choice of the right conservation concept depends on the final desti nation of the goods namely the climatic zone Zone A temperate zone zone B tropical zone The conservation measures taken for the transport packing are only useful as long as the packing is kept unopened and in its original condition Loading and For loading and unloading the converter with the help of a hoisting device Unloading following points have to be observed Caution The converter has to be transported in upright position Caution Use always the lifting eyes on the top of the converter The lifting eyes may only be removed after the converter has been in stalled at its final position They have to be remounted if the converter has to be transported again The material and diameter of the transport rope or chain have to corre spond to the weight of the converter unit ACS 1000 User s Manual Rev C 3BHS102769 9 3 of 10 Chapter 9 Transportation Storage Disposal and Recycling Lifting Angle minimum lifting angle between the rope or chain and the converter unit is 45 see Figure 9 1 Caution The fan cover must not be mounted whi
211. rent trip limit for the ACS 1000 is 2 2 times the nominal inverter rms current If this level is exceeded a trip is initiated Loadability of the n order to insure that the inverter section does not exceed normal temper Inverter ature limits the current load of the inverter is supervised If a current time overload is detected a trip is initiated ACS 1000 User s Manual Rev C 3BHS102769 3 25 of 30 Chapter 3 Design and Functional Description Short Circuit of the Inverter Ground Fault Operating System Measurement Loss Battery Test Communication Fault ID Run Fault The inverter is monitored to insure that a short circuit condition does not exist If a short circuit is detected a trip is initiated The ground current in the output filter circuit is monitored If it exceeds a certain level a trip is initiated The operating system of the microprocessor board supervises 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 initiated during operation the system should be restarted In order to guarantee proper operation of the protection functions included in the converter all communications between the control boards are checked cyclically On the ADCVI board analog digital conversion for voltage and current analog signals are converted into digital signals The digital signal
212. rfaces and Application Macros Analog Inputs Outputs Terminal Parameter Remarks Al 2 1 IOEC 2 Remote speed reference if EXTERNAL SPEED REF X31 2 X32 2 Const Speed Sel 1 amp Const ERENCE 1 Speed Sel 2 are set to 0 AO 1 1 IOEC 1 15 01 Motor frequency actual value MOTOR FREQUENCY X31 6 X32 6 4 20 mA AO 1 2 IOEC 1 15 06 Motor torque actual value MOTOR TORQUE X31 7 X32 7 4 20 mA AO 2 1 IOEC 2 15 11 Shaft speed actual value SHAFT SPEED X31 6 X32 6 4 20 mA AO 2 2 IOEC 2 15 16 Actual value of filtered motor MOT TORQUE FILTERED X31 7 X32 7 torque 4 20 mA The control signal diagrams of the master see Figure 4 14 and of the follower see Figure 4 15 show how the control signals i e reference value starting stopping commands MCB opening closing commands are interconnected in the application software of the ACS 1000 Note that the follower receives all control signals via the fibre optic link channel 2 fast drive link from the master 4 36 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 4 I O Interfaces and Application Macros Figure 4 14 Control Signal Diagram of Master 12 06 12 03 33 33 01 EXT REF2 EXT REF1 CONSTANT CONST SPEED ANAL INPUTS SELECTION SELECTION SPEEDS SELECTION IOEC 2 1 REF1 2 IOEC 1 AH SPEED CONTROL REF2 LOOP 23 01 L gt NOT SEL LOCAL SPEED REF CHO 1
213. ription Analog Input Processing Offset Calibration Speed reference functions are set with parameter group 23 Speed Hef For further details refer to the Engineering Manual and to Appendix K Signal and Parameter Table The ACS 1000 has two programmable analog inputs voltage or current inputs hardware selected Each of these analog inputs can be processed by adjusting the signal min max levels the filtering time constant and the signal inversion selection with software parameters The minimum setting of 0 mA 0 V 4 mA 2 V or the input tuning can be selected The tuning function allows the ACS 1000 to read the actual value and define it as minimum signal level The maximum setting of 20 mA 10 V or the input tuning can be selected The tuning function allows the ACS 1000 to read the actual value and define it as maximum signal level The analog input signal filtering time constant is user adjustable from 0 01 10 s with software parameters Figure 3 11Analog input filtering time constant Al t Unfiltered Signal 100 4 63 Filtered Signal UHH t Filter time constant With inversion activated the minimum level of the analog input signal corresponds to the maximum reference and the maximum analog input signal corresponds to the minimum reference For further details on analog input allocation refer to the Engineering Manual Automatic offset calibration of analog inputs is possible For
214. rotection relay Loss of a phase or voltage un Check protection relay settings balance Check wiring and shielding of Loss of aux power supply for monitoring circuit unbalance protection relay f the fault cannot be located Wiring in monitoring circuit dis call local ABB service organiza turbed tion Shielding of cables not properly grounded Inv Curr HW HW supervision excessive invert Check fault history buffer for X er output current other possibly related error Possible causes messages Motor load not matched with in Check dimensioning of motor verter ratings and drive For inverter ratings ncorrect motor data see Appendix A ACS 1000 If fault occurs during accelera Technical Data tion the acceleration time might Verify start up parameters 99 3 be too short to 99 8 Compare with motor Stray currents in motor cabling nameplate See Appendix K Parameter Description Check if fault occurs only during acceleration If this is the case increase the acceleration time parameters 22 02 and 22 04 Check motor cable connections f the fault cannot be eliminated call local ABB service organiza tion Inv Curr SW supervision of Inverter cur Check fault history buffer for X SOA rents according to safe operating other possibly related error area excessive inverter output messages current Check dimensioning of motor Possible causes and drive For inverter ratings Motor load not matched with in
215. ry power are shut off Take appropriate measures when working with the unit i e deenergize and disconnect all such external devices auxiliary supply heaters coolers l O interfaces before you start work Danger This converter can influence the working of heart pacemakers Install a corresponding warning sign at the entrance to the converter room In case the ACS 1000 is located in an open hall the safety sign must be at a minimum distance of 6 meters 20 feet to the converter ACS 1000 User s Manual Rev C 3BHS102769 1 5 of 6 Chapter 1 Safety Instructions 1 6 of 6 3BHS102769 ACS 1000 User s Manual Rev C Chapter 2 Introduction Overview This manual provides you with detailed information on the installation and start up of the ACS 1000 frequency converter including detailed descrip tions of the functions installation and start up of the unit Fault tracing information technical data and dimensional drawings are included as well Range of The ACS 1000 is a standard medium voltage AC drive rated according Application of the to the technical specifications in Appendix A Technical Data ACS 1000 The ACS 1000 has been designed as converter drive for squirrel cage induction motors Standard applications are the control of fans pumps conveyors and compressors in petrochemical mining water pulp amp paper cement industries and power generation The customized engi neering content is minimal
216. s Setting the contrast Drive Selection Mode Operational Commands Local Control Remote Control Changing Control Location Start Stop Direction and Reference Appendix C Customer Specific Options Appendix D Quality Assurance Introduction to ABB s QA System ISO 9001 ISO 14000 Appendix E Applicable Codes and Standards Appendix F Layout and Mechanical Drawings Appendix G Wiring Diagrams 1 N S ACS 1000 User s Manual Rev C 3BHS102769 9 of 10 Appendix H Part List Appendix Recommended Spare Parts List Appendix K Signal and Parameter Table Appendix L Inspection and Commissioning Record Appendix M Parameter Setting List Index 10 of 10 3BHS102769 ACS 1000 User s Manual Rev C Chapter 1 Safety Instructions General The ACS 1000 is a high voltage device and when misused it can cause damage to personnel and property When located installed and connected in accordance with the instructions given in this Manual the device is safe Personnel involved in installation commissioning and maintenance work on the ACS 1000 must be electrical professionals who are fully acquainted with medium voltage MV equipment Operating the drive does not require special knowledge of frequency converters However the user must understand the meaning of the messages on the control panel of the converter If an alarm or a trip is registered by the converter control the oper
217. s are then transmitted via PPCC fiber optic bus system to the interface board which is the main interface to the converter control On the interface board the status of the communication is supervised If a fault is sensed a trip is initiated In order to guarantee correct fault indications and proper trip sequencing in the event that the auxiliary power source feeding the drive is lost the ACS 1000 is equipped with a battery to supply redundant DC control power While the converter is in operation the charge on the battery is checked periodically by applying a known load and measuring the resulting voltage drop If the battery is determined to be deficient in its ability to supply power a fault message is displayed and either a normal stop or an alarm is initiated Normal stop is initiated if the self excitation speed of the motor is lower than nominal speed An alarm is set if the self excitation speed is higher than nominal speed This is determined auto matically during the ID run Default value if no ID run has been done is normal stop Except for the measurement boards all communication links are realized by DDCS Distributed Drive Control System If one of these links is missing a trip is initiated An identification run is done during commissioning The commissioning engineer enters nominal data for the identification of the system parame ters If the data has not been entered correctly and therefore the system parameters cannot
218. s commands and reference from the integrated control panel or through digital and analog inputs It is possible to predefine two separate External Control Locations EXT1 and EXT2 for both the Start Stop Direction commands and the reference signal The active External Control Location 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 Control location functions are set with parameter groups 11 Start Stop Direction MCB Control and 12 Reference Select For further details see the Engineering Manual and Appendix K Signal and Parameter Table Reference Signal ACS 1000 can handle a variety of speed reference schemes in addi Processing tion to the conventional analog input signal and control panel signals The ACS 1000 reference can be given with two digital inputs One digital input increases the speed the other decreases it The active ref erence is memorized by the control 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 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 ACS 1000 User s Manual Rev C 3BHS102769 3 21 of 30 Chapter 3 Design and Functional Desc
219. se at a speed reference step typically 1 20 Speed step response can be seen by monitoring the actual SPEED signal A Normally tuned speed controller autotuning undercompensated t B Critically compensated speed controller C Optimally tuned speed controller manual tuning Better dynamic performance than with A or B D Overcompensated speed controller 3 16 of 30 3BHS102769 ACS 1000 User s Manual Rev C Chapter 3 Design and Functional Description Accurate Speed static speed control erroris typi Control cally 0 196 of motor nominal speed which satisfies most industrial appli cations If even more precise speed e regulation is required a pulse encoder can be connected With a pulse encoder the static speed 0 m control error is typically 0 0196 of 0 1 0 4 sec motor nominal speed Ty rated motor torque rated motor speed The dynamic speed control error is tad Actual speed Net Speed reference typically 0 4 sec at 100 load torque step without a pulse encoder or tachogenerator With a pulse encoder the dynamic speed control error is typically 0 1 sec The pulse encoder is an optional device If used parameter 75 03 of group Option Modules must be activated Parameters are set with group 50 Speed Measurement For further details see Appendix K Signal and Parameter Table Table 3 1 Typical performance figures for spe
220. sformer Ambient temperature too high manual Transformer cooling disturbed Check if installation conditions Wiring in protection circuit dis are satisfactory exposure to turbed sun obstacles in air flow etc Shielding of control cables not Check cooling equipment Refer properly grounded to description of cooling circuit in transformer manual Check wiring of monitoring cir cuit input O L TEMP TRIP on IOEC3 board Check if shielding of control ca bles is properly grounded If the fault cannot be eliminated call local ABB service organiza tion 8 30 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy 5 3 amp Comments meaning of message m M UJ oP 5 5 5 TrafTmpM Transformer winding or oil temper Check input O L TEMP on X Optional Los ature supervision loss of analog IOEC3 board signals must be gt Default setting input 2mA Alarm Possible causes Check power supply of monitor Measuring circuit output lt 2 ing device Wiring in protection circuit dis Check wiring between external turbed temperature measuring device Shielding of control cables not and ACS 1000 properly grounded Check wiring to monitoring de vice inputs Check if shielding of control ca bles is properly grounded
221. so located in this area cards have screw type terminals on which cables totaling 2 5 mm AWG12 may be connected See Figure 3 5 and Figure 3 6 ACS 1000 User s Manual Rev C 3BHS102769 3 7 of 30 Chapter 3 Design and Functional Description Figure 3 5 Front view of ACS 1000 Cooling air exhaust Inverter stacks VLSD boards Gate unit power supply GUSP Rectifier and protection IGCT s Common mode damping resistor Room Ground isolator Common mode choke Loom ADOVI board Cooling fan Drive control swing frame Electronic power supply EPS board IOEC2 board control board Interface board IOEC1 board Ap transmitters optional IOEC3 board optional IOEC4 board___ _ eee optional Motor start and circuit breakers Batteries A Snubber DC circuit Output filter DC link SU j acitors i franciormer Filter reactor L capacitor C resistor set er e M Behind the swing frame and a protective separation door is the drive s power terminal section To provide adequate access to this section the swing frame can be o
222. start ing with any work ACS 1000 User s Manual Rev C 3BHS102769 7 5 of 12 Chapter 7 Preventive Maintenance 3 Switch off auxiliary power supply open contactor Q1 and discon nect all external devices feeding dangerous voltages into the cubicle Figure 7 1 Control cabinet Auxiliary supply Contactor Q1 Miniature circuit breakers Q11 Q12 any of the 4 positions 4 Carry out the required maintenance tasks refer to the mainte nance schedule and to the detailed instructions in this chapter E es Note For your own safety follow exactly the instructions in this chapter 5 and never attempt to do any maintenance or repair work on the ACS 1000 beyond these instructions 5 Check that mains and motor connections are ok auxiliary power and control connections are ok no tools or other foreign objects are left in the cabinet All cabinet doors including protective shield and door of the control section are closed 5 Note When closing the protective separation door all fastening screws must be mounted and tightened in order to maintain performance 6 Switch on the auxiliary voltage
223. supply Call local ABB service organiza Xx tion ID Run ID run was not successful Verify parameter settings in pa X x Fault Possible cause rameter group 99 and repeat ID Wrong start up parameter set run tings If the fault reappears call local ABB service organization ID Run ID run is requested first start up Carry out ID run X Reqst has been attempted without ID run ID Run Stop ID run has been interrupted Repeat ID run X stop command This message will be followed by ID RUN REQST InplsolDis Input isolator feedback discrepan Check isolator operation follow X Optional ing isolator user manual and cir Two feedback sig Possible causes cuit diagram nals do not corre Malfunction of isolator or isolator Check wiring and shielding of spond control isolator control circuit Wiring in isolator control circuit If the fault cannot be located disturbed call local ABB service organiza Shielding of control cables not tion properly grounded 8 16 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy 5 3 amp Comments meaning of message 9 p d oP 5 5 3 InpVolt Converter input voltage is not bal Check input mains voltage x x Optional Unba anced Check auxiliary power supply for Possible causes p
224. t the machinery and process in such a serious fault condition This supervision function checks whether the motor load is above the specified load curve 5 different load curves can be selected by the customer Supervision limits underload curve and underload time can be chosen as well as the drive response to the underload condition alarm trip indica tion amp stop the drive no reaction 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 five options see Figure 3 13 2 The motor load has been below the selected underload curve longer than the time set by the user Underload time Underload protection is set with parameters 30 15 to 30 17 in group fault functions For further details see Engineering Manual and Appendix K Signal and Parameter Table Figure 3 13Load curves for underload function Load curves of underload function Torque 0 8 4 0 7 0 6 0 5 curve 1 B curve 2 0 4 4 curve 3 lt curve 4 curve 5 0 Sp d o o o o o o o o o o o o o ee 3 5 5 5 p 5 5 5 10 20 30 40 50 60 70 80 90 100 110 120 130 140 Overspeed Motor speed as determined by DTC is monitored If motor speed exceeds Undervoltage the maximum permitted mot
225. take the following steps Danger The cooling water system may start automatically as soon a the auxiliary voltage is swithed on even if the converter is de energized Check that all of the following prerequisites are met 1 Installation and commissioning according to Chapter 11 Commis sioning is completed Auxiliary voltage is switched on All drive specific start up parameters according to Chapter 6 Parameter Viewing and Editing are set and checked Warning Running the motor and the driven equipment with incorrect start up data can result in improper operation reduction in control accura 5 2 of 20 3BHS102769 ACS 1000 User s Manual Rev C Chapter 5 Operation cy and damage to equipment 4 Cooling water system is running if applicable Preparatory Steps 5 Close all doors including the rear panel of the inverter section the protective separation door and the control section front door Warning All doors including the control section front door and the separation door behind the swing frame must be closed before energizing the unit All fastening screws must be mounted and tightened in order to maintain EMC performance The power section doors must be closed for safety reasons The front doors are interlocked with the grounding isolator The control section door must be closed to maintain EMC performance 6 Open the grounding isolator located on the central section door of the converter
226. te and serial number can be displayed Information data are stored in parameter group 6 information A detailed list can be found in Appendix K Signal and Parameter Table Proceed as described in Selection of Actual Signals page 6 7to view Parameter Lock user can prevent unwanted parameter adjustment by activating the Parameter Lock Parameter lock is set with parameters 16 02 and 16 03 in group system ctr inputs For further details see Appendix K Signal and Parameter Table To set the parameter lock proceed as follows 1 Select parameter 16 02 Parameter lock as described in Verification and Modification of Parameters page 6 14 steps 1 to 5 Set parameter 16 02 to LOCKED Save and exit as described in Verification and Modification of Parameters page 6 14 steps 7 ff To open the parameter lock proceed as follows 1 Select parameter 16 03 Pass code as described in Verification and Modification of Parameters page 6 14 steps 1 to 5 2 Setthe correct pass code If not known see Appendix K Signal and Parameter Table 3 Saveand exit as described in Verification and Modification of Parameters page 6 14 steps 7 ff Uploading f one CDP 312 control panel is used for more than one ACS 1000 unit it Parameters _ is necessary to copy all parameters from the Flash PROM to the control panel when connecting it to a converter Uploading can be performed while the drive is running Note Parameter grou
227. ter mode press any of the mode keys or to check and if necessary to modify the parameters proceed as de scribed in section Verification and Modification of Parameters page 6 14 Recalling User Macro In order to recall the parameters saved in the user macro proceed as Parameters described above In step 5 select USER 1 LOAD USER 2 LOAD instead of USEH 1 SAVE or USER 2 SAVE 6 22 of 22 3BHS102769 ACS 1000 User s Manual Rev C Chapter 7 Preventive Maintenance Introduction Safety Instructions This chapter contains a general maintenance schedule that lists all sched uled maintenance and replacement actions to be carried out by the owner or by specialized ABB service staff In addition descriptions for those preventive maintenance tasks that can be carried out by the owner are included Maintenance work to be carried out by the owner is generally limited to various cleaning tasks and to parts replacement in the cooling circuit Warning Do not attempt any maintenance work parts replacement or other actions on the ACS 1000 you are not entitled to according to this manual Such maintenance work or installation of replacement parts on the ACS 1000 may only be carried out by service staff of ABB Industrie AG and by their authorized service representatives Failure to comply with these regulations will void guarantee and endanger correct operation of the installation All maintenance work must be carried
228. termediate circuit capacitors to discharge before grounding and starting work on the frequency converter the motor or the motor ca ble The ACS 1000 and adjoining equipment must be properly grounded and the auxiliary supply voltage must be switched off prior to start ing with any work Danger There can be dangerous voltages inside the ACS 1000 from ex ternal control circuits measurement inputs from PT s etc even if the ACS 1000 mains power and auxiliary power are shut off Take appropriate measures when working with the unit i e deenergize and disconnect all such external devices auxiliary supply heaters coolers l O interfaces before you start work Prior to start working on the ACS 1000 the general safety regulations in Chapter 1 Safety Instructions must be read and understood ACS 1000 User s Manual Rev C 3BHS102769 10 1 of 28 Chapter 10 Installation ABB Industrie AG declines all liability for any possible damage resulting from failure or negligence to observe these warnings Requirements to Foundation Space and Ambient Conditions Ambient Conditions See Appendix A Technical Data for load capacity derating factors and other requirements related to ambient conditions Derating may be neces sary due to the presence of elevated levels in air temperature altitude or cooling water temperature Sufficient air flow must be available see Figure 10 1 Other ambient factors such as relative humidity a
229. the EMC slot of the gland plate that leads to the front area of the control section Strip cable insulation in the gland area The conduc tive cushions of the EMC slot should contact the stripped part of the cable See Figure 10 21 If the surface of the screen is covered with nonconducting material cut the screen carefully without damaging the conductors and reverse draw it over the insula tion see Figure 10 21 bottom Figure 10 21 Control cable lead in Side view Bottom view Lead through plate A WWW EMI conductive cushions Base plate 7 Holes for position screws N Stripped cable Conductive surface of Stripped part covered the screen turned visible with copper foil mem ae Copper foi dps E 24 Screened twisted pair ae gt Grounding wire IP54andcable entry from above Remove the rubber ACS 1000 User s Manual Rev C 3BHS102769 10 25 of 28 Chapter 10 Installation grommets from the gland plate and cut them to ade quate diameter for the auxiliary power cable To en sure proper sealing cut along the diameter marking that corresponds to the cable diameter Slide the grommet onto the cable The grommet must sit close in order to prevent water from entering the cabinet If necessary seal the junctions with silicone rubber Loosen position screws of the lead
230. ting limit for Al2 on IOEC2 board last set speed Signal source or wiring dis and 30 18 activating Al2 turbed Measure input signal at Al1 and Shielding of control cables not verify correct signal level properly grounded Check external signal source Check wiring and shielding of control cables f the fault cannot be eliminated call local ABB service organiza tion Supp SW function supervision of sup Loss of a phase or voltage un xX xX Phase L ply phase is done by supervising balance the voltage ripple in the DC link f the fault cannot be located Possible cause call local ABB service organiza Loss of a phase or voltage un tion balance Swfreq HW HW function switching frequency Call local ABB service organiza X exceeds allowed limit tion Possible cause Control SW error Swfreq SW Switching frequency too high Check parameter group 99 X Possible cause Readjust current offset see er System parameters not correct ror message NO CUR OFFSET Wrong current offset Ifthe fault cannot be eliminated call local ABB service organiza tion Tacho Supervision of tachometer Replace tachometer X Optional Possible causes f the fault cannot be eliminated Faulty tachometer call local ABB service organiza Tachometer not compatible with tion pulse encoder type ACS 1000 User s Manual Rev C 3BHS102769 8 29 of 38 Chapter 8 Trouble Shooting amp Repair
231. ting the fault If no keys are pressed the fault or warning text is displayed as long as the fault exists Fault History Display fault history provides information on the 40 most recent faults that occurred in your ACS 1000 The name of the fault and the date and time of occurrence are displayed For complete details on fault analysis please refer to Chapter 8 Trouble Shooting amp Repair Proceed as follows to view fault history 1 Enter the actual signal display mode by pressing ACT on the CDP 312 control panel 2 Select the fault history display with the fast UP DOWN keys The most recent fault will be displayed together with the date and time of occurrence 3 Select previous UP key or next fault DOWN key Warning Do not clear the fault history buffer before you completely clari fied a possible error situation Clearing of the buffer cannot be undone 5 18 of 20 3BHS102769 ACS 1000 User s Manual Rev C Chapter 5 Operation 4 To clear the fault history press RESET The fault history buffer is now empty 5 Toreturn to the actual signal display mode press a fast UP DOWN key Other Operational Actions Panel and Display Several panel functions such as contrast of the display can be adjusted Functions For further information please refer to Appendix B The CDP 312 Control Panel ACS 1000 User s Manual Rev
232. tly and functioning properly Check with logbook if fault occurs repeatedly and record trip conditions If the fault cannot be eliminated call local ABB service organiza tion Overvolt Voltage in the dc circuit is too high age in status Ready to start 8 26 of 38 3BHS102769 ACS 1000 User s Manual Rev C Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy 2 3 amp Comments meaning of message amp 0 5 5 5 5 Overvolt HW supervision detection of ov Verify measured dc voltage Pa X HW ervoltage in the dc circuit rameters 2 02 to 2 09 Possible cause Check whether mains supply Mains supply voltage too high voltage is within the tolerated limits See Appendix A Techni cal Data Adjust input transformer taps If the fault cannot be eliminated call local ABB service organiza tion Overvolt Redundant SW supervision de Verify measured dc voltage Pa SW tection of overvoltage in the dc rameters 2 02 to 2 09 circuit Check whether mains supply Possible cause voltage is within the tolerated Mains supply voltage too high limits See Appendix A Techni cal Data Adjust input transformer taps If the fault cannot be eliminated call local ABB service organiza tion Panel Lost Control panel connection is dis Check if control panel is con X tur
233. to ABB Industrie AG Dept IA Sales CH 5300 Turgi Fax 41 56 2993400 3BHS102769 Chapter 10 Installation Overview Safety Instructions In this chapter the mechanical and electrical installation of the ACS 1000 is explained The instructions include cabinet mounting grounding mains motor and control connections For information on optional modules and other extras installed in your drive refer to Appendix C Customer Specific Options The ACS 1000 is a high voltage device and when misused it can cause damage to personnel and property When located installed and connected in accordance with the instructions given in this manual the device is safe Warning All electrical installation and maintenance work on the ACS 1000 must be carried out by qualified electricians in compliance with local regulations Any installation work must be done with mains and auxiliary power off In put and output isolators must be open and secured any adjoining ground ing device must be closed and power cables must be grounded Never apply power to the installation unless authorization is given by ABB commissioning staff Danger Never work on a powered ACS 1000 The main circuit breaker and the input isolators must always be opened and secured Do not ac cess the main power circuit nor the motor as long as the system is not grounded When switching off the mains after initial energizing of the system always allow the in
234. tor of the intermediate DC link is still charged Prior to access ing the power circuit disconnect the converter from mains power circuit and ground the system as described in section De energizing the ACS 1000 page 5 12 In remote control mode a stop is initiated when the STOP command is given by remote control ACS 1000 User s Manual Rev C 3BHS102769 5 11 of 20 Chapter 5 Operation De energizing the ACS 1000 In Local Control Mode The unit stops following the preset stop function The main circuit breaker remains closed Danger Do not access the main power circuit nor the motor after an operational stop The capacitor of the intermediate DC link is still charged Prior to access ing the power circuit disconnect the converter from mains power circuit and ground the system as described in section De energizing the ACS 1000 page 5 12 To disconnect the drive from main power supply proceed as follows 1 Stopthe ACS 1000 by performing the steps described in the previous section 2 Pressthe main circuit OFFLINE button on the control section door of the ACS 1000 see Figure 5 1 The MCB will open Danger Do not access the main power circuit nor the motor as long as the system is not grounded After switching off the mains and after the motor has come to a stop al ways allow the intermediate circuit capacitors 5 minutes to discharge yel low indicator GND SWITCH UNLOCKED must be on b
235. uality Assurance gives you an introduction to ABB s QA system introduces you to ISO 9001 and ISO 14000 and contains the declaration of CE conformity and the UL CSA approval Appendix E Applicable Codes and Standards is a list of all applicable codes and standards for the ACS 1000 Appendix F Layout and Mechanical Drawings is a collection of mechan ical outline drawings showing all relevant information for floor mounting cable entries water flanges etc Appendix Wiring Diagrams is a collection of electrical schematics and terminal diagrams Appendix H Part Listis a list of all major components including the parts in the repair tool kit Appendix Recommended Spare Parts Listis a converter specific list of recommended spare parts Those parts which have to be exchanged as part of the regular maintenance program are listed as well Appendix K Signal and Parameter Table includes a complete description of all control parameters Appendix L Inspection and Commissioning Record contains all records from factory testing Commissioning test records and a provisional accep tance certificate shall also be included in this Appendix Appendix Parameter Setting List is a customer specific parameter list ACS 1000 User s Manual Rev C 3BHS102769 2 3 of 4 Chapter 2 Introduction with all parameter settings after commissioning The ndex contains an alphabetical list of topics treated in this manual with refer
236. ult cannot be eliminated call local ABB service organiza tion MotWdgM Motor winding temperature mea Check Input X31 3 X32 3 X Los suring lost X31 4 X32 4 and X31 5 X32 5 Possible causes on IOEC2 board signals must measuring circuit output lt 2 mA be gt 2mA Wiring in protection circuit dis Check power supply of monitor turbed ing device Shielding of control cables not Check wiring between external properly grounded temperature measuring device and ACS 1000 Check wiring to measuring de vice inputs Check if shielding of control ca bles is properly grounded f the fault cannot be eliminated call local ABB service organiza tion MotWdg Motor winding temperature too Check motor ratings load and X sum of 3 signals Temp HW high cooling Possible causes excessive load ACS 1000 parameters not prop erly adjusted to motor data Check torque and power limits parameters 20 04 and 20 05 Check motor temperature su pervision parameters parame ters 13 21 to 13 35 If the fault cannot be eliminated call local ABB service organiza tion ACS 1000 User s Manual Rev C 3BHS102769 8 23 of 38 Chapter 8 Trouble Shooting amp Repair Table 8 1 Error messages and fault elimination Continued Message Possible cause Suggested remedy 2 3 amp Comments meaning of message amp 0 5 5 5 5 MotWdg Motor winding temperature too
237. umentation supplied with the order or reference the transformer specification which was provided when the order was placed The cables from the transformer secondaries to the ACS 1000 main pow er input buses are exposed to common mode voltages resulting from nor mal inverter operation of the ACS 1000 For this reason it is required that 10 6 of 28 3BHS102769 ACS 1000 User s Manual Rev C Chapter 10 Installation cable rated 5 kV or higher be utilized for all transformer secondary cabling regardless of the transformer secondary voltage rating 1327 1903 or 2305 VAC Maximum installed cable length should not exceed 300 meters 1000 feet A cable with 3 individually shielded conductors is recommended in order to insure compliance with EMC requirements and to provide a low imped ance high frequency path through which the common mode currents can flow Shields should be terminated and grounded in as short a distance as possible at both ends The ACS 1000 includes a vertical ground bus within the cable termination compartment in order to facilitate this Non shielded 3 conductor cable with a continuous corrugated aluminum armor may be used as an alternate to the individually shielded conductor cable described above Steel armored or interlocked aluminum armored cable should not be used Connectors with 360 electrical contact to the armor should be used to terminate the cable ends to ground The ampacity rating of the cable
238. un page 6 15 6 10 of 22 3BHS102769 ACS 1000 User s Manual Rev C Chapter 6 Parameter Viewing and Editing Parameter 99 15 DRIVE ID NUMBER is optional 9 To exit the parameter mode press any of the mode keys Or to select another parameter group to continue with parameter input use the fast UP DOWN keys Selection or Verification of Application Macro Warning Never change the application macro setting of a system which is already in operation if you do not have a very specific reason to do so Changing the application macro setting will affect the basic control struc ture of the ACS 1000 and the input output allocation on the IOEC 2 board This can result in improper operation loss of control and damage to equip ment To view or select an application macro setting proceed as follows 1 Select the parameter mode by pressing the key The parameter mode display appears indicating the previously selected group and parameter when this mode is entered for the first time after power up the dis play will show the first parameter of the first group 2 Select parameter group 99 using the fast UP DOWN keys 3 Select parameter 99 2 APPLICATION MACRO using the slow UP ACS 1000 User s Manual Rev C 3BHS102769 6 11 of 22 Chapter 6 Parameter Viewing and Editing DOWN keys 4 Press ENTER 5 Select an application macro us
239. using these keys alternately Always keep keys pressed for some time 0 5 1 sec in order to avoid misinterpretation 6 6 of 22 3BHS102769 ACS 1000 User s Manual Rev C Chapter 6 Parameter Viewing and Editing Ger Note When you change the parameter values of a standard macro the j new settings will be stored into the Flash PROM of the ACS 1000 They become active immediately and stay active if the power of the ACS 1000 is switched off and on However the factory set default values of each standard macro are still available and they can be restored see section Restoring Default Settings page 6 19 Parameter group 99 is common to all standard macros It comprises the start up data i e basic system parameters information on display lan guage and active application macro A new setting replaces immediately the old setting in the permanent memory and the old settings cannot be restored Prerequisites following preconditions must be fulfilled in order to view or edit para meters 1 Installation of the system according to Chapter 10 Installation is completed All drive specific parameters are known Control l O wiring is completed and tested Auxiliary voltage is switched on a 5 o N CDP 312 control panel is connected Alternative personal computer with Drive Window please refer to the relevant manual Selection of Actual Actual signals are used to monitor ACS 1000 functions and do not af
240. value is connected to Al 1 1 The analog input on IOEC 1 is acces sible through terminals X301 3 and 4 The speed reference value is given as a percentage of the maximum speed of the drive see parameters 12 7 and 12 8 One constant speed can be selected through DI 2 6 The drive is speed controlled when the Hand Auto Macro is selected By default the direction is fixed to FORWARD see parameter 11 03 Control Overview Figure 4 5 Hand Auto Macro Control Overview 1L gt 600 0 rpm 1 Input Status Runnin EXT1 rpm 5 rad UM Power MotSpeed 600 00 rpm MotCurr 75 0 96 Ex Reference start stop and direction commands are given from EID the control panel To change to EXTERNAL press LOC REM Hand Auto key Const Speed1 PLC ext controls gt 600 0 rpm 1 Status Running gt MotSpeed 600 00 rpm EXT2 Auto Control MotCurr 75 0 Panel display in REMOTE Hand control Reference is read from analog input Al 1 1 Start stop command is given through digital input DI 2 1 Motor ACS 1000 User s Manual Rev C 3BHS102769 4 17 of 38 Chapter 4 I O Interfaces and Application Macros Input and Output default I O signals of the Hand Auto Macro regarding opening closing Signals the MCB starting stopping the drive speed control location reference and actual values are shown in the following table The corresp
241. very with your order In case any parts are missing please contact immediately your local ABB service organiza tion and or the shipping company Figure 9 2 Unpacking the converter top of the box end wall To unpack the converter the following steps have to be followed 1 Remove the top of the box 2 Remove the end and the side walls 3 Take off the bottom of the box 4 Check whether the converter has any transportation damag es end wall bottom of the box side wall ACS 1000 User s Manual Rev C 3BHS102769 9 5 of 10 Chapter 9 Transportation Storage Disposal and Recycling Transportation Damages Storage Storage Conditions In case of transportation damages please proceed as follows 1 Take several photos of the damage s 2 Return the Transportation Damage Description Form for the ACS 1000 included at the end of this chapter together with the photos to the ship ping company and a copy to ABB Industrie AG Dept IA Sales CH 5300 Turgi Switzerland Fax 41 56 2993400 The minimum requirements for storage are based on the following norms ABB HDST 601 070 Classification of environmental conditions e IEC 721 3 1 Code 1 5 121 125 1 1 1 62 151 1 1 e IEC 721 3 3 Code 3K4 3Z1 3Z7 3B1 3C2 3S1 3M1 Storage time up to 1 year Microclimatic class ABB class HDST 601 012 Pay attention to always fulfill the following conditions during the storage period Air temperature
242. xternal signal for fault reset only e not REMOTE RESET X13 3 4 certain faults can be reset from possible remote DO 2 1 IOEC 2 Digital output indicating drive is e possible DRIVE READY X24 1 3 ready for operation i e MCB is closed DC link is charged no interlocks are active DO 2 2 IOEC 2 Digital output indicating drive is e possible DRIVE RUNNING X22 1 3 running DO 2 3 IOEC 2 Digital output indicating an alarm e possible DRIVE ALARM 23 1 3 has up DO 2 4 2 Digital output indicating drive has e possible DRIVE TRIP 24 1 3 tripped DO 3 2 IOEC 3 Digital output indicating drive is in possible LOCAL MODE 22 1 3 local mode control panel CDP312 9 is in command ACS 1000 User s Manual Rev C 3BHS102769 4 5 of 38 Chapter 4 I O Interfaces and Application Macros Table 4 1 Signals Remote Control Interface Continued Signal Terminals Remarks Stan Signal dard Inversion Al 2 1 IOEC 2 Macro specific e possible REF VALUE 1 X31 2 X32 2 Al 1 1 X301 Macro specific e Possible REF VALUE 2 4 5 AO 1 1 1 Default setting e possible MOTOR FREQUENCY X31 6 X32 6 Actual value of motor frequency AO is programmable AO 1 2 IOEC 2 Default setting e possible MOTOR TORQUE X31 7 X32 7 Actual value of motor torque AO is programmable AO 2 1 IOEC 2 Default setting e possible SHAFT SPEED X31 6 X32 6 Actual
243. y Power Cable 10 9 Control Cables 10 9 Cable Routing 10 10 Power Cables 10 10 Cable Termination 10 10 Cable Length 10 10 Grounding Wire 10 10 Control Cables 10 10 Mains and Motor Cable Connection Diagrams 10 10 Mechanical Installation 10 12 Required Tools and Parts 10 12 Preparation of Mounting Site 10 12 Displacement to Installation Site 10 13 Mounting the Cabinet 10 13 Electrical Installation 10 16 Mains and Motor Cable Lead In 10 16 Inserting Mains and Motor Cables 10 18 Grounding Connections 10 21 Insulation Checks 10 21 Mains and Motor Cable Connections 10 22 Auxiliary Power Cable Connection 10 23 Control Cable Connection 10 25 Wiring Tests 10 28 Final Work 10 28 Preparation for commissioning 10 28 Chapter 11 Commissioning Overview 11 1 Preparation of Commissioning 11 1 General Preconditions 11 1 High Voltage Equipment 11 1 Auxiliary Voltage Supply and Control 11 1 Cooling Circuit 11 1 Miscellaneous 11 2 Commissioning Procedure 11 2 Required Customer Manpower 11 2 Acceptance 11 2 Warranty 11 2 8 of 10 3BHS102769 ACS 1000 User s Manual Rev C Appendix A Technical Data Appendix B The CDP 312 Control Panel Overview ACS 1000 Parameter Programming Application Macros Parameter Groups Start up Data Parameters Control Panel Display Keys Panel operation Keypad Modes Identification Display Actual Signal Display Mode Actual Signal Display Parameter Mode Function Mode Copying parameters from one unit to other unit

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