abb acs 1000 tech catalog revd[1]

Technical catalog

Medium voltage AC driveACS 1000, ACS 1000i315 kW - 5 MW, 2.3 - 4.16 kV

ABB

Table of contents

List of figures 7

List of tables 9

Chapter 1 - Overview 11

1.1 Introduction 111.2 The standard solution 121.2.1 ACS 1000 types 151.3 Key technology 161.4 Technical benefits 161.5 Benefits for the customer 171.6 CE declaration and UL listing 19

Chapter 2 - Functional description, operation 21

2.1 Overview 212.2 Standard control functions 212.2.1 Direct torque control 212.2.2 Application parameters 252.2.3 Speed control functions 252.2.4 Motor-related functions 272.2.5 Ride-through functions 272.2.6 Main circuit breaker control 282.2.7 Input signal source selection and signal processing 282.2.8 Control and operation modes 292.3 Operation and diagnostics 302.3.1 Local and remote operation 302.3.2 Diagnostics 322.4 Converter protection functions 332.4.1 Alarm and fault handling 332.4.2 Tripping loop 342.4.3 Protection functions related to the converter system 342.4.4 Internal converter protection functions 362.4.5 External protection functions 382.5 Additional features 382.6 Optional features 38

ACS 1000 Technical catalog 3BHS125029 ZAB E01 Rev. D 3 / 118

Table of contents ABB

Chapter 3 - Hardware design 39

3.1 Overview 393.2 Converter topology 393.3 Technology 413.3.1 Fuseless design 413.3.2 Input stages 413.3.3 Voltage Source Inverter (VSI) technology 413.3.4 Output stages 423.3.5 IGCT power semiconductor 433.4 Cabinet layout 443.4.1 Air-cooled ACS 1000 443.4.2 Air-cooled ACS 1000i with integrated transformer 463.4.3 Water-cooled ACS 1000 473.4.4 Power terminals 493.4.5 DC grounding switch for safe grounding 493.5 Hardware modules (air-cooled ACS 1000) 493.5.1 Terminal and control section 493.5.2 Inverter section 523.5.3 Rectifier section 533.6 Hardware modules (air-cooled ACS 1000i) 533.6.1 Control section 533.6.2 Inverter section 553.6.3 Input section 563.7 Hardware modules (water-cooled ACS 1000) 573.7.1 Terminal and control section 573.7.2 Converter section 573.7.3 Filter section 583.7.4 Water cooling system 593.8 Cabinet design 633.8.1 Mechanical design 633.8.2 Electromagnetic compatibility (EMC) 643.8.3 Door locks and door interlocking 643.8.4 Safety labels 653.8.5 Compliance with international standards 653.9 Busbars and grounding 653.10 Lifting arrangements 663.11 Additional cabinets 66

Chapter 4 - Control system and process interfaces 67

4.1 Overview 674.2 Hardware and structure of the control system 684.3 Local control devices 694.3.1 CDP control panel 694.3.2 Control switches 71

4 / 118 3BHS125029 ZAB E01 Rev. D ACS 1000 Technical catalog

6

ABB Table of contents

4.4 Customer I/O interfaces 724.4.1 Programmable digital and analog outputs 734.4.2 Scalable analog inputs 734.4.3 Customer control signals 744.5 Control software 744.5.1 Control software structure 744.5.2 Operating system 744.5.3 Motor and control software 754.5.4 FCB application software 754.5.5 Panel application software 75

Chapter 5 - Engineering information 77

5.1 Overview 775.2 Main circuit breaker 775.2.1 Main circuit breaker control 775.2.2 Tripping loop 785.3 Converter input transformer selection 795.4 Motor selection 795.4.1 Selection criteria 805.4.2 Retrofit 805.4.3 Load capacity curves 815.4.4 Torsional excitation 825.5 Selection of power cables 825.5.1 Transformer primary cables 825.5.2 Transformer secondary cables 825.5.3 Motor cables 835.5.4 Power cable dimensions 835.5.5 Equipment grounding 845.6 Control cabling 845.7 Auxiliary power cables 84

Chapter 6 - Options 85

6.1 Overview 856.2 Environmental conditions 856.3 Converter enclosure 856.4 Input section 876.5 Motor side 896.6 Converter cooling 926.7 Synchronized bypass 936.8 Auxiliary supply 956.9 Auxiliary and control interfaces 966.10 Input / output disconnector 976.11 Optional diagnostic software 99


Table of contents ABB

6.11.1 DriveWindow 996.11.2 DriveMonitorTM 100

Chapter 7 - Installation guidelines 103

7.1 Overview 1037.2 Environmental conditions 1037.3 Mounting 1037.4 Power equipment installation 1077.4.1 General 1077.4.2 Cable routing 1077.4.3 ACS 1000 cable entry and termination

(only ACS 1000A/W) 1087.4.4 Transformer wiring diagram for 12-pulse ACS 1000 1107.4.5 Transformer wiring diagram for 24-pulse ACS 1000 1107.4.6 Motor wiring diagram for 12 / 24-pulse ACS 1000 111

Chapter 8 - Ordering information 113

8.1 General 1138.2 Converter selection 1138.2.1 ACS 1000 output filter 1148.2.2 Non-quadratic load applications 1148.3 Type code 1148.4 Option list 1148.5 External system data 1148.6 Technical data 114

Index 115


6

ABB

List of figuresFigure 1-1 ACS 1000A 13Figure 1-2 ACS 1000W 14Figure 1-3 ACS 1000i including optional output isolator and

redundant fans 14Figure 2-4 DTC block diagram 22Figure 2-5 DTC: typical dynamic speed response 24Figure 2-6 DTC vs. PWM: typical torque response times 24Figure 2-7 Setting the control panel to local / remote 30Figure 2-8 Typical start and stop sequences 31Figure 2-9 Signal display on CDP control panel 32Figure 2-10 Stall region of the motor 34Figure 2-11 Load curves for underload function 35Figure 3-12 Elementary diagram - ACS 1000, 12-pulse

version 39Figure 3-13 Elementary diagram - ACS 1000, optional

24-pulse version 40Figure 3-14 Elementary diagram - ACS 1000i 40Figure 3-15 3-level voltage source inverter principle 42Figure 3-16 Voltage and current waveforms at converter

output 43Figure 3-17 IGCT 43Figure 3-18 The ACS 1000 air-cooled type (12 / 24-pulse,

typical layout) 44Figure 3-19 Air flow through ACS 1000A 45Figure 3-20 The ACS 1000i air-cooled type 46Figure 3-21 Air flow through ACS 1000i 47Figure 3-22 The ACS 1000 water-cooled type (12-pulse) 48Figure 3-23 Control section with open front door

(ACS 1000 air, typical layout) 50Figure 3-24 Control section with open swing frame

(ACS 1000A, typical layout) 51Figure 3-25 Inverter section (ACS 1000A, typical layout) 52Figure 3-26 Filter section (ACS 1000A, typical layout) 53Figure 3-27 Control section with open front door

(ACS 1000i, typical layout) 54Figure 3-28 Inverter section (ACS 1000i, typical layout) 55Figure 3-29 Input section (ACS 1000i, typical layout) 56Figure 3-30 Converter section (ACS 1000W, typical layout) 57Figure 3-31 Filter section (ACS 1000W, typical layout) 58Figure 3-32 Cooling section (ACS 1000W, typical layout) 59Figure 3-33 Principle of water cooling circuit 60Figure 3-34 Cooling unit of the water-cooled ACS 1000 62Figure 3-35 Typical safety labels 65Figure 3-36 Lifting rails air-cooled ACS 1000 66


List of figures ABB

Figure 3-37 Lifting rails water-cooled ACS 1000 66Figure 3-38 Lifting lugs ACS 1000i 66Figure 4-39 Typical configuration of control system 68Figure 4-40 AMC Board 69Figure 4-41 CDP control panel 70Figure 4-42 Local control devices 71Figure 4-43 Software block diagram of the AMC controller 74Figure 5-44 Load capacity curves 81Figure 6-45 Additional cabinet with power equipment

(option output isolator) 87Figure 6-46 Synchronized bypass, single line diagram 95Figure 6-47 Additional cabinet with two disconnectors 98Figure 6-48 Typical DriveWindow display 100Figure 6-49 DriveMonitorTM installed in a console with a

touchscreen, wall-mounted 101Figure 7-50 Foundation plan with position of anchor holes:

12-pulse / 24-pulse, ACS 1000A 104Figure 7-51 Foundation plan with position of anchor holes:

12-pulse, ACS 1000W 105Figure 7-52 Foundation plan with position of anchor holes:

additional cabinet for ACS 1000A and ACS 1000W 105

Figure 7-53 Foundation plan with position of anchor holes: ACS 1000i 106

Figure 7-54 Cabinet mounting with bolts and lock washers 106Figure 7-55 Top cable entry 108Figure 7-56 Bottom cable entry 109Figure 7-57 Typical 3-line transformer wiring diagram. 110Figure 7-58 Typical 3-line transformer wiring diagram 110Figure 7-59 Typical 3-line motor wiring diagram 111


8

ABB

List of tablesTable 1-1 List of abbreviations used in this catalog 11Table 1-2 List of documents referred to in this catalog 11Table 1-3 Standard power ranges for ACS 1000

converters 15Table 2-4 DTC versus current vector control 22Table 2-5 Typical performance figures for torque control,

when direct torque control is used 26Table 3-6 Comparison of semiconductors 44Table 4-7 I/O board configuration with number and type

of I/O 72Table 5-8 Control cable requirements 84Table 6-9 I/O signals for extended transformer monitoring 88Table 6-10 I/O Signals for extended motor monitoring 89Table 6-11 Power ratings for different circuit breaker sizes 91Table 6-12 Power ratings for different starter sizes 91Table 7-13 Required clearance in front and above of the

converter 103Table 7-14 Maximum number of cables per phase 109


List of tables ABB


10

ABB

Chapter 1 - Overview

1.1 IntroductionThis Technical Catalog describes the main electrical, mechanical and environmental features of the ACS 1000 – ABB’s contribution to new solutions for medium voltage AC converters. In addition, the Catalog looks at the various options available for the converter and offers advice on selecting a motor and converter combination. It also provides useful instal-lation tips.

Table 1-1 List of abbreviations used in this catalog

Table 1-2 List of documents referred to in this catalog

Abbreviation Meaning

AMC Application and Motor Controller

AMCOS Application and Motor Controller Operating System

DDCS Distributed Drive Control System

FCB Function Chart Builder

HVAC Heating, Ventilating and Air Conditioning

IOEC Input and Output Electronical Card

MSM Main State Machine

PPCS Power Plate Communication System

RMS Root Mean Square

SPDT Single-Pole Double-Throw

UPS Uninterruptible Power Supply

VSI Voltage Source Inverter

Document number Document title

3BHS232441 ZAB E01 Rev. A ACS 1000 - Applicable codes and standards

3BHS189994 ZAB E01 Rev. - ACS 1000 Technical Specification for Power Cables

3BHS127225 ZAB E01 Rev. A ACS 1000A Dimensions and Floor Mounting

3BHS127224 ZAB E01 Rev. B ACS 1000A Dimensions and Floor Mounting with Redundant Fan

3BHS223999 ZABE01 Rev. - ACS 1000A Terminal list

3BHS216859 ZAB E01 Rev. B ACS 1000i Dimensions and Floor Mounting A1

3BHS206087 ZAB E01 Rev. D ACS 1000i Dimensions and Floor Mounting A2/A3

3BHS224056 ZABE01 Rev. - ACS 1000i Terminal list


Chapter 1 - Overview ABB

1.2 The standard solutionThe ACS 1000 is a standard, medium voltage AC converter, rated from 315 to 5000 kW (400 to 6700 hp) for motor voltages of 2.3, 3.3 and 4.0 (4.16) kV.

The ACS 1000 has been designed as a product that requires minimum engineering for standard industrial converter configurations and is available in a 12-pulse and a 24-pulse version. As such, the converter uses standard components, software tools and design principles as employed in the low voltage ACS range. This vastly increases the reliability of the converter and offers users a consistent addition to the extensive ACS product range.

3BHS127226 ZAB E01 Rev. B ACS 1000W Dimensions and Floor Mounting W1 12-pulse

3BHS127227 ZAB E01 Rev. B ACS 1000W Dimensions and Floor Mounting W1 12-pulse with Redundant Fan

3BHS127228 ZAB E01 Rev. B ACS 1000W Dimensions and Floor Mounting W1 24-pulse

3BHS127229 ZAB E01 Rev. B ACS 1000W Dimensions and Floor Mounting W1 24-pulse with Redundant Fan

3BHS127230 ZAB E01 Rev. B ACS 1000W Dimensions and Floor Mounting W2/W3 12-pulse

3BHS127231 ZAB E01 Rev. B ACS 1000W Dimensions and Floor Mounting W2/W3 12-pulse with Redundant Fan

3BHS127232 ZAB E01 Rev. B ACS 1000W Dimensions and Floor Mounting W2/W3 24-pulse

3BHS127233 ZAB E01 Rev. B ACS 1000W Dimensions and Floor Mounting W2/W3 24-pulse with Redundant Fan

3BHS224400 ZABE01 Rev. - ACS 1000W Terminal list

3BHS216635 ZAB E01 Rev. - Application Note, Control and Operation Modes for Software Version MSOH4200 and higher

3BHS261596 ZAB E01 Rev. B Application Note, Mechanical Interlock

3BHS200260 ZAB E01 Rev. A Data Sheet, Water Cooling Unit

3BHS268039 ZAB E01 Rev. A DriveMonitorTM User’s Manual for Software Version 2.0

3BHS104785 ZAB E01 Rev. C Engineering Guidelines, Input Circuit Breaker Control

3BHS107197 ZAB E01 Rev. C Synchronized Bypass, Installation and Start-up Manual

3BHS213402 ZAB E01 Rev. D Technical data, ACS 1000A

3BHS213404 ZAB E01 Rev. E Technical data, ACS 1000i

3BHS213403 ZAB E01 Rev. D Technical data, ACS 1000W

3AFY 58056685 R0025 Technical Guide No. 1 Direct Torque Control

3BHS103892 ZAB E01 Rev. B Technical Specification, Motors for ACS 1000 Frequency Converters

3BHS103412 ZAB E01 Rev. I Type Code

3BHS205465 ZAB E01 Rev. A Wiring and Busbar Specification

Document number Document title


20

ABB Chapter 1 - Overview

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

The ACS 1000 is available in air-cooled and water-cooled versions. The air-cooled ACS 1000 delivers output powers up to 2400 kVA and is also available with an integrated input transformer. The water-cooled ACS 1000 covers the power range up to 6000 kVA.

The ACS 1000i is an air-cooled version with integrated input transformer and (optional) input contactor.

Figure 1-1 ACS 1000A



Figure 1-2 ACS 1000W

Figure 1-3 ACS 1000i including optional output isolator and redundant fans


20


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

The following industries can benefit from this approach:

Cement, mining andminerals

• Grinding mills

• Conveyors

• Fans

• Pumps

Chemical, oil and gas • Compressors

• Extruders

• Pumps

Metals • Blast furnace blowers

• Fans

• Pumps

Pulp and paper • Fans and pumps

Power generation • GT starters

• ID/FD fans and pumps

Water and wastewater

• Pumps

1.2.1 ACS 1000 typesThe table below provides an overview of the rated output power range, covering air and water-cooled converters for all three medium voltage levels.

For further details, refer to Chapter 8 - Ordering information.

Table 1-3 Standard power ranges for ACS 1000 converters

Motor voltage (kV) Type

Rated motor power rangea

(HP)

Rated motor power range

(kW)

2.3 ACS 1000 Air 400 - 2250 298 - 1678

3.3 ACS 1000 Air 422 - 2414 315 - 1800

3.3 ACS 1000i Air 450 - 2011 315 - 1500

3.3 ACS 1000 Water 2682 - 6705 2000 - 5000



Note: Derating factors may apply. For details see Technical data.

1.3 Key technologyTwo main technology features distinguish the ACS 1000 from other types on the market:

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

DTC allows the speed of any standard squirrel cage induction motor to be controlled without the need for pulse encoder devices for speed feedback.

• The ACS 1000 has been the first converter to utilize a new power semiconductor switching device. Known as IGCT (Integrated Gate Commutated Thyristor), the device provides a less complex, more efficient and reliable converter. This is achieved by fast switching and inherently low losses which mean less cooling is needed.

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

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

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

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

4.0 ACS 1000 Air 400 - 2250 298 - 1678

4.16 ACS 1000i 400 - 2700 298 - 2014

4.0 ACS 1000 Water 2500 - 6700 1864 - 5000

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

Motor voltage (kV) Type

Rated motor power rangea

(HP)

Rated motor power range

(kW)


20


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

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

For details refer to ACS 1000 - Applicable codes and standards.

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

1.5 Benefits for the customerMaximum availability

short repair timeHigh reliability and short repair time result in maximum availability.

High reliability is achieved by:

• Proven technology:

The design of the IGCT used in the ACS 1000 is based on well-proven GTO technology. IGCTs have been used successfully in medium voltage converters for more than 10 years. See Chapter 3 - Hardware design, 3.3.5 IGCT power semiconductor.

• Low parts count:

The fast switching capability of the IGCT allows snubberless circuit topologies. This results in a smaller number of power components which improves the operational reliability. See Chapter 3 - Hardware design, 3.3.3 Voltage Source Inverter (VSI) technology.

• Fuseless design:

The ACS 1000 does not use any medium voltage power fuses which are known to be unreliable and subject to aging. Compared to fuses, power semiconductors used for short circuit protection act extremely fast in case of a fault and therefore limit effectively any potential electrical fault energy flowing into the converter. See Chapter 3 - Hardware design, 3.3.1 Fuseless design.

Short repair time is achieved by:

• Diagnostics system:

A comprehensive self-diagnostic monitoring system generates error messages with information on error type and location. This enables quick and precise localization of disturbances and reduces time spent on fault finding. See Chapter 2 - Functional description, operation, 2.3.2 Diagnostics.



• Simplicity of power circuit:

The simplicity of the power circuit and the modular design of the hardware do not only lead to extremely high availability but also provide the base for a maintenance and repair concept which is characterized by minimum outage times, e.g. a complete phase module can be exchanged in less than 1 hour. See Chapter 3 - Hardware design.

Top performance Fast and accurate process control in combination with low energy consumption results in top performance.

Fast and accurate process control based on DTC results in high and constant production quality and minimum machinery wear. DTC guarantees:

• Highly dynamic response times without overshoot

• Accurate static speed and torque control

• Smooth output current waveforms resulting in minimum torque ripple.

See Chapter 2 - Functional description, operation, 2.2.1 Direct torque control.

Low maintenance cost Maintenance costs are minimized thanks to extended maintenance periods, low number of maintenance tasks and the possibility to perform maintenance tasks on the running system.

What you need is whatyou get

Customer requirements are precisely met. The flexible design with standard converter components and well-proven control platform allows optimum configuration of the converter system.

• Each converter consists of well-proven and standardized modules, thus minimizing the risk of design errors.

• Water cooling for higher power ratings allows for a very compact design, reducing floor space requirements and minimizing heat losses into the room (minimizing the heat load to the HVAC system of the building).

• Installation and commissioning time is reduced due to standardized procedures and documentation.

Proven ABB medium voltage converter’s control platform:

• Configurable application software and standard interfaces for hardwired I/Os allow optimum integration into the industrial environment.

• Interfaces for all common fieldbus types are available for communi-cation with the overriding control system.

• Standardized control panels and operator interfaces, common for all ABB medium voltage converters, allow simple and user friendly operation.


20


1.6 CE declaration and UL listingThe ACS 1000 is marked with a CE symbol. The symbol indicates that the ACS 1000 complies with the requirements stipulated in the relevant European health, safety and environmental protection directives and that documents proofing the compliance are available.

In order to meet the requirements of the North American market, the ACS 1000 is also UL and Canadian UL listed.




20

ABB

Chapter 2 - Functional description, operation

2.1 OverviewThis chapter provides information about the standard control, monitoring and protection functions of the ACS 1000. A description of the basic operation and diagnostic devices is included as well.

The description of the related control hardware, software and customer interfaces can be found in Chapter 4 - Control system and process inter-faces.

Links to otherdocuments

List of references to other documents in this chapter:

• Technical data (for document details see Chapter 1 - Overview, Table 1-2)

2.2 Standard control functionsThe ACS 1000 control system is based on ABB's well-proven ACS variable frequency converter control platform which includes the low voltage and medium voltage frequency converter family. The control system is fully based on microprocessor technology and offers a wide range of unique control features.

The most relevant control, monitoring and protection functions which are set with parameters are discussed in this chapter. These functions are integrated in the control system described in Chapter 4 - Control system and process interfaces.

2.2.1 Direct torque controlDirect Torque Control (DTC) enables highest torque and speed control performance ever achieved with medium voltage converters.

2.2.1.1 DTC principle

DTC is an optimized motor control method for AC converter systems, which allows direct control of motor torque and flux. In DTC, each switching instance is determined separately based on the values of actual flux and torque, rather than switching in a predetermined pattern as in conventional PWM flux vector converters.


A TC_ACS5000 Technical Data.pdf

Chapter 2 - Functional description, operation ABB

Figure 2-4 DTC block diagram

The measured motor currents and DC link voltages are inputs to an adaptive motor model which calculates exact values of torque and flux every 25 μs. Motor torque and flux comparators compare the actual values to reference values which are produced by the torque and flux reference controllers.

Depending on the outputs from the hysteresis controllers, the optimum switching logic directly determines the optimum inverter switch positions every 25 μs. Switching takes place whenever required while in conven-tional Pulse Width Modulation (PWM) controlled converters switching is done only in predetermined patterns which results in slower response times.

2.2.1.2 DTC performance and benefits

DTC provides excellent speed control accuracy even without pulse encoder feedback. It virtually eliminates the excitation of any torque resonances on the motor shaft by avoiding explicitly assigned PWM modulation frequencies. Control of the frequency converter is immediate and smooth under all conditions and the audible noise in the motor is considerably reduced compared to other control methods.

The torque response times are up to ten times faster than with conven-tional control methods such as current vector control. This results in minimum torque ripple and most accurate static speed and torque control.

DTC versus currentvector control

Table 2-4 DTC versus current vector control

PID

REF=

IM3~

Torque reference

Speed reference

Actualspeed

Speed control

Torquereferencecontroller

Torqueand fluxcomparator

Motor model

Switchinglogic

SwitchpositionsVoltage Current

Asynchronous motor

Direct torque control (asynchronous motor)

Vector control

Motor control variables Switching is based on core motor variables flux

and torque

Switching is based on the separate control of

magnetic field and torque producing current compo-

nents


38

ABB Chapter 2 - Functional description, operation

Other DTC benefits Other major features and benefits of DTC are:

• High speed accuracy: typically 0.1% of nominal speed (without speed encoder)

• High torque performance

Full torque at zero speed and very fast torque step response time of <10 milliseconds

• Robust control method

DTC is extremely robust and compensates disturbances and inaccu-racies on supply, motor and load side. This avoids nuisance tripping and increases the reliability of the ACS 1000.

• Low audible motor noise and negligible low torque ripple by avoiding dedicated modulation frequencies

• Minimum inverter switching losses at maximum control performance.

DTC provides fast control without requiring high switching frequency. This is possible because control is NOT based on a fixed PWM modulation frequency. Instead, switching takes place exactly when needed. Conventional PWM control would need >10 kHz switching frequency for equivalent performance.

Requirements for speedencoder

Shaft speed and position are not required (only

high performance appli-cations as for example in

the mining and metal industry require speed

encoders)

Mechanical speed is essential. Requires shaft

speed and position (measured or estimated)

Maximum inverterresponse time

Each inverter switching process is determined

separately (every 25 μs)

Inverter switching is based on average refer-ences to a pulse width modulator resulting in

delays in response and unnecessary switching

Torque step rise time Torque step rise time is less than 3 ms at 70%

speed

Torque step rise time closed loop: 10 to 20 ms

sensorless: 100 to 200 ms

Direct torque control (asynchronous motor)

Vector control



DTC performance Figure 2-5 illustrates a typical dynamic speed response caused by a load step.

Figure 2-5 DTC: typical dynamic speed response

In many applications there is no need for speed and position encoders to meet the performance requirements. See Table 2-4 and Technical data for detailed information.

The example in Figure 2-6 shows the response to a setpoint change. Torque response times can be reduced substantially if DTC is used instead of Pulse Width Modulation.

Figure 2-6 DTC vs. PWM: typical torque response times

For more information on DTC, see Technical Guide No. 1 Direct Torque Control (3AFY 58056685 R0025).

2.2.1.3 Scalar control (open loop version of DTC)

This control algorithm sets the output frequency and output voltage instead of acting directly on the torque of the motor.

PWM without encoder

PWM with encoder

DC drive with encoder

DTC without encoder

Static speed error ± 1...3% ± 0.01% ± 0.01% ± 0.1...0.5%

Dynamic speed error 3% sec 0.3% sec 0.3% sec 0.4% sec

Speed(rpm) Torque (kNm)

Time

Speed

Torque

Value depending on process

Torque:

DTC

PWM

Typical torque step:response times at 70% speed- DTC: 3 ms- PWM flux vector: 10…20 ms- PWM: > 150 ms (scalar con-..trol)


38



The scalar control, based on the same hysteresis controllers as DTC, is an open loop control, used for applications where:

• a step-up or step-down transformer is installed between the converter and the motor

• extra long cables from the converter to the motor are used or

• one converter is connected to two parallel motors.

2.2.2 Application parametersThe ACS 1000 is configured and customized by means of application parameters. These parameters can be altered by the user, either by means of the integrated CDP control panel or by using a PC and the DriveWindow software package, as described in Chapter 6 - Options.

Control and monitoring functions of the ACS 1000 can be activated by setting parameters one by one or by invoking a predefined control /operation mode (see Application Note, Control and Operation Modes) which is optimized for a particular application. Therefore some of the functions described in the following sections will be configured automati-cally if an application macro is selected.

2.2.3 Speed control functions

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

Accurate torque controlwithout speed

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

100

t(s)

TTN

< 10 ms

90

10

(%)

Tref

Tact

TN ..= Rated motor torqueTref .= Torque referenceTact = Actual torque



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

Table 2-5 Typical performance figures for torque control, when direct torque control is used

Speed and torque performance figures meet or exceed the requirements of IEC 61800-4.

Acceleration anddeceleration ramps

ACS 1000 provides two user-selectable acceleration and deceleration ramps. It is possible to adjust the acceleration / deceleration times (setting values: 0...1800 s) and select the ramp shape. The value has to be selected depending on the process. Switching between the two ramps can be controlled via a digital input.

The available ramp shapes are:

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

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

The shape of the ramp can be adjusted via parameters as follows:

S1: Suitable for short acceleration / deceleration times.

S2: Suitable for medium acceleration / deceleration times

S3: Suitable for long acceleration / deceleration times.

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

Full torque at zerospeed

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

Torque control ACS 1000without pulse encoder

ACS 1000with pulse encoder

Linearity error + 4%a

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

+ 3%

Torque rise time < 10 ms < 10 ms

Linear

1 t (s)

Motor

1.25 2

S1

S2

S3

speed


38


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

Critical speed The critical speed function is needed 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) limit until the reference is out of the critical speed range. The motor is accelerated/decelerated through the critical speed band according to the acceleration or deceleration ramp.

2.2.4 Motor-related functions

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

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

2.2.5 Ride-through functionsThe ride-through function prevents an undervoltage fault when short voltage dips of the main supply voltage occur.

Auxiliary ride-through The auxiliary ride-through function guarantees correct fault indication and proper trip sequencing in the event that the auxiliary power source feeding the converter is lost. The function is activated by a parameter. During ride-through the power for the control circuits of the ACS 1000 is supplied by internal batteries. The ride-through time is limited to 5 sec.

s 1 Lows1 High s2 Low s2 High

Speed

540 690 1380 1560

(rpm)

540690

1380

1560

(rpm)Motorspeed

reference



Power loss ride-through

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

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

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

2.2.6 Main circuit breaker controlThe main circuit breaker (MCB) is an important switching and protection device of the converter system. Therefore it is controlled and monitored by the converter.

The feedback signals from the main circuit breaker upon a close or an open command from the converter are monitored. These signals must have the correct status and must arrive within a preset time at the converter:

• If the converter applies a close command and the expected feedback signal does not arrive after a preset time, the close command is reset and the main circuit breaker is tripped.

• If the open command from the converter to the main circuit breaker is a single pulse signal, it is reset after receiving the open feedback signal from the switchgear. If the feedback signal does not arrive after a preset time, a trip command to the main circuit breaker is issued.

External trip signals (e.g. transformer and motor monitoring relays, process trip commands, etc.) can be wired into the MCB "emergency off loop" of the converter. The trip signals are connected in series.

Refer to 5.2 Main circuit breaker for further information.

2.2.7 Input signal source selection and signal processing

Two programmablecontrol locations

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


38


Alternatively, it is possible to predefine two separate external control locations (EXT1 and EXT2) for these signals. 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.

Optionally, the converter can be equipped with a fieldbus adapter module, (see Chapter 6 - Options).

Reference signalprocessing

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

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

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

It is possible to override the actual speed reference with predefined constant speeds (see Constant speeds, page 26).

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.

2.2.8 Control and operation modesParameters allow the user the specific configuration of the ACS 1000. They can be set using the CDP control panel.

The control and operation modes consist of preprogrammed parameter sets that are adapted for a specific application. They offer preset signal interfaces for opening/closing the main circuit breaker, starting/stopping the converter system and setting reference values.

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

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

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

Control modes • Speed control

• Torque control

• PID control



• Sequential control

• Master/Follower

Macros • Hand/Auto

• User 1

• User 2

For details refer to Application Note, Control and Operation Modes.

2.3 Operation and diagnostics

2.3.1 Local and remote operationThe standard ACS 1000 provides all interfaces for local and remote operation.

Local operation is performed by means of the CDP control panel and the pushbuttons located on the front door of the control section.

When in remote control, the operational commands and the reference value are transmitted to the converter from a remote control station via fieldbus or remote I/O.

2.3.1.1 Selection of local or remote operation

Selecting the local operation is possible if no remote request from the overriding control system is present. The local operation is set directly by pushing the LOC/REM pushbutton on the CDP control panel (See Chapter 4 - Control system and process interfaces, 4.3 Local control devices). An L on the panel display indicates local operation. In remote control, the L is not shown (see circle in Figure 2-7).

Figure 2-7 Setting the control panel to local / remote

Local control When the converter is switched to local control, local operation from the ON/OFF pushbuttons on the converter front door and from the CDP control panel is possible. In local operation mode, no remote control command will be accepted.

1 Status

POWER MotorSpeed

550.0 rpm 1Running0.00 rpm

0.0 %

->L 1

POWER 0.0 %

-> 550.0 rpm 1 Status Running MotorSpeed 0.00 rpm


38


Remote control When the converter is switched to remote control, local operation from the pushbutton on the front door of the control unit and from the control panel is disabled. All commands like close/open main circuit breaker, start/stop or speed reference values are only received through the remote control interface, either via hardwired I/Os or via fieldbus.

Emergency off The local emergency off switch on the front door of the control unit is active in local and remote mode.

Start and stopsequences

The converter can be started and stopped either manually from the local control panels or from a remote overriding control system.

If all preconditions for energization are fulfilled, the converter can be switched on by pressing the local ON button.

Figure 2-8 Typical start and stop sequences

Ready on

Charge DC linkClose MCB

Start modulation

Operation

Not

according to setpoint

Ready ref.

Ready run

Ramp down speedStop modulation

Open MCB

Discharge DC link

Stop sequenceStart sequence

START command

Supply OFFcommand

STOP command

Supply ONcommand

> Aux. supply on> Doors closed> No fault> Ground switch

open> WCU ready **

read on

Ready run

Ready ref.

Ready on

**WCU = water cooling unitonly applicable for water-cooled converter



2.3.1.2 Prevention of local operation

To prevent unauthorized local operation of the ACS 1000, the local mode can be enabled and disabled from the remote overriding control system via hardwired I/O or by entering a password into the local CDP control panel.

Changing the control mode from local to remote and vice versa can be disabled by setting digital input disable local.

2.3.2 Diagnostics

Fault logger In the event of an alarm or a fault in the ACS 1000 or in the equipment monitored by the converter, a specific message can be saved in the fault logger. Information on the 64 most recent alarm and fault events can be stored.

The messages can be called up on local CDP control panel of the ACS 1000 or they can be viewed with one of the following PC-based tools: DriveWindow, DriveDebug or DriveMonitorTM.

Data loggers The ACS 1000 provides two data loggers. Each data logger is capable of monitoring up to six different analog or binary signals. Sample time and trigger level for each signal can be adjusted independently.

The data loggers are set up and their content viewed either using the DriveWindow or DriveDebug tool.

Actual signalmonitoring

Three signals can be displayed simultaneously on the control panel.

Figure 2-9 Signal display on CDP control panel

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

For example:

• ACS 1000 output frequency, current, voltage and power

• Motor speed and torque

• DC Link voltage

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

• Reference values

1 Status Running

POWER MotSpeed

600.0 rpm 1

600.00 rpm 75.0 %

->L


38


• ACS 1000 inverter air temperature

• Cooling water temperature, pressure and conductivity

• Operation time counter (h), kWh counter

• Digital I/O and analog I/O status

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

2.4 Converter protection functions

2.4.1 Alarm and fault handlingAll relevant system variables of the converter are continuously monitored by the control system of the ACS 1000. Preprogrammed protection functions ensure that these variables remain within certain limits to maintain safe operation of the converter. These internal functions are not programmable by the user. Optionally, the converter can monitor standard and customer specific signals from external equipment. Alarm and trip levels for each signal can be activated and adjusted by parameter settings.

If an alarm or a fault condition occurs in the converter or the related equipment, it will be indicated with an error message on the CDP control panel. The message can also be viewed using either the DriveWindow, DriveDebug or DriveMonitorTM tool.

Two error message levels are used in the converter:

• Alarm (warning): an alarm does not shut down the converter. However, a persisting alarm condition can often lead to a fault if the condition causing the alarm is not corrected. An alarm cannot be reset manually. The alarm message will be deleted from the display as soon as the alarm condition has been corrected.

• Fault: a fault always shuts down the converter. The type of shutdown depends on the origin of the fault.

• Depending on the type of fault, the main circuit breaker (MCB) is opened by the converter or stays closed:

• Class 1 faults (FC 1) open the MCB, e.g.:

DC overvoltage

• Class 2 faults (FC 2) do not open the MCB, e.g.:

Motor overspeed

Since the MCB is controlled and monitored entirely by the converter, no external opening command must be given to the MCB when a fault condition occurs.

In general, a fault condition must be corrected and the fault be manually reset before the converter can be started again.



The faults are entered into the fault logger as they occur and are numbered; the last fault entered always has number 1 assigned to it and the first fault always has the highest number in the fault logger. Information of the fault classification (e.g. FC 1 or FC 2) is also saved when the first fault of the fault class is active. Date and time stamps facilitate fault tracing, especially when a fault leads to several subse-quent faults.

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

For further information refer to Engineering Guidelines, Input Circuit Breaker Control.

2.4.3 Protection functions related to the converter system

Motor stall The ACS 1000 protects the motor if a stall condition is detected. The monitoring 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 converter responds with an alarm or a trip when a stall is detected.

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

Figure 2-10 Stall region of the motor

1. The output frequency is below the set stall frequency.

2. The converter is in torque limit. The maximum output torque possible for the application is set in a parameter. Although it indirectly effects operation of the motor stall protection, it should not be considered a motor stall parameter.

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

Stall region

Tm.a

Stall

Torque

Frequencyf (Hz)


38


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

Monitoring limits: underload curve and underload time can be chosen as well as the converter response to the underload condition (alarm / trip indication and stop the converter / 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 (see Figure 2-11).

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

Figure 2-11 Load curves for underload function

Overspeed The motor speed as determined by DTC is monitored. If the motor speed exceeds the maximum permitted motor speed (user adjustable) a trip is initiated.

Undervoltage In order to detect a loss of the main power supply, the positive and negative DC link voltage levels are monitored. If these voltage levels drop below 70% of their nominal levels, an undervoltage alarm is initiated and power loss ride-through is activated (provided it is selected) (refer to 2.2.5 Ride-through functions). If the DC link voltage levels drop below 65% of their nominal values, an undervoltage trip is initiated.

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

110%

120%

130%

140%

curve 1

curve 2

curve 3

curve 4

curve 5

Torque

Speed



2.4.4 Internal converter protection functions

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

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

Monitoring limit values The values of user selectable signals can be monitored for adjustable low and high limits:

• two speed values

• current value

• two torque values

• two reference values

• two actual values of the PID controller

The digital status of the active limit appears on the control panel display and can also be allocated to a digital output.

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

Short circuit in therectifier bridge

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

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


38


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

Overcurrent Inverter phase currents are monitored. If a preset level is exceeded, a trip is initiated. This protection is implemented both in software and in hardware.

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

Air cooling Temperature and fan pressure are monitored to ensure proper function.

Water cooling The operating condition of the cooling circuit is monitored. If any of the monitored signals such as water temperature, water pressure or conduc-tivity exceed a preset limit, a trip is initiated. In addition, the status of the cooling water pumps, the water level in the expansion vessel and the auxiliary fan are monitored.

Short circuit of theinverter

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

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

The ground fault detection includes the ACS 1000 transformer secondary side and the motor.

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

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

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

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



Battery test An automatic presence check (every minute), automatic quality test (once a week), temperature-determined charging, and electronic overcurrent protection ensure that the battery modules are ready to operate at all times if the converter has been equipped with batteries.

2.4.5 External protection functionsExternal converter protection functions require external measuring devices.

Motor winding andbearing temperature

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

The ACS 1000 provides analog inputs for measuring and monitoring the motor winding and bearing temperature.

Values for alarm and trip levels can be set.

For further information refer to Chapter 6 - Options, 6.5 Motor side.

External motorprotection trip

An external motor protection relay can be connected to a predefined protection input of the ACS 1000. The motor protection input is integrated into the tripping loop by a normally closed (NC) contact.

External transformerprotection trip

An external transformer protection relay can be connected to a predefined protection input of the ACS 1000. The transformer protection input is integrated into the tripping loop by a normally closed (NC) contact. This function is not applicable for the ACS 1000i.

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

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

For further details see Chapter 4 - Control system and process interfaces.

2.5 Additional featuresConverter information The converter software version and serial number can be displayed on the

CDP control panel.

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

2.6 Optional featuresSee Chapter 6 - Options for information.


38

ABB

Chapter 3 - Hardware design

3.1 OverviewThis chapter provides a description of the standard power, control and cooling hardware of the different ACS 1000 types.



• ACS 1000 Dimensions and Floor Mounting (for document details see Chapter 1 - Overview, Table 1-2)


3.2 Converter topologyFigure 3-12 to Figure 3-14 show the elementary circuit diagram of the ACS 1000.

Figure 3-12 Elementary diagram - ACS 1000, 12-pulse version

NP M

3 Convertertransformer

Main circuitbreaker

Mediumvoltage switchgear

Dioderectifier

ProtectionIGCTs

Intermediate DC link

Three levelinverter

Outputsine filter

Squirrel cageinduction motor

MNP



OutlineDrawings_ACS5000.pdf

Chapter 3 - Hardware design ABB

Figure 3-13 Elementary diagram - ACS 1000, optional 24-pulse version

Figure 3-14 Elementary diagram - ACS 1000i

The ACS 1000 system consists of the following main components:

• Input Circuit Breaker (ICB) / Main Circuit Breaker (MCB)

• Input transformer

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

• ACS 1000 frequency converter

with fuseless rectifier bridges (12-pulse or 24-pulse), voltage DC-link, 3-phase inverter and output sinus filter. Refer to Figure 3-12, Figure 3-13 and Figure 3-14.

• Motor of asynchronous type

Convertertransformer

Main circuitbreaker


Dioderectifier

ProtectionIGCTs


Three levelinverter

Outputsine filter


M3

Convertertransformer


Dioderectifier

ProtectionIGCTs


Three levelinverter

Outputsine filter


Input contactor(optional)

MNP


66

ABB Chapter 3 - Hardware design

3.3 Technology

3.3.1 Fuseless designThe ACS 1000 features a fuseless protection concept.

The patented design uses the IGCT power semiconductor for circuit protection.

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

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

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

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

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

The ACS 1000i (with integrated input transformer) is equipped with a 24-pulse diode rectifier input bridge as a standard configuration.

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



Figure 3-15 3-level voltage source inverter principle

3.3.4 Output stagesAt 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 3-16). 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.

• Harmonic heating is virtually eliminated. The converter may be used to supply standard medium voltage motors (existing or new) without applying 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 frequency content does not exist). Therefore, any standard medium voltage winding insulation system (existing or new) is compatible with the ACS 1000.

• The maximum length of the motor cables is limited to 1000 m. Longer motor cables are available on request.

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

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


66


Figure 3-16 Voltage and current waveforms at converter output

3.3.5 IGCT power semiconductorThe Integrated Gate Commutated Thyristor (thyristor and gate unit are integrated in one unit, see Figure 3-17) is a power semiconductor switching device specifically developed for medium voltage converters. Based on well established GTO (Gate Turn Off Thyristor) technology, it enables intrinsically less complex, more efficient and reliable converter designs.

Figure 3-17 IGCT

IGCTs combine high speed switching capabilities as known from IGBTs (Insulated Gate Bipolar Transistors) with high blocking voltage and low conduction losses as known from GTOs. See also Table 3-6.

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

Gate-commutated thyristor

Gate unit



Table 3-6 Comparison of semiconductors

3.4 Cabinet layout

3.4.1 Air-cooled ACS 1000

Figure 3-18 The ACS 1000 air-cooled type (12 / 24-pulse, typical layout)

GTO thyristor High voltage IGBT IGCT

Switching technology High blocking voltage Low on-state losses

High switching frequency Low switching lossesHigh on-state lossesSnubberless

High blocking voltage High switching frequencyLow on-state and switching lossesSnubberless

Equipment design Proven reliability Compact Fuseless design

Modular design Proven reliabilityCompact and modular equipment design Simple topologies with low parts countSnubberless

1 2 3 4 5 6


66


1 Power cable connection section for top and bottom entry and exit, control electronics mounted on swing frame (local control terminal and pusbuttons on front door)

2 Grounding switch and common mode choke (optional)

3 Sine filter choke

4 Input bridge, cooling fan for low noise level

5 Inverter stacks, output filter and DC link capacitors

6 Air intake in front door

The air-cooled ACS 1000 is designed with inverter stacks, output filter and DC link capacitor in one section. This section is situated at the air intake which is advantageous for the temperature sensitive capacitors. The construction of the inverter stacks allows easy exchange of IGCTs by means of a specially designed tool which is part of the supply.

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

Figure 3-19 Air flow through ACS 1000A

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

Control section Inverter sectionRectifier section

Air intake



3.4.2 Air-cooled ACS 1000i with integrated transformerThe ACS 1000i is equipped with an input transformer. The 24-pulse input bridge is standard.

Figure 3-20 The ACS 1000i air-cooled type

1 Power cable connections, sections for top and bottom entry, input isolator

2 24-pulse input transformer, 24-pulse input bridge, grounding switch, protection IGCTs and air intake

3 Control electronics mounted on swing frame (local control terminal and pusbuttons on front door)

4 3-level voltage source inverter, air intake, output filter and DC link capacitors

5 Cooling fans

6 Air intake in front door

1 2 3 45 65


66


Figure 3-21 Air flow through ACS 1000i

3.4.3 Water-cooled ACS 1000

12-pulse version The water-cooled type of the ACS 1000 is equipped with a closed circuit water cooling system. Part of the cooling system is a fan and an air-to-water heat exchanger to maintain cooling of all non-water-cooled compo-nents.

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

Air intake



Figure 3-22 The ACS 1000 water-cooled type (12-pulse)

1 Control section on swing frame with power cable connection section behind (local control terminal and pusbuttons on front door), cable connection section for top and bottom entry and exit

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

3 Gate unit supplies (GUSP, top) and common mode choke (bottom)

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

5 Water cooling unit and fan

6 Redundant fan (optional)

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

1 2 3 4 65


66


3.4.4 Power terminals

Air and water-cooledACS 1000

The leftmost sections of the air and water-cooled ACS 1000 contain the swing frame with the control equipment (see 3.5.1 Terminal and control section). The power terminal section with busbars for mains and motor cables is located behind this swing frame and protective cover plate. The swing frame can be opened more than 120° to provide optimum access to the power terminals.

The terminals can be accessed by removing the bolted cover plate behind the swing frame.

ACS 1000i The power terminals of the ACS 1000i are located in the leftmost section, together with the input disconnector.

Please refer to Chapter 7 - Installation guidelines for further details on cable entry and connection.

3.4.5 DC grounding switch for safe groundingThe power section is equipped with a grounding switch. The grounding switch connects the DC link to earth.

The grounding switch is electromechanically interlocked with a discharge monitoring circuit to prevent closing of the switch while the DC link capac-itors are still charged.

3.5 Hardware modules (air-cooled ACS 1000)

3.5.1 Terminal and control sectionThe control hardware (processor and communication boards) is mounted on the swing frame. Details can be seen in Figure 3-23. The customer I/Os for customer control and protection signals as well as I/Os for auxiliary power supply are located on the swing frame and behind the swing frame on the right side wall (see Figure 3-24).



Figure 3-23 Control section with open front door (ACS 1000 air, typical layout)

Control power supply

Swing frame

Terminal blocks for internal

AMC controller board /

Pulse encoder /

Delta p-transmitter

IOEC1 board

Motor starters and


Control panel

Control pushbuttons and

Emergency off switch

interface board

fieldbus interface

circuit breakers

option: external UPS safelineother options: internal UPS

indication lights

auxiliary power

with batteries


66


Figure 3-24 Control section with open swing frame (ACS 1000A, typical layout)

The control system is described in Chapter 4 - Control system and process interfaces.

IOEC4 boardoptional

Spare terminals

Swing frame (rear side)

IOEC2 board (standard)

Auxiliary voltage

IOEC3 board (optional)

Space for options

terminals

(optional)



3.5.2 Inverter sectionThe inverter section (Figure 3-25) contains the inverter stacks, the sine filter and DC link capacitors.

Figure 3-25 Inverter section (ACS 1000A, typical layout)

Phase U Phase V Phase W

Sine filter andDC link capacitors


66


3.5.3 Rectifier sectionThe rectifier section (Figure 3-26) contains the rectifier stacks and protection IGCTs, the output filter choke as well as the optional common mode choke. The grounding switch and the cooling fan are also located in this section.

Figure 3-26 Filter section (ACS 1000A, typical layout)

3.6 Hardware modules (air-cooled ACS 1000i)

3.6.1 Control sectionThe control hardware (processor and communication boards) are mounted on the swing frame. Details can be seen in Figure 3-27. The customer I/Os are located inside the cabinet. Terminals for customer control and protection signals as well as for auxiliary power supply are located on the right hand side of the section.

Batteries are optional.

Grounding switch

Common mode choke

Filter choke

Cooling fan

Rectifier (including protection IGCTs)



Figure 3-27 Control section with open front door (ACS 1000i, typical layout)

IOEC4 board

IOEC3 board

IOEC2 board

IOEC1 board

Delta p-transmitter

Delta p-transmitterFused terminal block for

Motor starters and

Option: batteries

AC aux. supply

Terminal blocks (internal,

Control panel

Control pushbuttons and

Emergency off switch

transformer


circuit breakers

cooling, fans, external)

protectionindication lights

AMC and interface board

internal aux. power

(optional)

(optional)


66


3.6.2 Inverter sectionThe inverter section (Figure 3-28) contains the inverter stacks, the sine filter and the DC link capacitors. The filter choke is located behind the inverter stacks.

Figure 3-28 Inverter section (ACS 1000i, typical layout)

Sine filter and

Phase U Phase V Phase W

DC link capacitors



3.6.3 Input sectionThe input section (Figure 3-29) contains the rectifier stacks and protection IGCTs, as well as the input transformer. The grounding switch is also located in this section.

Figure 3-29 Input section (ACS 1000i, typical layout)

Grounding switch

Input grounding switch

Input transformer

Surge arrestors

Rectifier

Rectifier

(behind rectifiers)

interlock


66


3.7 Hardware modules (water-cooled ACS 1000)

3.7.1 Terminal and control sectionThe layout of the control cabinet is identical with the air-cooled type (see Section 3.5.1 Terminal and control section).

3.7.2 Converter sectionThe converter section (Figure 3-30) contains the rectifier, inverter and protection IGCT stacks.

Figure 3-30 Converter section (ACS 1000W, typical layout)

Phase U

Phase V

Phase W

Protection IGCT

Rectifier



3.7.3 Filter sectionThe filter section (Figure 3-31) contains the output filter components as well as the optional common mode choke. The grounding switch is also located in this section.

Figure 3-31 Filter section (ACS 1000W, typical layout)

Filter capacitors

GUSP

DC capacitors

Grounding switch

Output filter choke

Snubber circuit

Common mode choke (optional)


66


3.7.4 Water cooling system

3.7.4.1 Overview

Figure 3-32 Cooling section (ACS 1000W, typical layout)

The cooling system of the ACS 1000 comprises:

• the water cooling circuit for the main power components (rectifier and inverter stacks as well as the chokes)

• additional air-to-water heat exchanger for the heat dissipation of non-water-cooled components inside the power section of the converter

• small fan units for the air circulation for the control system.

Expansion vessel

Connection box

Ion exchange vessel

Air-to-water heat exchanger

Cooling fan

Water-to-water heat exchanger



Figure 3-33 Principle of water cooling circuit

Water cooling system The cooling system consists of the following circuits:

• The raw water cooling circuit transfers the heat losses from the water-to-water heat exchanger in the WCU to the exterior. The water flow through the heat exchanger is controlled by a two-way valve. The circuit is designed for the use of industrial cooling water.

• The internal cooling water circuit is filled with deionized water and transfers the heat losses of the main power components to the water-to-water heat exchanger. The closed circuit is equipped with a pressurized expansion vessel.

Optionally, the cooling circuit can be filled with a glycol water mixture for frost-proofing.

• The internal cooling water treatment circuit continuously de-ionizes the internal cooling water to keep the conductivity at a low level. The circuit includes the make-up water connection.

Air cooling system • The auxiliary air-to-water heat exchanger and the internal air circu-lation fan are used for removal of all remaining heat out of the ACS 1000 via the raw water circuit. Therefore, virtually no heat losses are dissipated into the control room (typically < 1 kW, depending on room and water temperature).

• With the option IP42 no air-to-water heat exchanger is used. The control room air is used for cooling. The heat losses of up to 7 kW are dissipated into the control room.

Internal cooling water circuit

Internal cooling water

Raw watercooling circuit

Internal air cooling circuit

treatment circuit


66


3.7.4.2 Main components of the cooling unit

The cooling unit is equipped with the following standard components:

• Stainless steel water-to-water heat exchanger

• Water-cooling pump

For information on the redundant water cooling pump refer to Chapter 6 - Options, 6.6 Converter cooling.

• Expansion vessel

• Deionized cooling water treatment

• Air cooling fan and air-to-water heat exchanger

A redundant fan is available as option. See also Chapter 6 - Options, 6.6 Converter cooling

• Control system monitoring

• Water temperature

• Water pressure

• Water conductivity

• Water level

• Leakage (optional, sensor installed at the bottom of the cooling unit)

• Water temperature control valve

The 2-way valve is standard. For information on the optional 3-way valve refer to Chapter 6 - Options, 6.6 Converter cooling.



Figure 3-34 Cooling unit of the water-cooled ACS 1000

3.7.4.3 Raw water connection

Raw water connection The raw water pipes are connected to the cooling unit with hoses which are part of the scope of supply. Flanges can be delivered optionally. The feeding and return hoses are entered either through the top or the bottom of the cooling unit.

• Raw water connection

• Flexible hoses

• Top and bottom entry

• Option: flanges

• Material of raw water circuit

• Water-to-water heat exchanger: stainless steel

• Air-to-water heat exchanger: copper (optional: stainless steel)

• Cooling water piping: stainless steel

• Control valve: stainless steel

Raw waterrequirements

See Technical data for a detailed list of parameters of the water cooling system and options regarding extended raw water temperature and pressure.

OPTION

OPTION

to converternipple

from converternipple

raw water inletnipple

raw water outletnipple

V5

V13

V12V16

V11

V14

V18

V3

V4

V1

V2

V15 V82

Strainer (Z1)

Air-to-waterheat exchanger (E2)

Water-to-water heatexchanger

(E1)

Make-upwater

C1C/A

Ion exchange vessel

Expansion vessel (C2)

Microfilter (Z2)

M

M

P1

P2V80

S1

S2

V81

M11

M12

B10

B14

M

B11 B12 B13

OPTION


66


3.8 Cabinet designThe following information applies to the air-cooled and the water-cooled ACS 1000. Exceptions are marked specifically.

3.8.1 Mechanical design

3.8.1.1 Basic design

The basic mechanical structure consists of:

• The supporting frame (only ACS 1000i)

• The riveted and folded sheet metal

• Hinged front doors

• Interior partitions separating sections of different voltage levels.

The sheet metal of the panels and the doors has a thickness of 2 mm.

3.8.1.2 IP rating

The following list contains the standard IP classes of the converter enclo-sures. Refer to Chapter 6 - Options, 6.3 Converter enclosure for optional IP classes.

• Protection rating of air-cooled ACS 1000: IP 21

• Protection rating of water-cooled ACS 1000: IP 31

• Protection rating of ACS 1000i: IP 21

• Protection rating of low voltage compartment: IP 20 (doors open)

3.8.1.3 Enclosure type and painting

• Enclosure type

• Corrosion protected (galvanized) steel enclosure

• EMC conform design

• EMC gaskets on converter doors

• The complete cabinet is zinc plated.

• Cabinet paint finish: painted doors

• Standard cabinet color: RAL 7035 (light grey), other colors as option

• Paint thickness: powder coating ≥ 50 μm, optional up to 150 μm

3.8.1.4 Transportation

The converter is shipped in one unit. The fans of the ACS 1000i are always shipped separately. Options like the redundant fan or additional cabinets may be shipped separately.



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

The design fulfils the requirements of international standards like UL 347A. Refer to ACS 1000 - Applicable codes and standards for details.

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

Accordingly, only the front of the ACS 1000 cabinet is painted while all other walls are galvanized. However, the cabinet can be ordered optionally with the whole of the outside painted.

EMC performance is further enhanced by the use of metal cable channels

3.8.3 Door locks and door interlockingAll doors are hinged and locked using carriage key locks.

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

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

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


66


3.8.4 Safety labelsSafety labels are attached to the converter enclosure to alert personnel of potential hazards when working on the converter. The standard language of the label text is English. If specified when ordering the converter the labels are provided in the national language of the customer. The label design is based on the relevant ANSI and ISO standards.

Figure 3-35 Typical safety labels

3.8.5 Compliance with international standardsThe design of the ACS 1000 fulfills the requirements of international standards listed in ACS 1000 - Applicable codes and standards.

3.9 Busbars and groundingAC and DC power connections within the converter cabinet are made with busbars or cables.

Safety ground The frequency converter is equipped with a ground bus which is located in the power cable termination section.

The grounding cable is connected to this ground bus. The connection must be in compliance with local regulations.



3.10 Lifting arrangementsThe cabinets of the air and water-cooled ACS 1000 are fitted with lifting rails on the roof as standard. The ACS 1000i is fitted with lifting lugs on the base frame.

Figure 3-36 Lifting rails air-cooled ACS 1000

Figure 3-37 Lifting rails water-cooled ACS 1000

Figure 3-38 Lifting lugs ACS 1000i

3.11 Additional cabinetsThe ACS 1000 cabinet system provides the flexibility to add optional cabinets to the converter. Cabinets can be added in widths of 644 and 844 mm (25 and 33 inches). For further information see Chapter 6 - Options, Additional cabinet.


66

ABB

Chapter 4 - Control system and process inter-faces

4.1 OverviewThis chapter provides a description of the control hardware and software of the ACS 1000, as well as the hardwired and fieldbus interfaces that are at the customer’s disposition. Furthermore, the available control options are explained as well.



• ACS 1000 Terminal lists (for document details see Chapter 1 - Overview, Table 1-2)

• Application Note, Control and Operation Modes, (for document details see Chapter 1 - Overview, Table 1-2)

• ACS 1000 Type Code, (for document details see Chapter 1 - Overview, Table 1-2)


Chapter 4 - Control system and process interfaces ABB

4.2 Hardware and structure of the control system

Figure 4-39 Typical configuration of control system

AMC controller The control system is based on ABB’s well-proven Application and Motor Controller (AMC), see Figure 4-39. Fitted with a 150 MHz Motorola DSP processor, the controller is equipped with two PPCS and eight DDCS communication channels. PPCS (Power Plate Communication System) and DDCS (Distributed Drive Control System) are acronyms for serial communication protocols tailored for high speed data transfer via fiber optic cables, namely with:

• Converter control interfaces

• Higher-level process control systems via advant or fieldbus adapters

• I/O devices, see section 4.4 Customer I/O interfaces

• Service tools (e.g. DriveWindow, DriveMonitorTM)

DD

CS

DDCS

RS485D

DC

SDDCS

AMC controller

IOEC1

Customer interface section

Control section

Higher-levelcontrol systemDriveMonitorTM

CDP control panel

Converter section

PC tools

Fieldbus

Fiber optic

Fiber optic

IOEC2

IOEC3* IOEC4**

INT board

*/** Additional option for air-cooled ACS 1000** ..Additional option for water-cooled ACS 1000


76

ABB Chapter 4 - Control system and process interfaces

Figure 4-40 AMC Board

Control panel The AMC controller communicates with the CDP control panel (see Figure 4-39 and Figure 4-41) which is mounted on the door of the control unit. The control panel serves as a local user interface for monitoring, control and operation of the converter and setting of parameters. The communication of the AMC controller with the control panel is accom-plished via a RS-485 link. For further information refer also to section 4.3.1 CDP control panel.

General control tasks General control, protection and monitoring tasks regarding the whole converter as well as all rectifier and line related functions of the converter are implemented in the AMC controller. These tasks include control and monitoring of:

• Main Circuit Breaker (MCB)

• Grounding switch

• Door interlocking

• Cooling system

4.3 Local control devices

4.3.1 CDP control panelThe ACS 1000 is equipped with the CDP control panel, the same panel as used on all frequency converters of the ACS family. The CDP control panel is an intelligent digital control panel with function keypad and LCD display. It provides full control of the frequency converter and allows adjustment of the system parameters.



The key features of the CDP control panel are:

• 4-line display for easy monitoring of actual signal values and converter status

• user selectable display of actual values, such as motor speed, current, voltage, torque, power

• fault memory to support maintenance.

The panel allows the operator:

• to enter startup data into the converter

• to control the converter by setting reference values and by giving start, stop and direction commands

• to display three actual values at a time

• to display and set parameters

• to display information with time stamp on the last 64 fault events.

Figure 4-41 CDP control panel

Stop button

Mode selection buttons

Alphanumeric display(4 lines x 20 characters)

Enter button

Start button

Setpoint setting button

Forward, reverse buttons

Local, remote button

Reset button

Selection and changing buttons

1242,0 rpm I1 L -> MotCurr 76.00 A

1242.0 rpmMotSpeed

86.00 %Torque


76


4.3.2 Control switchesThe illuminated on/off switches for the main supply, the ground isolator status lamp and the emergency off switch are located below the CDP control panel (see Figure 4-42). The emergency off switch shuts down the whole converter when activated.

Figure 4-42 Local control devices

Control panel- used to start and stop the motor- displays status messages of the con-..verter- displays alarm and fault messages - used to reset alarm and fault messages

Illuminated pushbuttons- OFFline opens main circuit breaker- ONline closes main circuit breaker

Lamp grounding switch unlockedindicates when DC link is discharged and grounding switch can be turned to posi-tion “grounded”

Emergency off switch- prevents start-up if actuated at standstill - main circuit breaker opens and DC link dis-..charges if activated during operation



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

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

• The air-cooled ACS 1000i is equipped with two I/O boards (IOEC1 and IOEC2) as a standard with the option of two additional I/O boards (IOEC3 and IOEC4).

• The water-cooled ACS 1000 is equipped with three I/O boards (IOEC1, IOEC2, IOEC3) with the option of one additional I/O board (IOEC4).

The actual configuration and the exact number of available signals depends on the selected control and operation mode (refer to Application Note, Control and Operation Modes) as well as on the selected options.

All I/O boards are identical in design with the same number of I/Os. The analog and digital I/Os are floating and galvanically isolated with ratings as indicated in Table 4-7.

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

Table 4-7 I/O board configuration with number and type of I/O

Refer to Chapter 6 - Options for information on additional interface signals on the optional I/O boards.

Number Signal type Ratings

4 Analog Inputs

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

2 Analog Outputs

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

14 Digital Inputs

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

6 Digital Outputs

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


76


4.4.1 Programmable digital and analog outputs

Programmable digitaloutputs

Four digital outputs on the IOEC2 board can be programmed individually. Each output has floating change-over contacts and can be allocated to an internal binary control or status signal via parameter setting.

Examples are:

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

If optional boards IOEC3 and/or IOEC4 are installed, a maximum of 12 additional digital outputs (6 on each board) are available (refer to Chapter 6 - Options).

Programmable analogoutputs

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

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

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

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

4.4.2 Scalable analog inputsEach analog input can be adapted individually to the type and range of the connected input signal:

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

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

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

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

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

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



4.4.3 Customer control signalsThe complete list of standard and optional customer control signals is provided in the ACS 1000 Terminal lists.

4.5 Control software

4.5.1 Control software structureThe control software of the converter is organized into the following functional groups (see Figure 4-43):

• Operating system software (AMCOS)

• Rectifier and inverter control software

• FCB application software for configurable functions

Figure 4-43 Software block diagram of the AMC controller

4.5.2 Operating systemThe AMC Operating System (AMCOS) is a real-time multitasking system providing functions such as task scheduling and FLASH memory management as well as standardized interfaces to the AMC table and services for I/O communication and diagnostics.

The AMC table contains data for motor, rectifier and application control functions including the process I/O image. The AMC table serves also as an interface for data interchange between different software groups.

Inverter control AMC controller

AMCOS (AMC Operating System)

Function blocklibrary (FCB)

Panel application

Motor control +Main state machine

Speedcontroller

Direct TorqueController

AMC table

Modulatorinterface

Magnetizationsetpoint to EXU

Fieldbus adapter

Advant ACcontrollerProcess I/O

Control panel

FCB applicationsoftware

software (DTC)


76


4.5.3 Motor and control software

Motor control The control software includes control algorithms for Direct Torque Control (DTC), the motor control method for highest torque and speed perfor-mance.

Fault handler The fault handler classifies each detected event and allocates each regis-tered fault to one of several predefined fault classes. The fault classes determine if the main circuit breaker opens in case of a fault or not. Upon an event, the fault handler updates the fault logger and the alarm and fault words of the AMC table and accesses the Main state machine which in turn coordinates the reaction of the converter.

Refer to Chapter 2 - Functional description, operation, 2.4.1 Alarm and fault handling for further information.

Main state machine The Main State Machine (MSM) is a predefined program serving as the prime control place for converter control systems based on the AMC controller. The MSM is called up cyclically by the operating system, reads the drive command words and controls the converter functions such as start, stop and fault sequences, DC link charging and discharging etc. according to the internal state of the converter. It determines the optimum reaction on any event or fault occurring in the converter.

4.5.4 FCB application software The application software which is also implemented on the AMC controller is programmed with a graphical PC software tool, the Function Chart Builder (FCB). The FCB makes use of a function block library which consists of a selection of preprogrammed software blocks.

The application software contains:

• I/O handling routines

• Customer and converter interfaces

• Selection logic for reference and control location

• Fault and alarm monitoring

• Converter operation sequences and interlocking

• Auxiliary device control.

4.5.5 Panel application softwareThe panel application software exchanges information between the AMC table of an AMC controller and the CDP control panel connected to it (see Figure 4-39).

The panel application software provides also the PC interface to DriveWindow.




76

ABB

Chapter 5 - Engineering information

5.1 OverviewThis chapter describes the requirements for system components which are not included in the converter scope of supply. Further information on the requirements for system components are available in the following specifications:




• Engineering Guidelines, Input Circuit Breaker Control (for document details see Chapter 1 - Overview, Table 1-2)

• Technical Requirement Specification, Motors for ACS 1000 Frequency Converters (for document details see Chapter 1 - Overview, Table 1-2)

• Technical Specification for Power Cables (for document details see Chapter 1 - Overview, Table 1-2)

• Wiring and Busbar Specification (for document details see Chapter 1 - Overview, Table 1-2)

5.2 Main circuit breakerRefer also to Engineering Guidelines, Input Circuit Breaker Control.

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

• Vacuum or gas insulated (SF6) circuit breakers

• Fused contactor

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

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

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



Chapter 5 - Engineering information ABB

The MCB is opened by:

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

• the hardwired tripping loop (see Section 5.2.2 Tripping loop)

• any trip signal directly given to the MCB.

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

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

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

5.2.2 Tripping loop

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

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

For details refer to Engineering Guidelines, Input Circuit Breaker Control.

ACS 1000 tripping loopsignals

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

• Digital output "MCB ORDER TRIP"

• Emergency off switch on the ACS 1000 front door

The digital output "MCB ORDER TRIP" is initiated:

• if the grounding switch is closed or not completely opened

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

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


84

ABB Chapter 5 - Engineering information

Customer signals The following signals from customer devices can, but do not have to, be wired to the tripping loop terminals:

• External emergency off

• Transformer protection trip

The following signal require the optional IOEC3 board:

• Motor protection trip

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

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

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

The transformer may be supplied from ABB or alternatively from a third party supplier in accordance with the specifications provided by ABB. The design of the transformer must take into account site-specific line condi-tions (voltage, short circuit capacity, existing harmonics, etc.) to insure compliance with harmonic standards invoked by the specifications. Trans-former quality is critical with respect to effecting proper limitation of harmonic currents and voltages.

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

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

5.4 Motor selectionRefer also to Technical Requirement Specification, Motors for ACS 1000 Frequency Converters.



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

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

• Overloadability requirements

• Motor voltage

• Number of motor poles

• Shaft power (nominal)

• Shaft speed (nominal)

• Rated current (nominal)

• Motor efficiency

• Motor power factor

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

Depending on the mechanical configuration of the motor, load, gearbox and shaft, there may be some critical speeds within the operating speed range of the converter. The critical speeds have to be known and if they have to be avoided, the appropriate parameter settings have to be made. Special attention has to be paid to variable speed applications using two-pole motors, since there is usually a critical motor speed below its rated speed. For more information see Chapter 2 - Functional description, operation, Critical speed, page 27.

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

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


84


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

5.4.3 Load capacity curvesThis chapter provides the necessary information regarding the selection criteria of the motor to match the ACS 1000.

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

Figure 5-44 Load capacity curves

2.01.91.81.71.61.51.41.31.21.11.00.90.80.70.60.50.40.30.20.10.0

0 10 20 30 40 50 60 70 80 90 100

0 600 1200 1800 2400 3000 3600

0 300 600 900 1200 1500 1800 2100 2400

0 200 400 600 800 1000 1200 1400 1600

p = 2

p = 4

p = 6

f (Hz)

T/TN

n (rpm)

n (rpm)

n (rpm)

0 150 300 450 600 750 900 1050p = 8

n (rpm)

p .= .number of polesT .= .load torqueTN= .rated motor........torquen .= .speedf ..= .output frequency of ........ACS 1000

Curve 2ACS 1000 loadability

Curve 1Motor loadability

Curve 1: Typical continuous load capacity curve of an IEC34 self-ventilated motor, controlled by the ACS 1000.Curve 2: Load capacity of the ACS 1000, rated for normal use (i.e. 100% continuous, 110% for 1 min. every 10 min.).



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

5.5 Selection of power cablesThe following chapters include recommendations on the power cable selection. Refer also to Technical Specification for Power Cables for further information.

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

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

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

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


84


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

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

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

For information regarding the maximum length of the transformer secondary cables see Technical data.

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

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

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

Motor cables are terminated within the ACS 1000 cabinet in the same way as the transformer secondary cables (see Chapter 7 - Installation guide-lines, Figure 7-58).

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



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

5.6 Control cablingControl cables should be provided in accordance with Table 5-8. Cable shields should be terminated on the ACS 1000 side only. Either single or multiple twisted pair cables may be used.

Table 5-8 Control cable requirements

5.7 Auxiliary power cablesAny cable up to 10 mm2 can be used. Type and ratings are to be selected according to local regulations. For ratings see also Technical data.

Signal type General cable type Cross-section

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

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

Digital input Twisted pair(s) - Overall shield 0.5 to 2.5 mm2 / AWG 20 to AWG 12

Digital output Twisted pair(s) - Overall shield 0.5 to 2.5 mm2 / AWG 20 to AWG 12

Speed encoder Twisted pair cable with separately shielded pairs and overall shield

0.5 mm2 4 x (2+1)

Position encoder Twisted pair cable with separately shielded pairs and overall shield

0.5 mm2 4 x (2+1)


84

ABB

Chapter 6 - Options

6.1 OverviewThis section provides an overview of the main options available for the ACS 1000. A complete list of all available options is provided in the Type Code.

Links to OtherDocuments



• Type Code (for document details see Chapter 1 - Overview, Table 1-2)

• Application Note, Mechanical Interlock (for document details see Chapter 1 - Overview, Table 1-2)

6.2 Environmental conditionsExtended ambient

temperature (air-cooled only): 50 °C

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

Extended raw watertemperature

The extended raw water temperature range is +27...+38 °C (+80...+100 °F). For deratings refer to Technical data.

Corrosion protectedbusbars

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

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

6.3 Converter enclosureIP rating The standard IP classes of the converter enclosures are given in Chapter

3 - Hardware design, 3.8.1.2 IP rating.

The following IP ratings are optional:

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

• IP42 (for ACS 1000i converters)

• IP54 (for water-cooled converters)



Chapter 6 - Options ABB

Door interlocking The ACS 1000 can be equipped with an additional mechanical inter-locking system for the grounding switch. Refer to the Application Note, Mechanical Interlock for further information.

Cabinet color Other RAL colors and paint thicknesses are available optionally and must be specified explicitly when ordered.

Cabinet paint finish The standard converter has painted front doors. Optionally, the entire cabinet exterior is available with painted surfaces.

Split cabinet The water-cooled ACS 1000 can be delivered split into two sections if the standard converter size exceeds the transportation limits. All materials necessary for joining the two parts are supplied with the converter.

Extended groundingbusbar

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

Additional cabinet The ACS 1000 can be delivered with an additional cabinet for optional equipment, such as input or output isolators, additional terminals, additional line or motor side protection equipment, or other customer specific devices.

Two different sizes (644 mm and 844 mm width) are available. The additional cabinet is mounted to the left side of the ACS 1000. The cabinet is equipped with mounting profiles to have flexibility for the interior design.

The additional cabinet can be provided for power and/or control equipment.


102

ABB Chapter 6 - Options

Figure 6-45 Additional cabinet with power equipment (option output isolator)

Undrilled entry plates Undrilled entry plates are available in various materials. Refer to the Type Code for more information.

6.4 Input sectionInput bridges 24-pulse diode rectifier for ACS 1000A and ACS 1000W (standard for

ACS 1000i).

This type is recommended if superior network behavior is required.

Extended transformermonitoring interface

In addition to the standard signal “Transformer Protection Trip” (wired into tripping loop), the signals according to Table 6-9 can be included optionally in the signal interface between the transformer and the ACS 1000.

Note: This option requires the IOEC3 board.



Table 6-9 I/O signals for extended transformer monitoring

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

Refer to Temperature transducers for PT100, page 97, if a temperature transducer for PT100 is required.

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

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

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

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

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

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

The common mode choke functions like a transformer. Together with the common mode damping resistor it provides damping of the common mode voltages and limits the common mode currents experienced by the main power transformer and transformer secondary cables.

Type Signal name Remarks

DI OIL LEVEL ALARM Transformer oil level alarm indication

DI OIL TEMP ALARM, or

TRAFO WDG TEMP ALARM

Transformer oil temperature alarm inidication

Transformer winding temperature alarm indication

DI /OIL TEMP TRIP, or

/TRAFO WDG TEMP TRIP

Transformer oil temperature trip indication

Transformer winding temperature trip indication

DI /BUCHHOLZ ALARM Transformer alarm indication from Buchholz relay

DI /BUCHHOLZ TRIP Transformer trip indication from Buchholz relay

AI OIL TEMP, or

TRAFO WDG TEMP

Temperature measurement of trans-former oil

Temperature measurement of trans-former winding


102


6.5 Motor sideExtended motor

monitoring interfaceIn addition to the standard signal “Motor Protection Trip” (wired into tripping loop) the signals according to Table 6-10 can be included optionally in the signal interface between the motor and the ACS 1000.

Table 6-10 I/O Signals for extended motor monitoring

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

Refer to Temperature transducers for PT100, page 97, if temperature transducers for PT100 are required.

Type Signal name Remarks

DI EXT MOT PROT ALARM (External) motor protection alarm indication (IOEC3 required)

DI EXT MOT PROT TRIP (External) motor protection trip indication (IOEC3 required)

DI MOT COOLING ALARM (External) motor cooling alarm indication (IOEC3 required)

DI /MOT COOLIING TRIP (External) motor cooling trip indication (IOEC3 required)

DI VIBRATION SV ALARM Motor vibration alarm indication (IOEC3 required)

DI /VIBRATION SV TRIP Motor vibration trip indication (IOEC3 required)

AI BRG TEMP DE Motor bearing temperature of driven end (IOEC3 required)

AI BRG TEMP NDE Motor bearing temperature of non-driven end (IOEC3 required)

AI MOTOR WDG TEMP PHASE U1 Motor winding temperature phase U

AI MOTOR WDG TEMP PHASE U2 Motor winding temperature phase U 2nd measurement (IOEC4 required)

AI MOTOR WDG TEMP PHASE V1 Motor winding temperature phase V

AI MOTOR WDG TEMP PHASE V2 Motor winding temperature phase V 2nd measurement (IOEC4 required)

AI MOTOR WDG TEMP PHASE W1

Motor winding temperature phase W

AI MOTOR WDG TEMP PHASE W2

Motor winding temperature phase W 2nd measurement (IOEC4 required)



Pulse encoderinterface module

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

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

The requirements for a pulse encoder are as follows:

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

• Single-ended or differential connection can be used

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

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

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

Increased outputfrequency

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

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

Braking choppers are available for all ACS 1000 types.

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

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

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

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

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


102


Circuit breaker formotor space heater

A motor space heater can be connected directly to a single-phase auxiliary power circuit breaker installed in the converter cabinet. Depending on the power rating of the heater, one of the circuit breaker sizes as indicated in Table 6-11 can be used.

Table 6-11 Power ratings for different circuit breaker sizes

Motor starter for motorcooling fan or pump

Motor cooling fan(s) or pump(s) can be connected directly to an auxiliary motor starter installed in the converter. Depending on the power rating of the cooling fan(s) or pump(s), one of the following motor starter sizes can be chosen:

Table 6-12 Power ratings for different starter sizes

Auxiliary voltage (single phase)

Circuit breaker rating 120 VAC (50/60 Hz) 240 VAC (50/60 Hz)

0.5 A 60 W 120 W

1.0 A 120 W 240 W

2.0 A 240 W 480 W

3.0 A 360 W 720 W

4.0 A 480 W 960 W

5.0 A 600 W 1200 W

6.0 A 720 W 1440 W

10.0 A 1200 W 2400 W

Auxiliary voltage (three phase)

Overload current rating

400 VAC50/60 Hz

480 VAC60 Hz

575 VAC60 Hz

2.5 - 4.0 A 0.75 kW - 1.5 kW1 hp - 2 hp

(1.1 kW - 2.2 kW)1.5 hp - 3 hp

(1.1 kW - 2.2 kW)

4.0 - 6.3 A 1.5 kW - 2.2 kW2 hp - 3 hp

(2.2 kW -3 kW)3 hp - 5 hp

(2.2 kW - 3 kW)

6.3 - 10.0 A 2.2 kW - 4 kW3 hp - 5 hp

(3 kW - 4 kW)5 hp - 7.5 hp(3 kW - 4 kW)

10.0 - 16.0 A 4 kW - 7.5 kW5 hp - 10 hp(4 kW -9 kW)

7.5 hp - 10 hp(4 kW - 11 kW)

16.0 - 20.0 A 7.5 kW - 9 kW10 hp - 12 hp

(9 kW -12.5 kW)10 hp - 15 hp

(11 kW - 12.5 kW)

2 x (2.5 - 4.0 A) 2 x (0.75 kW - 1.5 kW)2 x (1 hp - 2 hp)

(2 x (1.1 kW - 2.2 kW))2 x (1.5 hp - 3 hp)

(2 x (1.1 kW - 2.2 kW))

2 x (4.0 - 6.3 A) 2 x (1.5 kW - 2.2 kW)2 x (2 hp - 3 hp)

(2 x (2.2 kW -3 kW))2 x (3 hp - 5 hp)

(2 x (2.2 kW - 3 kW))



6.6 Converter coolingRedundant cooling fan

(ACS 1000A)The redundant cooling fan is an option intended for applications where enhanced reliability of the installation is required.

The redundant fan unit is supplied as a separate unit to be mounted on top of the ACS 1000 converter. If delivered together with the ACS 1000, both fans are already mounted in the unit.

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

If this option is ordered the derating of the converter output power needs to be considered (see Technical data, Environment).

Redundant coolingfans (ACS 1000i)

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

The redundant fan units (always two units) are supplied as separate units to be mounted on top of the ACS 1000i (see Chapter 1 - Overview, Figure 1-3). If delivered together with the ACS 1000i, all four fans (the two standard fans and the two optional fan units) are delivered separately.

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

Redundant coolingpump (ACS 1000W)

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

Redundant cooling fan(ACS 1000W)

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

The redundant fan unit is supplied as a separate unit and is mounted on top of the ACS 1000. This option is needed when continuous operation of the converter is required in case of a fan failure.

2 x (6.3 - 10.0 A) 2 x (2.2 kW - 4 kW)2 x (3 hp - 5 hp)

(2 x (3 kW - 4 kW))2 x (5 hp - 7.5 hp)2 x (3 kW - 4 kW)

2 x (10.0 - 16.0 A) 2 x (4 kW - 7.5 kW)2 x (5 hp- 10 hp)

(2 x (4 kW -9 kW))2 x 7.5 hp - 10 hp

(2 x (4 kW - 11 kW))

Auxiliary voltage (three phase)

Overload current rating

400 VAC50/60 Hz

480 VAC60 Hz

575 VAC60 Hz


102


3-way valve(ACS 1000W)

The cooling unit of the ACS 1000 can be ordered with a 3-way valve in the raw water circuit. This option is required if the raw water flow must be kept at a constant rate. If the cooling unit is equipped with a 3-way valve, the water-to-water heat exchanger is bypassed and the total raw water flow is kept constant even if the water flow in the heat exchanger varies.

Raw water circuit(ACS 1000W)

The material of the raw water circuit is stainless steel (AISI316).

Raw water connectionflanges (ACS 1000W)

Connecting flanges mounted to the right side of the ACS 1000. Counter flanges are provided.

This option cannot be ordered in combination with the option braking chopper.

Raw water shut-offvalves (ACS 1000W)

Shut-off valves mounted between the connection flanges and their counter flanges.

Space heater fortropicalized version

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

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

Monitored air filter(ACS 1000A/i)

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

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

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

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

If the ACS 1000 is ordered with an air filter with finer mesh, the derating of the converter output power needs to be considered (see Technical data, Environment).

6.7 Synchronized bypassThe synchronized bypass (Figure 6-46) allows for automatic synchroni-zation of a motor with the line after a soft start. Two versions are available:

• Synchronized bypass for one motor

• Synchronized bypass for up to four motors



A bidirectional synchronized bypass (Figure 6-46) allows for automatic synchronization of a motor with the line after a soft start and taking back the motor from the line if required. The following version is available:

• Bidirectional synchronized bypass for up to two motors

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

• Interface for external commands and feedback signals

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

• Control unit for synchronizing and switching coordination

• Optional voltage measuring equipment

Dimensions The width of the bypass cabinet is 644 mm.

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

Note: The ACS 1000 does not support manual or automatic bypass functions. All bypass related interlocks and the controls for the bypass switches have to be realized externally to the converter. Only an output disconnector switch can be monitored via digital inputs if IOEC4 board is installed. These inputs are used to interlock the converter.


102


Figure 6-46 Synchronized bypass, single line diagram

Refer to Synchronization Bypass, Installation and Start-up Manual for further information.

6.8 Auxiliary supplyThe following options for the auxiliary power supply are available:

• A: external 3-phase supply + external single phase UPS supply

Preferred solution if UPS supply is available on site.

• B: external 3-phase supply + internal UPS control supply

Standard, required if UPS supply is not available on site.

• F: external 3-phase supply + external single phase UPS supply + internal UPS control supply (standard)

• D: internal 3-phase supply + external single phase control supply

Main supply

MCBTransformer

ACS 1000 frequency converter12-pulserectifier

3-levelinverter

Outputfilter

ACS 1000 control

Sm1

U2

Synchronizedbypasscontrol

MCB 1 Transformer 1

MCB 2 Transformer 2

(if necessary)

(if necessary)

U11

U12

Sbp1

Sm2

Sbp2

M13-Ph

M23-Ph



Required if UPS supply is not available on site, only available with a 60 Hz power supply.

Only for ACS 1000i.

• E: Completely internal auxiliary supply

Only available with a 60 Hz power supply.

Only for ACS 1000i.

Refer to Technical data for further information.

6.9 Auxiliary and control interfacesOptional control inputs /

outputsOptional I/O boards (IOEC3 and IOEC4) can be ordered for an extended range of signal interfaces.

The actual configuration and the exact number of available signals depends on the selected control and operation mode as well as on the selected optional functions.

• The IOEC3 board has to be selected in combination with the following options:

• motor monitoring interface

• transformer monitoring interface

• air-cooled converters with redundant cooling fans

• The IOEC4 board has to be selected in combination with the following options:

• On / off control of a chiller

• PID macro

• braking chopper

• redundant cooling fan for water-cooled converters

• transformer monitoring interface

• input / output disconnector

Water-cooled converters are always equipped with an IOEC3 board.

Fieldbus adaptermodules

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

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

• Profibus DP / FMS

• Modbus

• Allen-Bradley DeviceNet

• ABB Advant Fieldbus 100

• Interbus S


102


• Ethernet

The fieldbus is connected to the adapter module via a twisted pair bus (RS 485) or via BNC-connectors (for ABB Advant Fieldbus 100). The adapter communicates with the AMC controller of the ACS 1000 via a fast (4 Mbit/s) Duplex Fiber Optic Link.

Temperaturetransducers for PT100

Configurable temperature measuring transducers for motor and trans-former temperature measurement are available (see also section Extended transformer monitoring interface, page 87 and Extended motor monitoring interface, page 89).

They are suitable for the connection of PT100 resistance thermometers in 2, 3 and 4 -conductor connection systems.

Optional EEx ia/ib approved transducers are available.

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

6.10 Input / output disconnectorInput disconnector Used in addition to the main circuit breaker, the off-load input disconnector

provides a visible break between the transformer and the rectifier of the ACS 1000 when the input disconnector is in the open position.



Figure 6-47 Additional cabinet with two disconnectors

Output disconnector The ACS 1000 can be equipped with a motor-operated offload discon-nector at the motor output.

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

Disconnectorconfigurations

The following configurations are possible:

• Input disconnector: for ACS 1000A and ACS 1000W in 12-pulse configuration

• Output disconnector: available for all converters

Input and output isolator cannot be combined in one converter.

Input / outputdisconnector cabinet

The input and / or output disconnectors are located in an additional cabinet next to the converter.

The open and close command for the disconnector can be given locally via pushbuttons on the cabinet door, or remotely via floating contacts. The local / remote selection is done via a key switch.


102


The disconnector cabinet door is equipped with a solenoid interlock which ensures that the door can only be opened when the converter is grounded. The interlock is wired into the ACS 1000 tripping loop.

Dimensions Input isolator: 844 mm

Output isolator: 644 mm (844 mm for currents above 1000 A).

6.11 Optional diagnostic softwareAdditional PC-based software packages for commissioning, monitoring and diagnostics are available as option:

6.11.1 DriveWindowDriveWindow is an easy-to-use 32 bit Windows application for commis-sioning and maintaining ABB converters. Communication between the ACS 1000 and the PC is achieved via fiber optic cables and a PCMCIA card using DDCS communication protocol. See also Chapter 4 - Control system and process interfaces, Figure 4-39.

The following functions are possible with the DriveWindow software tool:

• Displaying system configuration

• Monitoring actual signal values

• Viewing and changing parameters

• Fault logger

• Event logger

• Data logger for fast and accurate measurements

• Converter control

• Backup and restore



Figure 6-48 Typical DriveWindow display

Including DriveOPC (OPC server for DDCS-network) DirveWindow provides also remote connection possibility.

DriveOPC is a software package for building customized PC applications with signal exchange between PC and converter system, e.g. production planning and statistics, preventive maintenance planning and others.

6.11.2 DriveMonitorTM

DriveMonitorTM is an option enabling real-time access to the diagnostic data of the ACS 1000. DriveMonitorTM allows monitoring of up to 9 converters and provides an Ethernet port to an external PC, to the Intranet of the customer or the Internet. The Internet connection enables ABB service engineers to monitor the performance of the converter without being on site.

The DriveMonitorTM hardware standard solution is a wall-mounted cabinet containing the DriveMonitorTM PC.

DriveMonitorTM provides the following functions:

• Acquisition of all available converter data thus ensuring that no data will be lost in the event of a converter failure

• Fault and alarm notification with causes and hints for rectification

• Automatic reporting on predefined templates

• Automatic recording of parameter changes


102


• Tracking of operational conditions

• Long-term data logging for monitoring of component lifetime

• Remote diagnostics according to the service and support-line contracts

Figure 6-49 DriveMonitorTM installed in a console with a touchscreen, wall-mounted

See DriveMonitorTM User’s Manual for Software Version 2.0 for further information.




102

ABB

Chapter 7 - Installation guidelines

7.1 OverviewThis section provides an overview of mounting requirements such as clearances and foundation plans as well as information on power equipment installation.

Links to OtherDocuments



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

See Technical data for load capacity derating factors and other require-ments related to environmental conditions.

Converter enclosure Refer to Chapter 3 - Hardware design, 3.8.1.2 IP rating for information on the standard IP protection classes. For information on higher IP protection classes for the converter enclosure, refer to Chapter 6 - Options, 6.3 Converter enclosure.

7.3 MountingSpace requirements All units must be mounted in an upright position with adequate clearance

provided in accordance with Table 7-13.

Table 7-13 Required clearance in front and above of the converter

(The dimensions given are minimum values)

Converter type

Above mm / (in.)

Below mm /(in.)

Left / right mm / (in.)

Front mm / (in.)

Back mm / (in.)

ACS 1000A 500(1)(2)(3)

(20")0(1)

(0")0(5)

(0")1000(4)

(39.4")0(6)

(0")

ACS 1000W 0/700(1)(2)

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

(0")0(5)

(0")1000(4)

(39.4")0(6)

(0")

ACS 1000i 700(1)(2)(3)

(27.6")0(1)

(0")0(5)

(0")1000(4)

(39.4")0(6)

(0")



Chapter 7 - Installation guidelines ABB

Table notes:

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

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

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

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

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

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

For cabinet dimensions refer to Technical data.

The foundation plans and the positions of the anchor holes for the ACS 1000A, ACS 1000W and ACS 1000i as well as for the additional cabinet are given in Figure 7-50 to Figure 7-53.

The dimensions are indicated in mm. The indications in inches are given in brackets.

Figure 7-50 Foundation plan with position of anchor holes: 12-pulse / 24-pulse, ACS 1000A

2928 (115.3)72 (2.8)

875 (34.4)

7262 (2.4)

37.5

37.5

12 (0.5)

20 (0.8)

(1.5)


112

ABB Chapter 7 - Installation guidelines

Figure 7-51 Foundation plan with position of anchor holes: 12-pulse, ACS 1000W

Figure 7-52 Foundation plan with position of anchor holes: additional cabinet for ACS 1000A and ACS 1000W

52 (2) 585.5 (23) 2760 (108.6) 802.5 (31.6)

902

20

12 (0.5)

(35.5)

(0.8)

844 (33.2)

902 (35.5)

74.5 (2.9) 74.5

38

38

(1.5)



Figure 7-53 Foundation plan with position of anchor holes: ACS 1000i

The cabinet should be fixed with anchor bolts and lock washers (recom-mended size M12, not part of supply) as shown in Figure 7-54. The anchor holes in the base mounting channels can be accessed through the cabinet.

Figure 7-54 Cabinet mounting with bolts and lock washers

Floor levelling andcable ducts

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

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

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

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

3300 (129.9)

1096.5

350 (13.8)

119.5 (4.7)

5555 (2.2)

350

119.5

18 (0.7)

18

(43.2)

Anchor holes


112


7.4 Power equipment installation

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

• Main circuit breaker / controller

• Instrumentation and protection equipment

• Transformer primary cables

• Transformer

• Transformer secondary cables

• Cable termination - ACS 1000

All applicable manufacturer’s instructions and local regulations must be followed when installing this equipment. If any of the stated instruction appears to be in conflict with the requirements, please contact your local ABB representative for further assistance.

Refer to Chapter 2 - Functional description, operation and Chapter 5 - Engineering information, 5.2 Main circuit breaker for information regarding the main circuit breaker / controller, instrumentation and protection equipment.

Refer to Chapter 5 - Engineering information, 5.5 Selection of power cables for requirements on transformer primary and secondary cables, motor cables, power cable dimensions and equipment grounding.

Refer to Chapter 5 - Engineering information, 5.6 Control cabling and Chapter 5 - Engineering information, 5.7 Auxiliary power cables for requirements on control cables and auxiliary power cables.

7.4.2 Cable routing

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

• For best EMC performance, shielded 3-phase cables are recom-mended.

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

• 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 entry plates of the ACS 1000.



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

Cable termination Cables must be terminated with connectors according to the cable manufacturer’s requirements.

Ground wire Routing of the ground connection must comply with local regulations.

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

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

7.4.3 ACS 1000 cable entry and termination (only ACS 1000A/W)Access to the power termination section of the ACS 1000 is via the control cabinet, located on the left of the converter. A bolted access door is located behind the control swing frame. Once the access door is opened, all power terminations are readily available. As an aid to interfacing the main power connections, removable bus stubs are included.

Cables can be entered through the cabinet roof (see Figure 7-55) or floor (see Figure 7-56). If the cable entry is from below, the entry plates mounted on top of the cable termination section must be relocated to the bottom and the bottom cover plate must be fixed to the top of the cabinet.

Figure 7-55 Top cable entry

Undrilled entry plates are available optionally. The ACS 1000i is delivered only with undrilled entry plates.


112


Figure 7-56 Bottom cable entry

Table 7-14 Maximum number of cables per phase

The figures indicated in Table 7-14 are valid for transformer and motor cables. The maximum cable diameter is 45 mm.

2.3 kV 3.3 kV 4.0 kV

A1 1 1 1

A2 2 1 1

A3 2 2 1

W1 - 2 2

W2 - 2 2

W3 - 3 2



7.4.4 Transformer wiring diagram for 12-pulse ACS 1000

Figure 7-57 Typical 3-line transformer wiring diagram.

7.4.5 Transformer wiring diagram for 24-pulse ACS 1000

Figure 7-58 Typical 3-line transformer wiring diagram

Transformer

ACS 1000

Factoryground

Shielding

Factoryground

a1 b1 c1 a2 b2 c2

1U1 1V1 1W1 2U1 2V1 2W1

Armouring

PE

PE

Transformer

ACS 1000

Factoryground

Shielding

Factoryground

a1 b1 c1 a2 b2 c2

1U1 1V1 1W1 2U1 2V1 2W1

Armouring

3U1 3V1 3W1 4U1 4V1 4W1

a3 b3 c3 a4 b4 c4

PE

PE


112


7.4.6 Motor wiring diagram for 12 / 24-pulse ACS 1000

Figure 7-59 Typical 3-line motor wiring diagram

Factoryground

Factoryground

PE

ACS 1000

MU V W

U2V2

W2

PE




112

ABB

Chapter 8 - Ordering information

8.1 GeneralThis chapter provides assistance when selecting the appropriate converter and the included options.




• Type Code, (for document details see Chapter 1 - Overview, Table 1-2)

8.2 Converter selectionThe basic converter configuration and dimensioning is done by ABB sales based on the customer’s application specification and by using specialized configuration tools.

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

If a motor with six or more poles is used, the nominal motor current usually increases as compared to a motor with fewer poles. This may result in a different output filter configuration (see 8.2.1 ACS 1000 output filter). In such cases, please contact your ABB representative for further assistance before making a final converter selection.

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

• Ambient temperature

• Temperature of the cooling media

• Installation site altitude

• Frostproofing of the cooling water

• Presence of a redundant cooling fan

• Type of air filter

Refer to Technical data for information on:

• Rating tables

• Ambient conditions.



Chapter 8 - Ordering information ABB

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

8.2.2 Non-quadratic load applicationsFor constant torque or constant power applications a high overloadability (start-up torque) is usually required. This overloadability, together with possibly needed derating for low speed operation, requires some additional calculations for converter selection. To determine the appro-priate ACS 1000, please contact your ABB representative.

8.3 Type codeSee Type Code, BHS103412 ZAB E01

8.4 Option listSee Chapter 6 - Options.

8.5 External system dataSee Chapter 5 - Engineering information.

8.6 Technical dataSee Technical data.


114

ABB

Index

Numerics3-way valve 93

AABB Advant Fieldbus 100, see fieldbus adapter

modulesacceleration and deceleration ramps 26accurate speed control 25accurate torque control without speed feed-

back 25actual signal monitoring 32additional cabinet 48, 64, 66, 86, 87, 90air cooling 37air cooling system ACS 1000W 60air flow 45, 47air-to-water heat exchangers, see heat ex-

changeralarm handling 33Allen-Bradley DeviceNet, see fieldbus adapter

modulesAMC board 69AMC controller 68AMC operating system (AMCOS), see operat-

ing systemAMCOS, see operating systemapplication parameters 25automatic restart 28auxiliary interfaces 96auxiliary power cables 84auxiliary power supply 95auxiliary ride-through, see ride-through

Bbattery test 38bearing temperature 38braking chopper 90, 93, 96braking resistor 90busbars 65

Ccabinet color 86cabinet layout 44–49cabinet paint finish 86

cable ducts 106cable entry 108cable routing 107cable termination 108CDP control panel, see control panelcharging fault 36circuit breaker for motor space heater 91circuit diagram 39clearance, see space requirementscoated printed circuit boards 85common mode choke 45, 48, 53, 58, 88communication fault 37control cabling 84control devices 71control functions 21–30control inputs / outputs, optional 96control interfaces 96control modes 29control panel 69, 70control section ACS 1000A 49control section ACS 1000i 53control section ACS 1000W 57control software 74, 75

structure 74control switches 71control system, structure 68converter enclosure 63, 85, 103converter information 38converter section ACS 1000W 57converter selection 113cooling 92–93cooling unit, main components 61

air cooling fan 61air-to-water heat exchanger 61control system monitoring 61deionized cooling water treatment 61expansion vessel 61stainless steel water-to-water heat ex-

changer 61water temperature control valve 61water-cooling pump 61

cooling water circuit 60cooling water treatment circuit 60corrosion protected busbars 85critical speed 27

Index 3BHS125029 ZAB E01 Rev. D 115 / 118

ABB

Ddata logger 32deceleration ramps, see acceleration and de-

celeration rampsdiagnostics 30, 32Direct Torque Control (DTC) 16, 21

DTC block diagram 22DTC performance 24DTC versus vector control 22methods 22scalar control 24

disconnector configurations 98door interlocking 64, 86door locks 64DriveMonitorTM 100DriveWindow 99DTC, see Direct Torque Control (DTC)

Eelectromagnetic compatibility (EMC) 64elementary diagram 39emergency off 31enclosure type 63environmental conditions 85, 103equipment grounding 84Ethernet, see fieldbus adapter modulesextended ambient temperature 85extended grounding busbar 86extended motor monitoring interface 89

I/O signals 89extended raw water temperature 85extended transformer monitoring interface 87

I/O signals 88external emergency off 38external motor protection trip 38external transformer protection trip 38

Ffault handler 75fault handling 33fault logger 32fieldbus adapter modules 96filter section ACS 1000W 58floor levelling 106flux optimization 27flying start 27full torque at zero speed 26Function Chart Builder (FCB) 75

fuseless design 17

Gground fault 37grounding 65

HHand/Auto, see macroshardware modules 49–62heat exchanger 47, 59, 60, 61, 62, 93

II/O board 72, 73, 87, 89, 94, 96I/O interfaces 72IGCT 16, 17, 41, 43

comparison of semiconductors 44input bridges 87input disconnector 97

cabinet 98dimensions 99

input section ACS 1000i 56input signal source selection, see signal source

selectionInterbus S, see fieldbus adapter modulesinterlocking, see door interlockinginternal cooling water circuit 60internal cooling water treatment circuit 60inverter section ACS 1000A 52inverter section ACS 1000i 55inverter temperature 37IOEC, see I/O boardIP rating 63, 85

Llifting arrangements 66load capacity curves, see motor selectionlocal control 30local operation 30

Mmacros 30Main Circuit Breaker (MCB) 28, 29, 31, 33, 38,

40, 69, 77, 78, 82, 97, 107control 77control fault 78types 77

116 / 118 3BHS125029 ZAB E01 Rev. D Index

ABB

main state machine 75Master/Follower, see control modesmeasurement loss 37Modbus, see fieldbus adapter modulesmonitored air filter ACS 1000A/i 93monitoring limit values 36motor cables, see power cables selectionmotor control 75motor ID calculation 27motor overload 36motor phase loss 36motor related functions 27motor selection 79–82motor software 75motor stall 34motor starter for motor cooling fan / pump 91motor winding 38mounting 106

Nnon-quadratic load applications 114

Ooperating system 37, 74operation 30operation modes 29optional control inputs / outputs 96output disconnector 98

cabinet 98dimensions 99

output filter 114overcurrent 37overspeed 35overvoltage 36

Ppainting 63panel application software 75parameter lock 38PID control, see control modespower cable dimensions 83power cables selection 82power loss ride-through, see ride-throughpower range 15power semiconductor, see IGCTprocess stop 38Profibus DP, see fieldbus adapter modulesprogrammable analog outputs 73

programmable control locations 28programmable digital outputs 73protection functions 33–38PT100, see temperature transducers for PT100pulse encoder interface 90

Rraw water circuit 93raw water connection 62raw water connection flanges 93raw water cooling circuit 60raw water shut-off valves 93rectifier section ACS 1000A 53redundant cooling fan ACS 1000A 92redundant cooling fan ACS 1000i 92redundant cooling fan ACS 1000W 92redundant cooling pump 92reference signal processing, see signal pro-

cessingremote control 31remote operation 30ride-through 27

Ssafety ground 65safety labels 65scalable analog inputs 73scalar control 24semiconductor, see IGCTSequential control, see control modesshort circuit in the rectifier bridge 36short circuit of the inverter 37signal processing 28signal source selection 28software concept 74software, see control softwarespace heater for tropicalized version 93space requirements 103spare terminals 97speed control functions 25Speed control, see control modessplit cabinet 86start sequence 31stop sequence 31supply phase loss 37synchronized bypass 93

single line diagram 95

Index 3BHS125029 ZAB E01 Rev. D 117 / 118

ABB

Ttemperature transducers for PT100 97Torque control, see control modestorsional excitation, see motor selectiontransformer cables, see power cables selectiontransformer selection 79tripping loop 34, 78

Uunderload 35undervoltage 35

VVoltage Source Inverter (VSI) 41

3-level voltage source inverter principle 42

Wwater cooling protection function 37water cooling system 59water-to-water heat exchanger, see heat ex-

changerwiring diagram, motor 111wiring diagram, transformer 110

118 / 118 3BHS125029 ZAB E01 Rev. D Index

ABB

Technical data

Converter types and ratingsTable 1 12-Pulse converter types and ratings

AC

S 10

00 ty

pe

Rat

ed m

otor

vol

tage

U

Nom

Rat

ed m

otor

pow

er

Rat

ed o

utpu

t cur

rent

*

Con

vert

er in

put v

olta

ge

3-ph

ase

Con

vert

er in

put c

urre

nt *

Wei

ght

VAC kW HP A VAC A kg lbs

ACS 1012-A1-A0 2300 298 400 100 2x1327 73 1600 3530

ACS 1012-A1-B0 2300 336 450 100 2x1327 83 1600 3530

ACS 1012-A1-C0 2300 373 500 113 2x1327 92 1600 3530

ACS 1012-A1-D0 2300 447 600 138 2x1327 110 1600 3530

ACS 1012-A1-E0 2300 522 700 163 2x1327 128 1600 3530

ACS 1012-A1-F0 2300 597 800 188 2x1327 147 1600 3530

ACS 1012-A1-G0 2300 671 900 201 2x1327 165 1600 3530

ACS 1012-A1-H0 2300 746 1000 226 2x1327 183 1600 3530

ACS 1012-A2-J0 2300 932 1250 289 2x1327 229 1750 3860

ACS 1012-A2-K0 2300 1119 1500 339 2x1327 275 1750 3860

ACS 1012-A3-L0 2300 1305 1750 389 2x1327 321 2000 4410

ACS 1012-A3-M0 2300 1491 2000 452 2x1327 367 2000 4410

ACS 1012-A3-N0 2300 1678 2250 502 2x1327 413 2000 4410

ACS 1013-A1-A0 3300 315 422 70 2x1903 54 1600 3530

ACS 1013-A1-B0 3300 355 476 79 2x1903 61 1600 3530

ACS 1013-A1-C0 3300 400 536 87 2x1903 69 1600 3530

ACS 1013-A1-D0 3300 450 603 96 2x1903 77 1600 3530

ACS 1013-A1-E0 3300 500 671 105 2x1903 86 1600 3530

ACS 1013-A1-F0 3300 560 751 122 2x1903 96 1600 3530

ACS 1013-A1-G0 3300 630 845 131 2x1903 108 1600 3530

ACS 1000A 3BHS213402 ZAB E01 Rev. D 1 (14)

ABB

* Depending on the application of the converter, the output current printed on therating plate can be different from the value stated for the same converter in thistable.

ACS 1013-A1-H0 3300 710 952 149 2x1903 122 1600 3530

ACS 1013-A2-J0 3300 800 1073 166 2x1903 137 1750 3860

ACS 1013-A2-K0 3300 900 1207 192 2x1903 154 1750 3860

ACS 1013-A2-L0 3300 1000 1341 210 2x1903 172 1750 3860

ACS 1013-A2-M0 3300 1120 1502 236 2x1903 192 1750 3860

ACS 1013-A2-N0 3300 1250 1676 262 2x1903 214 1750 3860

ACS 1013-A2-P0 3300 1400 1877 297 2x1903 240 1750 3860

ACS 1013-A3-Q0 3300 1600 2146 332 2x1903 274 2000 4410

ACS 1013-A3-R0 3300 1800 2414 376 2x 1902 309 2000 4410

ACS 1014-A1-A0 4000 298 400 58 2x2305 42 1600 3530

ACS 1014-A1-B0 4000 336 450 58 2x2305 48 1600 3530

ACS 1014-A1-C0 4000 373 500 65 2x2305 53 1600 3530

ACS 1014-A1-D0 4000 447 600 79 2x2305 63 1600 3530

ACS 1014-A1-E0 4000 522 700 94 2x2305 74 1600 3530

ACS 1014-A1-F0 4000 597 800 108 2x2305 85 1600 3530

ACS 1014-A1-G0 4000 671 900 115 2x2305 95 1600 3530

ACS 1014-A1-H0 4000 746 1000 130 2x2305 106 1600 3530

ACS 1014-A2-J0 4000 932 1250 166 2x 2305 132 1750 3860

ACS 1014-A2-K0 4000 1119 1500 195 2x 2305 158 1750 3860

ACS 1014-A3-L0 4000 1305 1750 224 2x 2305 185 2000 4410

ACS 1014-A3-M0 4000 1491 2000 260 2x 2305 211 2000 4410

ACS 1014-A3-N0 4000 1678 2250 289 2x 2305 238 2000 4410

AC

S 10

00 ty

pe

Rat

ed m

otor

vol

tage

U

Nom

Rat

ed m

otor

pow

er

Rat

ed o

utpu

t cur

rent

*

Con

vert

er in

put v

olta

ge

3-ph

ase

Con

vert

er in

put c

urre

nt *

Wei

ght


2 (14) 3BHS213402 ZAB E01 Rev. D ACS 1000A

ABB

Table 2 24-Pulse converter types and ratings

AC

S 10

00 ty

pe

Rat

ed m

otor

vol

tage

U

Nom

Rat

ed m

otor

pow

er

Rat

ed o

utpu

t cur

rent

*

Con

vert

er in

put v

olta

ge

3-ph

ase

Con

vert

er in

put c

urre

nt *

Wei

ght


ACS 1022-A1-A0 2300 298 400 100 4x1327 37 1600 3530

ACS 1022-A1-B0 2300 336 450 100 4x1327 41 1600 3530

ACS 1022-A1-C0 2300 373 500 113 4x1327 46 1600 3530

ACS 1022-A1-D0 2300 447 600 138 4x1327 55 1600 3530

ACS 1022-A1-E0 2300 522 700 163 4x1327 64 1600 3530

ACS 1022-A1-F0 2300 597 800 188 4x1327 73 1600 3530

ACS 1022-A1-G0 2300 671 900 201 4x1327 83 1600 3530

ACS 1022-A1-H0 2300 746 1000 226 4x1327 92 1600 3530

ACS 1022-A2-J0 2300 932 1250 289 4x1327 115 1750 3860

ACS 1022-A2-K0 2300 1119 1500 339 4x1327 138 1750 3860

ACS 1022-A3-L0 2300 1305 1750 389 4x1327 160 2000 4410

ACS 1022-A3-M0 2300 1491 2000 452 4x1327 183 2000 4410

ACS 1022-A3-N0 2300 1678 2250 502 4x1327 206 2000 4410

ACS 1023-A1-A0 3300 315 422 70 4x1903 27 1600 3530

ACS 1023-A1-B0 3300 355 476 79 4x1903 30 1600 3530

ACS 1023-A1-C0 3300 400 536 87 4x1903 34 1600 3530

ACS 1023-A1-D0 3300 450 603 96 4x1903 39 1600 3530

ACS 1023-A1-E0 3300 500 671 105 4x1903 43 1600 3530

ACS 1023-A1-F0 3300 560 751 122 4x1903 48 1600 3530

ACS 1023-A1-G0 3300 630 845 131 4x1903 54 1600 3530

ACS 1023-A1-H0 3300 710 952 149 4x1903 61 1600 3530

ACS 1023-A2-J0 3300 800 1073 166 4x1903 69 1750 3860

ACS 1023-A2-K0 3300 900 1207 192 4x1903 77 1750 3860

ACS 1023-A2-L0 3300 1000 1341 210 4x1903 86 1750 3860


ABB


Cabinet design data

Length 3000 mm (9 ft 10 in)

Depth 900 mm (3 ft)

ACS 1023-A2-M0 3300 1120 1502 236 4x1903 96 1750 3860

ACS 1023-A2-N0 3300 1250 1676 262 4x1903 107 1750 3860

ACS 1023-A2-P0 3300 1400 1877 297 4x1903 120 1750 3860

ACS 1023-A3-Q0 3300 1600 2146 332 4x1903 137 2000 4410

ACS 1023-A3-R0 3300 1800 2414 376 4x1903 154 2000 4410

ACS 1024-A1-A0 4000 298 400 58 4x2305 21 1600 3530

ACS 1024-A1-B0 4000 336 450 58 4x2305 24 1600 3530

ACS 1024-A1-C0 4000 373 500 65 4x2305 26 1600 3530

ACS 1024-A1-D0 4000 447 600 79 4x2305 32 1600 3530

ACS 1024-A1-E0 4000 522 700 94 4x2305 37 1600 3530

ACS 1024-A1-F0 4000 597 800 108 4x2305 42 1600 3530

ACS 1024-A1-G0 4000 671 900 115 4x2305 48 1600 3530

ACS 1024-A1-H0 4000 746 1000 130 4x2305 53 1600 3530

ACS 1024-A2-J0 4000* 932 1250 166 4x 2305 66 1750 3860

ACS 1024-A2-K0 4000 1119 1500 195 4x 2305 79 1750 3860

ACS 1024-A3-L0 4000 1305 1750 224 4x 2305 92 2000 4410

ACS 1024-A3-M0 4000 1491 2000 260 4x 2305 106 2000 4410

ACS 1024-A3-N0 4000 1678 2250 289 4x 2305 119 2000 4410

AC

S 10

00 ty

pe

Rat

ed m

otor

vol

tage

U

Nom

Rat

ed m

otor

pow

er

Rat

ed o

utpu

t cur

rent

*

Con

vert

er in

put v

olta

ge

3-ph

ase

Con

vert

er in

put c

urre

nt *

Wei

ght



ABB

Height 2005 mm (6 ft 7 in)

2070 mm (6 ft 10 in) (including lifting eyes)

2285 mm (7 ft 6 in) (including air exhaust hood)

Enclosure classes IP21 (optional: IP22, IP31, IP32, IP42) according to IEC / EN 60529

Grounding bus bar Cross section: 50 x 6 mm

Material: copper (optional: copper nickeled)

Cabinet wall thickness 2 mm

Power cable diameter Standard entry plates with holes suitable for a maximum cable diameter of 45 mm

(optional: undrilled steel, aluminum, brass or stainless steel plates)

Table 3 Dimensions and weights of optional equipment

* ) including lifting lugs**) approximate values***) depending on installed equipment+) additional to cabinet length++) additional to cabinet height

Transformer connection / converter input

Primary side voltage Any medium AC voltage level at primary side of converter transformer

Converter transformersecondary side voltage

variation

+10% / -5%

(safe operation with reduced output power possible down to -25%)

Description Dimensions and Weights

Length Depth Height Weight**

mm in mm in mm in kg lbs

Air-exhaust fan cover 654 25.7 733 28.8’ 278++ 10.9

Redundant cooling fan unit

2000 78.7* 870 34.2’ 800++ 31.5 300 661

Braking chopper (placed on the right side)

644+ 25.3 902 35.5 20052070*

78.981.5*

460 1014

Synchronous bypass (placed on the left side)

644+ 25.3 902 35.5 20052070*

78.981.5*

460 1014

Extra cabinet 644+844+

25.333.2

902902

35.535.5

20052070*

78.981.5*

300...600***300...600***

661...1323***661...1323***


ABB

Phase shift Phase shift between transformer secondary windings:

• 30° for 12-pulse rectifier


Frequency 50/60 Hz

Voltage unbalance ± 2% between phases

Total power factor cos ϕ > 0.95

Transformer secondarycables

Maximum length:

• 12-pulse:

• 30 m (98ft)

• 200 m (656 ft) with common mode choke option

• 24-pulse:

• 20 m (66ft)

Converter output / motor connection

Output voltage UOut 0…UNom, 3-phase, sinusoidal, symmetrical

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

Field weakening point ≥ 45 Hz

Static speed deviation 0.1 % of nominal motor speed

Efficiency > 98% (at full load)

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

Short-term overloadcapacity

1 min/10 min: 110% of rated current

Motor cable length Maximum length: 1000 m (3281 ft), longer on request

Acceleration time 0…1800 s

Auxiliary power supplyThe converter requires auxiliary power for cooling fans and control electronics.

The total auxiliary power can be fed to the converter by a 3-phase power supply (see Table 4). Optionally, the auxiliary power for the control electronics can be supplied separately by a 1-phase supply (see Table 5) which can be backed up by a UPS if required.


ABB

If only a 3-phase supply provides the auxiliary power, the values for the auxiliary power consumption in Table 5 and Table 6 must be added to obtain the total power to be supplied.

Table 4 3-phase auxiliary power supply

*) Aux. power consumption values without any options

Table 5 1-phase auxiliary power supply for control system


Table 6 1-phase auxiliary power supply for cabinet space heater

Cooling

Cooling method Air cooling circuit with internal fan

Heat losses A1: maximum 14.4 kW

A2: maximum 23.6 kW

A3: maximum 31 kW

Air flow rate A1: 1.7 m3/s (3600 cu.ft./min)

A2: 2.5 m3/s (5300 cu.ft./min)

A3: 2.5 m3/s (5300 cu.ft./min)

A1 A2 A3

VAC Hz Aux. power consumption* VA Back-up fuse rating

400 ± 10% 50 3600 5900 5900 max. 50 A if lcu > 50 kA

60 3900 5600 5600

480 60 3800 5400 5400

575 60 3800 5700 5700

A1 A2 A 3

VAC Hz Aux. power consumption*VA Back-up fuse rating

120 50 / 60 430 500 620 max. 25 A if lcu > 10 kA

230

A1 A2 A3

VAC Hz Aux. power consumptionVA Back-up fuse rating

120 50 / 60 300 max. 25 A if lcu > 10 kA

230


ABB

Filter mats Depending on the mesh size of the filter mat the following derating of the output power applies:

Table 7 Derating factors for output power

Redundant cooling fan The converter output power must be reduced by 7.5% if a redundant fan is installed.

Environment

Operation

Ambient temperature 0…+40 °C (32…104 °F)

Above +40 °C (+104 °F) the rated output power decreases by 1.5 % for each additional 1 °C (0.85 % for each 1° K) up to the maximum permitted temperature of +50 °C (+122 °F).

Example: If the ambient temperature is 50 °C the derating is calculated as 100% - 1.5 %/°C · 10 °C = 85%. Hence, the maximum output power is 85% of the rated value.

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

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

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

Relative humidity 5…95% in the absence of condensation

5…60% in the presence of corrosive gases

Installation altitude 4.0 kV motor voltage: up to 3000 m (9843 ft)

3.3 kV motor voltage: up to 4000 m (13123 ft)


At locations 2000 m (6600 ft) above sea level, the reduction of the rated converter output power by 1% per additional 100 m (330 ft) must be accounted for. Possibly, a converter with a higher output power must be selected (The rated motor power in Table 1 and Table 2 can be taken as guidance value for the converter output power).

Output power derating Mesh size Remark

0% 18 μm Standard

5% 12 μm Option

10% 10 μm Option


ABB

Vibration Restrictions apply according to IEC / EN 60721-3-3 class 3M1:

Sinosoidal stationary vibration:

• Displacement amplitude: 0.3 mm (2...9 Hz)

• Acceleration amplitude: 1 m/s2 (9...200 Hz)

Non-stationary vibration (incl. shock):

• Shock response spectrum: 40 m/s2

Chemically activesubstances

Restrictions apply according to IEC / EN 60721-3-3 class 3C2

Mechanically activesubstances

Restrictions apply according to IEC / EN 60721-3-3 class 3S2

Sound pressure level Single fan: < 75 dB (A)

Redundant fan: < 85 dB (A)

Transport

Ambient temperature -25…+55 °C (-13…+131 °F) according to IEC / EN 60721-3-2 class 2K3

Up to 70 °C for up to 24 hours

Relative humidity Less than 95% at +40 °C (+110 °F)




• Acceleration amplitude: 10 m/s2 (9...200 Hz), 15 m/s2 (200...500 Hz)

Random stationary vibration:

• Acceleration spectral density: 1 m2/s3 (10...200 Hz), 0.3 m2/s3 (200...2000 Hz)



Storage


Relative humidity 5... 95% according to IEC / EN 60721-3-1 class 1K3






ABB



Derating of drive power

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

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

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

Derating for air filtersDepending on the mesh size of the filter mat the derating factors as stated in Table 8 apply to the rated output power:

Table 8 Derating factors for air filters

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

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

Analog inputs

Analog input (AI) Floating, galvanically isolated inputs

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

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

Mesh size Remark Derating in %

18 μm standard 0

12 μm option 5

10 μm option 10


ABB

Common mode voltage Maximum 48 V

Isolation voltage 350 VAC

Common moderejection ratio

> 80 dB at 50 Hz

Resolution 0.1% (10 bit)

Accuracy ± 0.25% (of upper range value) at 25 °C (±30 mV offset)

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

Input updating time 100 ms

Terminal size Suitable for conductor cross-sections of 0.5…2.5 mm2 (up to AWG12)

Optional PT100 Tansmitter

Analog outputs

Analog output (AO) Floating, galvanically isolated outputs

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



Accuracy ± 0.25% (of upper range value) at 25 °C (± 50 μA offset)

Max. load impedance 250 Ω

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

Output updating time 250 ms


Digital inputs

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

Signal level 22…250 VAC / 22…150 VDC

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

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

Filtering time constant 20 ms

Isolation Individually isolated


ABB

Isolation test voltage For 1 minute: 2300 VAC input / input

1350 VAC input / logic

1350 VAC input / ground



Digital outputs

Contact type Encapsulated switch-over contact (SPDT)

Contact rating

Isolation test voltage 4 kVAC, 1 minute



Auxiliary power output for control signals

Application Supply for digital inputs of ACS 1000 and / or external measurement transmitters for analog inputs

An external 120 VAC / 240 VAC supply can be used instead

Voltage 24 VDC +15% / -10%

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

Protection Short-circuit proof

Terminal block size Suitable for conductor cross-sections of 0.5…2.5 mm2 (up to AWG12)

MCB control voltages (UMCB)

Switchingcurrent Continuous current

24 VDC 8 A 6 A

24 VAC 8 A 6 A

48 VDC 1 A 1 A

48 VAC 8 A 6 A

120 VDC 0.4 A 0.4 A

120 VAC 8 A 6 A

230 VAC 8 A 6 A


ABB

Reference voltage output

Application Supply for external reference potentiometers

Voltage 10 VDC ±10%

Maximum current 10 mA



Fiber optic connection

Application Remotely operated control panel, Master/Follower link

Diameter 1 mm (0.04 in)

Maximum length 10 m (33 ft)

Minimum bend radius 25 mm (1 in) (short-term installation)

35 mm (1.4 in) (long-term installation)

Converter tests

Test voltages

Impulse test voltage(BIL Basic Impulse

Insulation Level)

30 kV according to IEC / EN 60071-1 (UL 347)

Dielectric withstandvoltage

9.6 kV during 1 min. according to UL 347

Electromagneticcompatibility

According to IEC / EN 61000-4-2:

• Contact discharge: 4 kV

• Air discharge: 15 kV


• Aux-supply power-ports: 2 kV, 5 kHz

• Signal-ports: 2 kV, 5 kHz


• Aux-supply power-ports line-to-earth: 4 kV

• Aux-supply power-ports line-to-line: 2 kV

• Signal-ports: 1 kV


ABB

Short-circuit strength of converter terminal unit

Steady state short-circuit current

15 kA


ABB

Technical data

Converter types and ratingsTable 1 12-pulse converter types and ratings


AC

S 10

00 ty

pe

Rat

ed m

otor

vol

tage

U

Nom

Rat

ed m

otor

pow

er

Rat

ed o

utpu

t cur

rent

*

Con

vert

er In

put v

olta

ge

3-ph

ase

Con

vert

er In

put c

urre

nt *

Wei

ght

Leng

th

VAC kW HP A VAC A kg lbs mm

ACS 1013-W1-S0 3300 2000 2682 420 1903 343 3300 7270 4200

ACS 1013-W1-T0 3300 2250 3017 472 1903 386 3300 7270 4200

ACS 1013-W1-U0 3300 2500 3353 525 1903 429 3300 7270 4200

ACS 1013-W2-V0 3300 2800 3755 586 1903 480 3680 8100 4700

ACS 1013-W2-W0 3300 3150 4224 656 1903 540 3680 8100 4700

ACS 1013-W2-X0 3300 3550 4761 744 1903 609 3680 8100 4700

ACS 1013-W3-Y0 3300 4000 5364 831 1903 686 3680 8100 4700

ACS 1013-W3-Z0 3300 4500 6035 936 1903 772 3680 8100 4700

ACS 1013-W3-10 3300 5000 6705 1041 1903 858 3680 8100 4700

ACS 1014-W1-P0 4000 1864 2500 332 2305 264 3300 7270 4200

ACS 1014-W1-Q0 4000 2237 3000 390 2305 317 3300 7270 4200

ACS 1014-W2-R0 4000 2610 3500 447 2305 370 3680 8100 4700

ACS 1014-W2-S0 4000 2983 4000 520 2305 422 3680 8100 4700

ACS 1014-W2-T0 4000 3356 4500 577 2305 475 3680 8100 4700

ACS 1014-W2-U0 4000 3729 5000 650 2305 528 3680 8100 4700

ACS 1014-W3-V0 4000 4101 5500 707 2305 581 3680 8100 4700

ACS 1014-W3-W0 4000 4474 6000 765 2305 634 3680 8100 4700

ACS 1014-W3-X0 4000 5000 6700 837 2305 708 3680 8100 4700

ACS 1000W 3BHS213403 ZAB E01 Rev. D 1 (12)

ABB

Table 2 24-pulse converter types and ratings


AC

S 10

00 ty

pe

Rat

ed m

otor

vol

tage

U

Nom

Rat

ed m

otor

pow

er

Rat

ed o

utpu

t cur

rent

*

Con

vert

er in

put v

olta

ge

3-ph

ase

Con

vert

er in

put c

urre

nt *

Wei

ght

Leng

th

VAC kW HP A VAC A kg lbs mm

ACS 1023-W1-S0 3300 2000 2682 420 4x1903 172 3800 8370 5044

ACS 1023-W1-T0 3300 2250 3017 472 1903 193 3800 8370 5044

ACS 1023-W1-U0 3300 2500 3353 525 1903 214 3800 8370 5044

ACS 1023-W2-V0 3300 2800 3755 586 1903 240 4180 9200 5544

ACS 1023-W2-W0 3300 3150 4224 656 1903 270 4180 9200 5544

ACS 1023-W2-X0 3300 3550 4761 744 1903 304 4180 9200 5544

ACS 1023-W3-Y0 3300 4000 5364 831 1903 343 4180 9200 5544

ACS 1023-W3-Z0 3300 4500 6035 936 1903 386 4180 9200 5544

ACS 1023-W3-10 3300 5000 6705 1041 1903 429 4180 9200 5544

ACS 1024-W1-P0 4000 1864 2500 332 2305 132 3800 8370 5044

ACS 1024-W1-Q0 4000 2237 3000 390 2305 158 3800 8370 5044

ACS 1024-W2-R0 4000 2610 3500 447 2305 185 4180 9200 5544

ACS 1024-W2-S0 4000 2983 4000 520 2305 211 4180 9200 5544

ACS 1024-W2-T0 4000 3356 4500 577 2305 238 4180 9200 5544

ACS 1024-W2-U0 4000 3729 5000 650 2305 264 4180 9200 5544

ACS 1024-W3-V0 4000 4101 5500 707 2305 290 4180 9200 5544

ACS 1024-W3-W0 4000 4474 6000 765 2305 317 4180 9200 5544

ACS 1024-W3-X0 4000 5000 6700 837 2305 354 4180 9200 5544

2 (12) 3BHS213403 ZAB E01 Rev. D ACS 1000W

ABB

Cabinet design data

Depth 900 mm (3 ft)

Height 2020 mm (6.6 ft)

2070 mm (6 ft 10 in) including lifting eyes

Enclosure classes IP31 (optional: IP42 / IP54) according to IEC / EN 60529

Grounding bus bar Cross section: 50 x 6 mm



Power cable diameter Standard entry plates with holes suitable for a maximum cable diameter of 45 mm

(optional: undrilled steel, aluminum, brass or stainless steel plates)




Primary side voltage Any medium AC voltage level at primary side of converter transformer

Converter transformersecondary side voltage

variation

+10% / -5% (safe operation with reduced output power possible down to -25%)




Redundant fan unit 650 25.6 865 34 312++ 12.3 100 220

24-pulse extension (placed on the left side)

844+ 33.2 902 35.5 20052070*

78.981.5*

350 771


644+ 25.3 902 35.5 20052070*

78.981.5*

460 1014


644+ 25.3 902 35.5 20052070*

78.981.5*

460 1014


25.333.2

902902

35.535.5

20052070*

78.981.5*

300...600*** 661...1323***


ABB

Phase shift Phase shift between transformer secondary windings:



Frequency 50/60 Hz

Voltage unbalance ± 2% between phases


Transformer secondarycables

Maximum length:

• 12-pulse:

• 30 m (98ft)


• 24-pulse:

• 20 m (66ft)






Static speed deviation 0.1% of nominal motor speed





Motor cable length Maximum length: 1000 m (3281 ft)





ABB







Cooling

Cooling method Closed water-cooled system with additional closed air cooling circuit

Heat dissipation toenvironment

Approximately 1 kW, based on 27 °C (80 °F) raw water and 32 °C (90 °F) ambient air temperature; up to 7 kW if IP42

Raw watertemperature

+4…+27 °C (+40…+80 °F)

Raw waterdesign pressure

10 bar (144.2 lb/sq in)

Extended raw watertemperature

+27…+38 °C (+80...+100 °F), higher on request

W1 W2 W3

VAC Hz Aux. Power Consumption* VA Back-up Fuse Rating

400 ± 10% 50 4700 5000 5000 max. 50 A if lcu > 50 kA

60 5400 5700 5700

480 60 5400 5700 5700

575 60 5400 5700 5700

W1 W2 W3

VAC Hz Aux. Power Consumption*VA Back-up Fuse Rating

120 50 / 60 800 1100 1100 max. 25 A if lcu > 10 kA

230

W1 W2 W3

VAC Hz Aux. Power ConsumptionVA Back-up Fuse Rating

120 50 / 60 400 max. 25 A if lcu > 10 kA

230


ABB

Raw water flow rate Refer to the Data Sheet of the Water Cooling Unit for additional information.

Water quality Refer to the Data Sheet of the Water Cooling Unit for additional information.

Environment

Operation

Ambient temperature +1...+50 °C (34…122 °F)

+5...+38 °C (41...100 °F) for cabinets with enclosure protection IP42




Relative humidity 5...95% in the absence of condensation

5...80% for cabinets with enclosure protection IP42

5...60% in the presence of corrosive gases

5...50% for cabinets with enclosure protection IP42

Installation altitude 4.0 kV motor voltage: up to 3000 m (9843 ft)












Sound pressure level < 70 dB (A)

< 75 dB (A) for cabinets with enclosure protection IP42


ABB

Transport












Storage










Derating for raw water temperatureIf the raw water temperature exceeds 27 °C (81 °F) the derating factors as stated in Table 7 apply to the rated output power:

Table 7 Derating factors for raw water temperature

Converter type Cooling waterinlet temp. range

Deratingin % per °C

ACS1013-W1 27 °C to max. 38 °C 0

ACS1013-W2 27 °C to max. 38 °C 0

ACS1013-W3 27 °C to max. 38 °C 0.4


ABB

Derating for frostproofingIf glycol is added to the make-up water, the derating factors as stated in Table Table 8 apply to the rated output power:

Table 8 Derating factors for glycol

Analog inputs


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





> 80 dB at 50 Hz


Accuracy ± 0.25% (of upper range value) at 25 °C (± 30 mV offset)





ACS1014-W1 27 °C to max. 38 °C 0.6

ACS1014-W2 27 °C to max. 38 °C 0

ACS1014-W3 27 °C to max. 38 °C 1.35

Converter type Cooling waterinlet temp. range

Deratingin % per °C

Frostproofing Glycol concentration Derating in %

-10 °C 20% 4.5

-20 °C 34% 7

-30 °C 44% 9

-40 °C 52% 11.5


ABB

Analog outputs


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








Digital inputs













ABB

Digital outputs


Contact rating







Voltage 24 VDC +15% / -10%












24 VDC 8 A 6 A

24 VAC 8 A 6 A

48 VDC 1 A 1 A

48 VAC 8 A 6 A

120 VDC 0.4 A 0.4 A

120 VAC 8 A 6 A

230 VAC 8 A 6 A


ABB


Application Remotely operated Control Panel, Master/Follower link





Converter tests

Test voltages

Impulse test voltage(BIL Basic Impulse

Insulation Level)

30 kV according to IEC / EN 60071-1 (UL 347)


9.6 kV during 1 min. according to UL 347














15 kA


ABB


ABB

Technical data

Converter types and ratingsTable 1 Converter types and ratings

AC

S 10

00i t

ype

Nom

inal

mot

or v

olta

geU

Nom

Rat

ed m

otor

pow

er

Rat

ed o

utpu

t cur

rent

*

Con

vert

er In

put v

olta

ge **

3-ph

ase

Con

vert

er in

put c

urre

nt **

Wei

ght


ACS 1043-A1-A0 3300 315 450 70 6000 35 3900 8600

ACS 1043-A1-B0 3300 355 500 79 6000 39 3900 8600

ACS 1043-A1-C0 3300 400 536 87 6000 44 3900 8600

ACS 1043-A1-D0 3300 450 603 96 6000 50 3900 8600

ACS 1043-A1-E0 3300 500 671 105 6000 56 3900 8600

ACS 1043-A1-F0 3300 560 751 122 6000 62 4300 9480

ACS 1043-A1-G0 3300 630 845 131 6000 70 4300 9480

ACS 1043-A1-H0 3300 710 952 149 6000 79 4300 9480

ACS 1043-A2-J0 3300 800 1073 166 6000 89 4300 9480

ACS 1043-A2-K0 3300 900 1207 192 6000 100 4300 9480

ACS 1043-A2-L0 3300 1000 1341 210 6000 111 5100 11250

ACS 1043-A3-M0 3300 1120 1502 236 6000 124 5100 11250

ACS 1043-A3-N0 3300 1250 1676 262 6000 139 5100 11250

ACS 1043-A3-P0 3300 1400 1877 297 6000 155 5500 12130

ACS 1043-A3-Q0 3300 1500 2011 332 6000 167 5500 12130

ACS 1044-A1-A0 4160 298 400 58 4160 48 4000 8820

ACS 1044-A1-B0 4160 336 450 58 4160 54 4000 8820

ACS 1044-A1-C0 4160 373 500 65 4160 60 4000 8820

ACS 1044-A1-D0 4160 447 600 79 4160 72 4000 8820

ACS 1044-A1-E0 4160 522 700 94 4160 84 4000 8820

ACS 1000i 3BHS213404 ZAB E01 Rev. E 1 (14)

ABB

* The output current depends on the application of the converter. Therefore, theoutput current printed on the rating plate can be different from the value stated inthis table.

**Converter input voltage and current depend on the voltage level of the mediumvoltage power supply. Besides the shown input voltages, the ACS 1000i isavailable for other input voltages as well (refer to the Type Code).

Cabinet design data

Length 3300 mm (10 ft 10 in)

Depth 1121 mm (3 ft 8 in)

1300 mm (4 ft 3 in) including lifting lugs

HeightFrame size A1

2050 mm (6 ft 9 in)

2517 mm (8 ft 3 in) (including fan hood)

2617 mm (8 ft 7 in) (including redundant fan hood and/or IP42)

HeightFrame size A2/A3

2150 mm (7 ft 1 in)

2562 mm (8 ft 5 in) (including fan hood)

2662 mm (8 ft 7 in) (including redundant fan hood and/or IP42)

Enclosure classes IP21 (optional: IP42) according to IEC / EN 60529

ACS 1044-A1-F0 4160 597 800 108 4160 96 4000 8820

ACS 1044-A1-G0 4160 671 900 115 4160 107 4000 8820

ACS 1044-A1-H0 4160 746 1000 130 4160 119 4000 8820

ACS 1044-A2-J0 4160 932 1250 166 4160 149 4900 10800

ACS 1044-A2-K0 4160 1119 1500 195 4160 179 4900 10800

ACS 1044-A3-L0 4160 1305 1750 224 4160 209 5600 12350

ACS 1044-A3-M0 4160 1491 2000 260 4160 239 5600 12350

ACS 1044-A3-N0 4160 1678 2250 289 4160 269 5600 12350

ACS 1044-A3-P0 4160 2014 2700 337 4160 323 5600 12350

AC

S 10

00i t

ype

Nom

inal

mot

or v

olta

geU

Nom

Rat

ed m

otor

pow

er

Rat

ed o

utpu

t cur

rent

*

Con

vert

er In

put v

olta

ge **

3-ph

ase

Con

vert

er in

put c

urre

nt **

Wei

ght


2 (14) 3BHS213404 ZAB E01 Rev. E ACS 1000i

ABB

Grounding busbar Cross section: 50 x 6 mm



Power cable entryplates

Steel plates without entry holes

(optional: aluminum, brass or stainless steel plates)




Primary side voltage 2.3, 4.16, 6.9 kV / 60 Hz

3.3 kV / 50 Hz

6 to 6.6 kV / 50 Hz

10 to 11 kV / 50 Hz

Not all input and output voltages can be combined with each other.

Convertertransformer voltage

variation

+10% / -10%

(safe operation with reduced output power possible down to -25%)

Phase shift Phase shift between transformer secondary windings: 15° for 24-pulse line rectifier

Frequency 50/60 Hz ± 2%

Voltage unbalance max. ± 2% between phases




Redundant cooling fan unit

714 28.1 858 33.8 332++ 13.1 100 220


644+ 25.3 1121 44.1 20052070*

78.981.5*

460 1014


644+ 25.3 1121 44.1 20052070*

78.981.5*

460 1014


25.333.2

11211121

44.144.1

20052070*

78.981.5*

300...600***300...600***

661...1323***661...1323***


ABB






Static speed deviation 0.1% of nominal motor speed





Motor cable length Maximum length: 1000 m (3281 ft)





Alternatively, the medium voltage transformer can be tapped to supply the converter with the required auxiliary power. This option can only be selected for 60 Hz supply voltage.



A1 A2 / A3

VAC Hz Aux. Power Consumption* VA Back-up Fuse Rating

400 ± 10% 50 4500 5400 max. 50 A if lcu > 50 kA

60 6400 8000

480 60 6400 8000


ABB




Cooling

Cooling method Air cooling circuit with internal fan

Heat losses ACS 1043-A1: maximum 25.2 kW

ACS 1043-A2: maximum 45 kW

ACS 1043-A3: maximum 67.5 kW




Air flow rate A1: 4.2 m3/s (8900 cu.ft./min)

A2: 5.0 m3/s (10600 cu.ft./min)

A3: 5.0 m3/s (10600 cu.ft./min)

Filter mats Depending on the mesh size of the filter mat the following derating of the output power applies:

Table 6 Derating factors for output power

Redundant cooling fan The ACS 1000i does not require any derating.

A1 A2 A 3

VAC Hz Aux. Power Consumption*VA Back-up Fuse Rating

120 50 / 60 430 500 620 max. 25 A if lcu > 10 kA

230

A1 A2 A3

VAC Hz Aux. Power ConsumptionVA Back-up Fuse Rating

120 50 / 60 300 max. 25 A if lcu > 10 kA

230

Derating of output power Mesh size Remark

0% 18 µm Standard

5% 12 µm Option

10% 10 µm Option


ABB

Environment

Operation

Ambient temperature 0…+40 °C (32…104 °F)

Above +40 °C (+104 °F) the rated output power decreases by 1.5% for each additional 1 °C (0.85% for each 1° K) up to the maximum permitted temperature of +50 °C (+122 °F).

Example: If the ambient temperature is 50 °C the derating is calculated as 100% - 1.5 %/°C · 10 °C = 85%. Hence, the maximum output power is 85% of the rated value.




Relative humidity 5…95% in the absence of condensation

5…60% in the presence of corrosive gases

Installation altitude Up to 3000 m (9843 ft)

At locations 2000 m (6600 ft) above sea level, the reduction of the rated converter output power by 1% per additional 100 m (330 ft) must be accounted for. Possibly, a converter with a higher output power must be selected (The rated motor power in Table 1 can be taken as the guidance value for the converter output power).











Sound pressure level < 85 dB (A)


ABB

Transport












Storage










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

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

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


ABB

Derating for air filtersDepending on the mesh size of the filter mat the derating factors as stated in Table 7 apply to the rated output power:

Table 7 Derating factors for air filters

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

Analog inputs


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





> 80 dB at 50 Hz


Accuracy ± 0.25% (of upper range value) at 25 °C (±30 mV offset)





Analog Outputs


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

Mesh size Remark Derating in %

18 μm standard 0

12 μm option 5

10 μm option 10


ABB








Digital inputs












Digital Outputs



ABB

Contact rating







Voltage 24 VDC +15% / -10%












24 VDC 8 A 6 A

24 VAC 8 A 6 A

48 VDC 1 A 1 A

48 VAC 8 A 6 A

120 VDC 0.4 A 0.4 A

120 VAC 8 A 6 A

230 VAC 8 A 6 A


ABB


Application Remote operated Control Panel, Master/Follower link





Converter tests

Test voltages

Impulse test voltageand


Figure 1 illustrates the different converter sections and the voltage levels applied to these sections for testing. The light grey areas represent sections which have been tested with the Impulse Test Voltage or the Basic Impulse Insulation Level (BIL) respectively. Sections which have been tested with the Dielectric Withstand Voltage are shaded darker.


ABB

Figure 1 Test voltages










28 kV

75 kV**

28 kV

66 kV**

For 7.2 kVinput voltage

For 12 kVinput voltage

* according to ANSI C57.12.01** according to IEC / EN 60071.1

1 Input disconnector2 Fused contactor3 Transformer4 Rectifier5 DC link6 Inverter7 Sine filter

1 2

3 4 5 6

7

Test voltages with open input disconnector

9.6 kV

30 kV

20 kV

60 kV**

28 kV

45 kV* 60 kV**1 2

3 4 5 6

7

Test voltages with closed input disconnector

For 7.2 kVinput voltage

For 12 kVinput voltage


ABB





35 kA


ABB


ABB

ACS 1000 - Applicable codes and standards.

International standards for design and construction

IEC / EN 60071-1 Insulation coordination - Part 1: Definitions, principles and rules

IEC / EN 60146-1-1 Semiconductor convertors - General requirements and line commutated convertors - Part 1-1: Specifications of basic requirements

IEC / EN 60529 Degrees for protection provided by enclosures (IP-Code)

IEC / EN 60664-1 Insulation coordination for equipment within low-voltage systems - Part 1: Principles, requirements and tests

IEC 62103 (EN 50178) Electronic equipment for use in power installations

IEC / EN 61800-4 Adjustable speed electrical power drive systems - Part 4: General requirements - Rating specifications for a.c. power drive systems above 1000 V a.c. and not exceeding 35 kV

UL 347: 2000 High Voltage Industrial Control Equipment

UL 508C: 2003 Power Conversion Equipment

EMC standards

CISPR 22 Cl A Information technology equipment - Radio disturbance characteristics; Limits and methods of measurement

IEC / EN 61000-4-2 Electromagnetic compatibility (EMC) - Part 4-2: Testing and measurement techniques - Electrostatic discharge immunity test

IEC / EN 61000-4-3 Electromagnetic compatibility (EMC) - Part 4-3: Testing and measurement techniques - Radiated, radio-frequency, electromagnetic field immunity test

IEC / EN 61000-4-4 Electromagnetic compatibility (EMC) - Part 4-4: Testing and measurement techniques - Electrical fast transient/burst immunity test

IEC / EN 61000-4-5 Electromagnetic compatibility (EMC) - Part 4-5: Testing and measurement techniques - Surge immunity test

IEC / EN 61000-4-6 Electromagnetic compatibility (EMC) - Part 4-6: Testing and measurement techniques - Immunity to conducted disturbances, induced by radio-frequency fields

IEC / EN 61000-6-2 Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity for industrial environments

3BHS232441 ZAB E01 Rev. A 1 (2)

ABB

IEC / EN 61000-6-4 Electromagnetic compatibility (EMC) - Part 6-4: Generic standards - Emission standard for industrial environments

IEC / EN 61800-3 Adjustable speed electrical power drive systems - Part 3: EMC requirements and specific test methods

Environmental Standards

IEC / EN 60721-3-1 Classification of environmental conditions – Part 3: Classification of groups of environmental parameters and their severities – Section 1: Storage

IEC / EN 60721-3-2 Classification of environmental conditions – Part 3: Classification of groups of environmental parameters and their severities – Section 2: Transport

IEC / EN 60721-3-3 Classification of environmental conditions – Part 3: Classification of groups of environmental parameters and their severities – Section 3: Stationary use at weatherprotected locations

2 (2) 3BHS232441 ZAB E01 Rev. A

2

ABB Switzerland LtdMedium Voltage DrivesCH-5300 Turgi

Phone: +41 58 589 27 95

Fax: +41 58 589 29 84

E-Mail: [email protected]

www.abb.com/drives

© C

op

yrig

ht

2009 A

BB

. A

ll rig

hts

rese

rved

. S

pecifi

catio

ns

sub

ject

to c

hange w

ithout

notic

e. 3B

HS

125029 Z

AB

E01 R

ev.

D.

Contact us