ABB ACS 1000 Tech Catalog RevD

Technical catalog
Medium voltage AC drive

ACS 1000, ACS 1000i
315 kW - 5 MW, 2.3 - 4.16 kV
2
ABB
Table of contents
List of figures 7
List of tables 9
Chapter 1 - Overview 11
1.1 Introduction 11
1.2 The standard solution 12
1.2.1 ACS 1000 types 15
1.3 Key technology 16
1.4 Technical benefits 16
1.5 Benefits for the customer 17
1.6 CE declaration and UL listing 19
Chapter 2 - Functional description, operation 21
2.1 Overview 21
2.2 Standard control functions 21
2.2.1 Direct torque control 21
2.2.2 Application parameters 25
2.2.3 Speed control functions 25
2.2.4 Motor-related functions 27
2.2.5 Ride-through functions 27
2.2.6 Main circuit breaker control 28
2.2.7 Input signal source selection and signal processing 28
2.2.8 Control and operation modes 29
2.3 Operation and diagnostics 30
2.3.1 Local and remote operation 30
2.3.2 Diagnostics 32
2.4 Converter protection functions 33
2.4.1 Alarm and fault handling 33
2.4.2 Tripping loop 34
2.4.3 Protection functions related to the converter system 34
2.4.4 Internal converter protection functions 36
2.4.5 External protection functions 38
2.5 Additional features 38
2.6 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 39
3.2 Converter topology 39
3.3 Technology 41
3.3.1 Fuseless design 41
3.3.2 Input stages 41
3.3.3 Voltage Source Inverter (VSI) technology 41
3.3.4 Output stages 42
3.3.5 IGCT power semiconductor 43
3.4 Cabinet layout 44
3.4.1 Air-cooled ACS 1000 44
3.4.2 Air-cooled ACS 1000i with integrated transformer 46
3.4.3 Water-cooled ACS 1000 47
3.4.4 Power terminals 49
3.4.5 DC grounding switch for safe grounding 49
3.5 Hardware modules (air-cooled ACS 1000) 49
3.5.1 Terminal and control section 49
3.5.2 Inverter section 52
3.5.3 Rectifier section 53
3.6 Hardware modules (air-cooled ACS 1000i) 53
3.6.1 Control section 53
3.6.2 Inverter section 55
3.6.3 Input section 56
3.7 Hardware modules (water-cooled ACS 1000) 57
3.7.1 Terminal and control section 57
3.7.2 Converter section 57
3.7.3 Filter section 58
3.7.4 Water cooling system 59
3.8 Cabinet design 63
3.8.1 Mechanical design 63
3.8.2 Electromagnetic compatibility (EMC) 64
3.8.3 Door locks and door interlocking 64
3.8.4 Safety labels 65
3.8.5 Compliance with international standards 65
3.9 Busbars and grounding 65
3.10 Lifting arrangements 66
3.11 Additional cabinets 66
Chapter 4 - Control system and process interfaces 67
4.1 Overview 67
4.2 Hardware and structure of the control system 68
4.3 Local control devices 69
4.3.1 CDP control panel 69
4.3.2 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 72

4.4.1 Programmable digital and analog outputs 73
4.4.2 Scalable analog inputs 73
4.4.3 Customer control signals 74
4.5 Control software 74
4.5.1 Control software structure 74
4.5.2 Operating system 74
4.5.3 Motor and control software 75
4.5.4 FCB application software 75
4.5.5 Panel application software 75
Chapter 5 - Engineering information 77
5.1 Overview 77
5.2 Main circuit breaker 77
5.2.1 Main circuit breaker control 77
5.2.2 Tripping loop 78
5.3 Converter input transformer selection 79
5.4 Motor selection 79
5.4.1 Selection criteria 80
5.4.2 Retrofit 80
5.4.3 Load capacity curves 81
5.4.4 Torsional excitation 82
5.5 Selection of power cables 82
5.5.1 Transformer primary cables 82
5.5.2 Transformer secondary cables 82
5.5.3 Motor cables 83
5.5.4 Power cable dimensions 83
5.5.5 Equipment grounding 84
5.6 Control cabling 84
5.7 Auxiliary power cables 84
Chapter 6 - Options 85
6.1 Overview 85
6.2 Environmental conditions 85
6.3 Converter enclosure 85
6.4 Input section 87
6.5 Motor side 89
6.6 Converter cooling 92
6.7 Synchronized bypass 93
6.8 Auxiliary supply 95
6.9 Auxiliary and control interfaces 96
6.10 Input / output disconnector 97
6.11 Optional diagnostic software 99

Table of contents ABB
6.11.1 DriveWindow 99
6.11.2 DriveMonitorTM 100
Chapter 7 - Installation guidelines 103
7.1 Overview 103

7.2 Environmental conditions 103
7.3 Mounting 103
7.4 Power equipment installation 107
7.4.1 General 107
7.4.2 Cable routing 107
7.4.3 ACS 1000 cable entry and termination
(only ACS 1000A/W) 108
7.4.4 Transformer wiring diagram for 12-pulse ACS 1000 110
7.4.5 Transformer wiring diagram for 24-pulse ACS 1000 110
7.4.6 Motor wiring diagram for 12 / 24-pulse ACS 1000 111
Chapter 8 - Ordering information 113
8.1 General 113

8.2 Converter selection 113
8.2.1 ACS 1000 output filter 114
8.2.2 Non-quadratic load applications 114
8.3 Type code 114
8.4 Option list 114
8.5 External system data 114
8.6 Technical data 114
Index 115
6
ABB
List of figures
Figure 1-1 ACS 1000A 13
Figure 1-2 ACS 1000W 14
Figure 1-3 ACS 1000i including optional output isolator and
redundant fans 14
Figure 2-4 DTC block diagram 22
Figure 2-5 DTC: typical dynamic speed response 24
Figure 2-6 DTC vs. PWM: typical torque response times 24
Figure 2-7 Setting the control panel to local / remote 30
Figure 2-8 Typical start and stop sequences 31
Figure 2-9 Signal display on CDP control panel 32
Figure 2-10 Stall region of the motor 34
Figure 2-11 Load curves for underload function 35
Figure 3-12 Elementary diagram - ACS 1000, 12-pulse
version 39
Figure 3-13 Elementary diagram - ACS 1000, optional
24-pulse version 40
Figure 3-14 Elementary diagram - ACS 1000i 40
Figure 3-15 3-level voltage source inverter principle 42
Figure 3-16 Voltage and current waveforms at converter
output 43
Figure 3-17 IGCT 43
Figure 3-18 The ACS 1000 air-cooled type (12 / 24-pulse,
typical layout) 44
Figure 3-19 Air flow through ACS 1000A 45
Figure 3-20 The ACS 1000i air-cooled type 46
Figure 3-21 Air flow through ACS 1000i 47
Figure 3-22 The ACS 1000 water-cooled type (12-pulse) 48
Figure 3-23 Control section with open front door
(ACS 1000 air, typical layout) 50
Figure 3-24 Control section with open swing frame
(ACS 1000A, typical layout) 51
Figure 3-25 Inverter section (ACS 1000A, typical layout) 52
Figure 3-26 Filter section (ACS 1000A, typical layout) 53
Figure 3-27 Control section with open front door
(ACS 1000i, typical layout) 54
Figure 3-28 Inverter section (ACS 1000i, typical layout) 55
Figure 3-29 Input section (ACS 1000i, typical layout) 56
Figure 3-30 Converter section (ACS 1000W, typical layout) 57
Figure 3-31 Filter section (ACS 1000W, typical layout) 58
Figure 3-32 Cooling section (ACS 1000W, typical layout) 59
Figure 3-33 Principle of water cooling circuit 60
Figure 3-34 Cooling unit of the water-cooled ACS 1000 62
Figure 3-35 Typical safety labels 65
Figure 3-36 Lifting rails air-cooled ACS 1000 66

List of figures ABB
Figure 3-37 Lifting rails water-cooled ACS 1000 66
Figure 3-38 Lifting lugs ACS 1000i 66
Figure 4-39 Typical configuration of control system 68
Figure 4-40 AMC Board 69
Figure 4-41 CDP control panel 70
Figure 4-42 Local control devices 71
Figure 4-43 Software block diagram of the AMC controller 74
Figure 5-44 Load capacity curves 81
Figure 6-45 Additional cabinet with power equipment
(option output isolator) 87
Figure 6-46 Synchronized bypass, single line diagram 95
Figure 6-47 Additional cabinet with two disconnectors 98
Figure 6-48 Typical DriveWindow display 100
Figure 6-49 DriveMonitorTM installed in a console with a
touchscreen, wall-mounted 101
Figure 7-50 Foundation plan with position of anchor holes:
12-pulse / 24-pulse, ACS 1000A 104
12-pulse, ACS 1000W 105
additional cabinet for ACS 1000A and
ACS 1000W 105
ACS 1000i 106
Figure 7-54 Cabinet mounting with bolts and lock washers 106
Figure 7-55 Top cable entry 108
Figure 7-56 Bottom cable entry 109
Figure 7-57 Typical 3-line transformer wiring diagram. 110
Figure 7-58 Typical 3-line transformer wiring diagram 110
Figure 7-59 Typical 3-line motor wiring diagram 111
8
ABB
List of tables
Table 1-1 List of abbreviations used in this catalog 11
Table 1-2 List of documents referred to in this catalog 11
Table 1-3 Standard power ranges for ACS 1000
converters 15
Table 2-4 DTC versus current vector control 22
Table 2-5 Typical performance figures for torque control,
when direct torque control is used 26
Table 3-6 Comparison of semiconductors 44
Table 4-7 I/O board configuration with number and type
of I/O 72
Table 5-8 Control cable requirements 84
Table 6-9 I/O signals for extended transformer monitoring 88
Table 6-10 I/O Signals for extended motor monitoring 89
Table 6-11 Power ratings for different circuit breaker sizes 91
Table 6-12 Power ratings for different starter sizes 91
Table 7-13 Required clearance in front and above of the
converter 103
Table 7-14 Maximum number of cables per phase 109

List of tables ABB
10
ABB
Chapter 1 - Overview
1.1 Introduction
This 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
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
Table 1-2 List of documents referred to in this catalog
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
Document number Document title
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
ACS 1000W Dimensions and Floor Mounting W2/W3 12-pulse with Redundant
3BHS127231 ZAB E01 Rev. B
Fan
3BHS127232 ZAB E01 Rev. B ACS 1000W Dimensions and Floor Mounting W2/W3 24-pulse
ACS 1000W Dimensions and Floor Mounting W2/W3 24-pulse with Redundant
3BHS127233 ZAB E01 Rev. B
Fan
3BHS224400 ZABE01 Rev. - ACS 1000W Terminal list
Application Note, Control and Operation Modes for Software Version MSOH4200
3BHS216635 ZAB E01 Rev. -
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
1.2 The standard solution

The 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.
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 and • Grinding mills

minerals
• 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 waste • Pumps

water
1.2.1 ACS 1000 types

The table below provides an overview of the rated output power range,
covering air and water-cooled converters for all three medium voltage
levels.
For further details, refer to Chapter 8 - Ordering information.
Table 1-3 Standard power ranges for ACS 1000 converters
Rated motor Rated motor

Motor voltage
Type power rangea power range
(kV)
(HP) (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

Rated motor Rated motor

Motor voltage
Type power rangea power range
(kV)
(HP) (kW)
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.
Note: Derating factors may apply. For details see Technical data.
1.3 Key technology

Two main technology features distinguish the ACS 1000 from other types
on the market:
• The motor control platform is based on Direct Torque Control (DTC)

which achieves 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 benefits

The technology described above brings many more practical benefits to
the ACS 1000, as described within this Catalog.
For instance, the use of IGCTs together with active feedback control by
means of an 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.
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 customer

Maximum availability High reliability and short repair time result in maximum availability.
short repair time
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 what Customer requirements are precisely met. The flexible design with
you get 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 listing

The 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 Overview
This 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 other List of references to other documents in this chapter:

documents
• Technical data (for document details see Chapter 1 - Overview,
Table 1-2)
2.2 Standard control functions

The 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 control

Direct 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.

Chapter 2 - Functional description, operation ABB
Torque
reference
Torque Torque
reference and flux Switching =
Speed Speed controller
REF comparator logic
reference control
Actual
speed
PID Switch
positions
Motor model Voltage
Current
IM
3~
Asynchronous motor
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 current Table 2-4 DTC versus current vector control
vector control
Direct torque control Vector control
(asynchronous motor)
Motor control variables Switching is based on Switching is based on the

core motor variables flux separate control of
and torque magnetic field and torque
producing current compo-
nents
38
ABB Chapter 2 - Functional description, operation
Direct torque control Vector control

(asynchronous motor)
Requirements for speed Shaft speed and position Mechanical speed is

encoder are not required (only essential. Requires shaft
high performance appli- speed and position
cations as for example in (measured or estimated)
the mining and metal
industry require speed
encoders)
Maximum inverter Each inverter switching Inverter switching is

response time process is determined based on average refer-
separately (every 25 μs) ences to a pulse width
modulator resulting in
delays in response and
unnecessary switching
Torque step rise time Torque step rise time is Torque step rise time
less than 3 ms at 70% closed loop: 10 to 20 ms
speed sensorless: 100 to
200 ms
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.

DTC performance Figure 2-5 illustrates a typical dynamic speed response caused by a load
step.
PWM without PWM with DC drive with DTC without

encoder encoder encoder 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)
Torque
Speed
Value depending
on process
Time
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.
Typical torque step: Torque:
response times at 70% speed
- DTC: 3 ms DTC
- PWM flux vector: 10…20 ms
- PWM: > 150 ms (scalar con-
..trol) PWM
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.
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 parameters

The ACS 1000 is configured and customized by means of application
parameters. These parameters can be altered by the user, either by
means of the integrated CDP 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 control T (%)

TN
without speed The ACS 1000 can perform precise Tref
feedback torque control without any speed 100
Tact
feedback from the motor shaft. With 90
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.
10
t(s)
< 10 ms
TN ..= Rated motor torque

Tref .= Torque reference
Tact = 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
ACS 1000 ACS 1000

Torque control
without pulse encoder with pulse encoder
Linearity error + 4%a + 3%
Torque rise time < 10 ms < 10 ms
a. When operated around zero frequency, the error may be bigger.
Speed and torque performance figures meet or exceed the requirements

of IEC 61800-4.
Acceleration and ACS 1000 provides two user-selectable acceleration and deceleration
deceleration ramps 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.
Motor
The available ramp shapes are: speed
• Linear: Suitable for converters S1

requiring long acceleration / Linear
deceleration where S-curve

ramping is not required. S2
• S-curve ramps are ideal for S3

conveyors carrying fragile loads,
or other applications where a 1 1.25 2 t (s)
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 zero A motor fed by the ACS 1000 can develop short-term motor nominal
speed 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.
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.
Motor
speed
Each critical speed setting allows the (rpm)
user to define a low and a high speed 1560
limit. If the speed reference signal 1380
requires the ACS 1000 to operate
within this speed range the critical
speeds function will keep the 690
ACS 1000 operating at the low (or 540
high) limit until the reference is out of Speed
reference
the critical speed range. The motor is (rpm)
accelerated/decelerated through the s 1 Low s1 High s2 Low s2 High
critical speed band according to the 540 690 1380 1560
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 functions

The 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.

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

The 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 programmable The ACS 1000 can receive the Start / Stop / Direction commands and the
control locations 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 signal The ACS 1000 can handle a variety of speed reference schemes in
processing 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 modes

Parameters 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 operation

The 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).
1 L -> 550.0 rpm 1 1 -> 550.0 rpm 1

Status Running Status Running
MotorSpeed 0.00 rpm MotorSpeed 0.00 rpm
POWER 0.0 % POWER 0.0 %
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.
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 stop The converter can be started and stopped either manually from the local
sequences 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.
Start sequence Stop sequence
Not
Ready ref.
> Aux. supply on read on
> Doors closed
> No fault
> Ground switch STOP command
open
> WCU ready ** Ramp down speed
Ready on Stop modulation
Supply ON
command Ready run
Charge DC link
Close MCB Supply OFF
command
Open MCB
Ready run
Discharge DC link
START command
Ready on
Start modulation
Ready ref.
Operation
according to setpoint **WCU = water cooling unit
only applicable for water-cooled converter
Figure 2-8 Typical start and stop sequences

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 signal Three signals can be displayed simultaneously on the control panel.
monitoring
1 L -> 600.0 rpm 1

Status Running
MotSpeed 600.00 rpm
POWER 75.0 %
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
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 handling

All 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 loop

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.
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:
Torque
Stall region
Tm.a
Stall f (Hz)
Frequency
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.
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).
Torque
0.8
0.7
0.6
0.5 curve 1
curve 2
0.4 curve 3
curve 4
0.3 curve 5
0.2
0.1
0
Speed
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
110%
120%
130%
140%
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.

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 the A short circuit in the rectifier bridge is detected by monitoring the DC link
rectifier bridge 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 the The inverter is monitored to ensure that a short circuit condition does not
inverter 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 functions

External converter protection functions require external measuring
devices.
Motor winding and The motor can be protected from overheating by activating the motor
bearing temperature 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 motor An external motor protection relay can be connected to a predefined

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

protection trip 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 features

Converter 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 features

See Chapter 6 - Options for information.
38
ABB
Chapter 3 - Hardware design
3.1 Overview
This chapter provides a description of the standard power, control and
cooling hardware of the different ACS 1000 types.

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

Figure 3-12 to Figure 3-14 show the elementary circuit diagram of the
ACS 1000.
3 Converter
transformer
NP
NP M
M
Main circuit
breaker
Medium Diode Protection Intermediate Three level Output Squirrel cage

voltage rectifier IGCTs DC link inverter sine filter induction motor
switchgear
Figure 3-12 Elementary diagram - ACS 1000, 12-pulse version

Chapter 3 - Hardware design ABB
3 Converter
transformer M
Main circuit
breaker

switchgear
Figure 3-13 Elementary diagram - ACS 1000, optional 24-pulse version
Converter
transformer NP M
Input contactor
(optional)

switchgear
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
66
ABB Chapter 3 - Hardware design
3.3 Technology
3.3.1 Fuseless design

The 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 stages

The ACS 1000 features a 12-pulse diode rectifier input stage. This is
adequate for most networks and normally meets the harmonic require-
ments demanded by standards such as IEEE 519.
For networks that are more demanding, the ACS 1000 can be supplied
optionally with a 24-pulse configuration for 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) technology

Each 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 stages

At the converter output a LC filter is used for reducing the harmonic
content of the output voltage. With this filter, the voltage waveform applied
to the motor is nearly sinusoidal (see Figure 3-16). 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
ACS 1000 Output voltage: 4.16kV

Output frequency: 60Hz
Figure 3-16 Voltage and current waveforms at converter output
3.3.5 IGCT power semiconductor

The 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.
Gate unit
Gate-commutated thyristor
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.

Table 3-6 Comparison of semiconductors
GTO thyristor High voltage IGBT IGCT
Switching technology High blocking voltage High switching frequency High blocking voltage
Low on-state losses Low switching losses High switching frequency
High on-state losses Low on-state and switching losses
Snubberless Snubberless
Equipment design Proven reliability Modular design Proven reliability

Compact Compact and modular equipment design
Fuseless design Simple topologies with low parts count
Snubberless
3.4 Cabinet layout
3.4.1 Air-cooled ACS 1000
1 2 3 4 5 6
Figure 3-18 The ACS 1000 air-cooled type (12 / 24-pulse, typical layout)
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.
Air intake
Control section Rectifier section Inverter section
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.

3.4.2 Air-cooled ACS 1000i with integrated transformer
The ACS 1000i is equipped with an input transformer. The 24-pulse input
bridge is standard.
1 2 5 3 5 4 6
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
66
Air intake
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.

1 2 3 4 5 6
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.
66
3.4.4 Power terminals

Air and water-cooled The leftmost sections of the air and water-cooled ACS 1000 contain the
ACS 1000 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 grounding

The 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 section

The 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).

Swing frame
Control power supply
Terminal blocks for internal

auxiliary power Control panel
AMC controller board /

interface board
Control pushbuttons and

Pulse encoder / indication lights
fieldbus interface
Delta p-transmitter Emergency off switch
IOEC1 board
Motor starters and

circuit breakers

option: external UPS safeline
other options: internal UPS
with batteries
Figure 3-23 Control section with open front door (ACS 1000 air, typical
layout)
66
Swing frame (rear side)
IOEC2 board (standard)
IOEC4 board
optional
Auxiliary voltage
terminals
IOEC3 board (optional)
Spare terminals
(optional)
Space for options
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.

3.5.2 Inverter section
The inverter section (Figure 3-25) contains the inverter stacks, the sine
filter and DC link capacitors.
Phase U Phase V Phase W
Sine filter and

DC link capacitors
Figure 3-25 Inverter section (ACS 1000A, typical layout)
66
3.5.3 Rectifier section

The 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.
Cooling fan
Grounding switch
Common mode choke
Rectifier (including
protection IGCTs)
Filter choke
Figure 3-26 Filter section (ACS 1000A, typical layout)
3.6 Hardware modules (air-cooled ACS 1000i)
3.6.1 Control section

The 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.

IOEC4 board
(optional)
IOEC3 board
(optional)
IOEC2 board
IOEC1 board
Delta p-transmitter
Delta p-transmitter
Fused terminal block for
internal aux. power
Motor starters and
circuit breakers
Option: batteries
Terminal blocks (internal,

cooling, fans, external)
AC aux. supply
AMC and interface board

Control panel
transformer
Control pushbuttons and protection
indication lights
Emergency off switch
Figure 3-27 Control section with open front door (ACS 1000i, typical
layout)
66
3.6.2 Inverter section

The 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.
Phase U Phase V Phase W
Sine filter and

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

3.6.3 Input section
The 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.
Grounding switch
Surge arrestors
Input grounding switch
interlock
Rectifier
Input transformer
(behind rectifiers)
Rectifier
Figure 3-29 Input section (ACS 1000i, typical layout)
66
3.7 Hardware modules (water-cooled ACS 1000)
3.7.1 Terminal and control section

The 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 section

The converter section (Figure 3-30) contains the rectifier, inverter and
protection IGCT stacks.
Phase U
Phase V
Phase W
Protection IGCT
Rectifier
Figure 3-30 Converter section (ACS 1000W, typical layout)

3.7.3 Filter section
The 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.
Filter capacitors
GUSP
DC capacitors
Snubber circuit
Grounding switch
Output filter choke
Common mode
choke (optional)
Figure 3-31 Filter section (ACS 1000W, typical layout)
66
3.7.4 Water cooling system
3.7.4.1 Overview
Cooling fan
Expansion vessel
Connection box
Water-to-water heat exchanger
Ion exchange vessel
Air-to-water heat exchanger
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.

Internal cooling water circuit
Internal cooling water

treatment circuit
Raw water
cooling circuit
Internal air cooling circuit
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.
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.

B11 B12 B13
V5
to converter
nipple V13
Expansion vessel (C2)
B10 V16
V12
from converter
nipple
S1
Micro
filter (Z2)
V11
V14 Strainer (Z1)

C1 raw water inlet
C/A nipple
Make-up Water-to-
Ion exchange vessel water water heat Air-to-water
exchanger heat exchanger (E2)
(E1)
M M11 V18
V15 V82
V1
P1 V3
S2
M M12 B14 OPTION
raw water outlet
V2 V4 nipple
OPTION M
V80 P2 V81
OPTION
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 water See Technical data for a detailed list of parameters of the water cooling
requirements system and options regarding extended raw water temperature and
pressure.
66
3.8 Cabinet design

The 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 interlocking

All 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 labels

Safety 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 standards

The design of the ACS 1000 fulfills the requirements of international
standards listed in ACS 1000 - Applicable codes and standards.
3.9 Busbars and grounding

AC 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 arrangements
The 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 cabinets

The 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 Overview
This 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.

documents
• 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 -

Chapter 4 - Control system and process interfaces ABB
4.2 Hardware and structure of the control system
Customer interface section
Higher-level
DriveMonitorTM control system
Fieldbus
Control section
PC tools
CDP control panel

DDCS
DDCS
RS485
DDCS
AMC controller
DDCS
IOEC1
Fiber optic
IOEC2
IOEC3*
INT board
IOEC4**
Fiber optic
Converter section
*/** Additional option for air-cooled ACS 1000
** ..Additional option for water-cooled ACS 1000
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)
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 panel

The 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.
1 L -> 1242,0 rpm I Alphanumeric display

MotCurr 76.00 A (4 lines x 20 characters)
MotSpeed 1242.0 rpm
Torque 86.00 %
Mode selection buttons
Selection and changing buttons Enter button
Reset button Setpoint setting button
Local, remote button Start button
Forward, reverse buttons Stop button
Figure 4-41 CDP control panel
76
4.3.2 Control switches

The 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.
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 unlocked

indicates 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
Figure 4-42 Local control devices

4.4 Customer I/O interfaces
The 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
Number Signal type Ratings
4 Analog (AI) 0...20 mA / 4...20 mA or 0...10 V / 2...10 V

Inputs scalable by parameter setting
2 Analog (AO) 0...20 mA / 4...20 mA

Outputs scalable by parameter setting
14 Digital (DI) Opto-coupled, rated for 22...250 VAC or

Inputs 22...150 VDC
6 Digital (DO) With switch-over contact (SPDT),

Outputs rated for 250 VAC, 2 A
Refer to Chapter 6 - Options for information on additional interface signals

on the optional I/O boards.
76
4.4.1 Programmable digital and analog outputs

Programmable digital Four digital outputs on the IOEC2 board can be programmed individually.
outputs 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 analog Two programmable analog outputs on each IOEC board are at the user’s
outputs 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 inputs

Each analog input can be adapted individually to the type and range of the
connected input signal:
• Signal type: voltage or current (selectable by DIP switches)

• Signal inversion: if a signal is inverted, the maximum input level corre-
sponds to the minimum signal value and vice versa
• Minimum level: 0 mA (0 V), 4 mA (2 V) or by input tuning function
(actual input value is read and set as minimum)
• Maximum level: 20 mA (10 V) or by input tuning function (actual input
value is read and set as maximum)
• Signal filtering time constant: adjustable between 0.01..10 s.
The offset of the analog inputs can be calibrated automatically or

manually.

4.4.3 Customer control signals
The 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 structure

The 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
Inverter control AMC controller
AMCOS (AMC Operating System)

Function block Motor control +
library (FCB) Main state machine
Fieldbus adapter Speed
Advant AC FCB application controller
controller software
Process I/O
Direct Torque Modulator
Panel application Controller interface
Control panel (DTC)
software
Magnetization
AMC table setpoint to EXU
Figure 4-43 Software block diagram of the AMC controller
4.5.2 Operating system

The 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.
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 software

The 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 Overview
This 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:

documents
Table 1-2)
• 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 -
• Technical Specification for Power Cables (for document details see
• Wiring and Busbar Specification (for document details see Chapter 1
- Overview, Table 1-2)
5.2 Main circuit breaker

Refer 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 control

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

All ACS 1000 converters must be supplied from an isolation transformer
with multiple phase-shifted secondary windings, designed in accordance
with the pulse number of the input bridge. For 12-pulse systems the
secondary side of the transformer has one star and one delta winding.
This creates the 30° phase shift between the two 3-phase secondary
windings, that is necessary to facilitate 12-pulse input bridge operation.
The secondary windings of transformers for ACS 1000 converters with 24-
pulse rectifier bridge are to be designed to provide a 15° phase shift.
A second purpose of the transformer is to provide sufficient impedance to
limit the line harmonics to acceptable levels.
The transformer may be an oil-immersed or a dry type. Based on 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 selection

Refer 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 Retrofit
Due 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 curves

This 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.
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.).
T/TN
2.0
1.9
1.8
1.7
1.6
1.5
1.4
1.3
1.2
Curve 2
1.1 ACS 1000 loadability
1.0
0.9
0.8
0.7
0.6
0.5
Curve 1
0.4
Motor loadability
0.3
0.2
0.1
p .= .number of poles 0.0

0 10 20 30 40 50 60 70 80 90 100 f (Hz)
T .= .load torque p=2
0 600 1200 1800 2400 3000 3600 n (rpm)
TN= .rated motor
p=4
........torque 0 300 600 900 1200 1500 1800 2100 2400 n (rpm)
n .= .speed p=6
0 200 400 600 800 1000 1200 1400 1600 n (rpm)
f ..= .output frequency of
p=8
........ACS 1000 0 150 300 450 600 750 900 1050 n (rpm)
Figure 5-44 Load capacity curves

5.4.4 Torsional excitation
Due 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 cables

The 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 cables

The 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 cables

The 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 cables

There 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 dimensions

In 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 grounding
It 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 cabling

Control 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
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 0.5 mm2

shielded pairs and overall shield 4 x (2+1)
Position encoder Twisted pair cable with separately 0.5 mm2

shielded pairs and overall shield 4 x (2+1)
5.7 Auxiliary power cables

Any 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.
84
ABB
Chapter 6 - Options
6.1 Overview
This 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 Other List of references to other documents in this chapter:

Documents
Table 1-2)
• Type Code (for document details see Chapter 1 - Overview,
Table 1-2)
• Application Note, Mechanical Interlock (for document details see
6.2 Environmental conditions

Extended ambient Above 40 °C ambient temperature the converter output power must be
temperature (air- derated by 1.5% per 1 °C and filter capacitors, suitable for high operating
cooled only): 50 °C temperatures, are supplied.
Extended raw water The extended raw water temperature range is +27...+38 °C
temperature (+80...+100 °F). For deratings refer to Technical data.
Corrosion protected For certain environmental conditions (e.g. salty air in combination with
busbars 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 enclosure

IP 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 grounding The standard grounding busbar which is located in the power cable termi-
busbar 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 section

Input 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 transformer In addition to the standard signal “Transformer Protection Trip” (wired into
monitoring interface 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
Type Signal name Remarks
DI OIL LEVEL ALARM Transformer oil level alarm indication
DI OIL TEMP ALARM, or Transformer oil temperature alarm

inidication
TRAFO WDG TEMP ALARM Transformer winding temperature
alarm indication
DI /OIL TEMP TRIP, or Transformer oil temperature trip

indication
/TRAFO WDG TEMP TRIP 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 Temperature measurement of trans-

former oil
TRAFO WDG TEMP Temperature measurement of trans-
former winding
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.
102
6.5 Motor side

Extended motor In addition to the standard signal “Motor Protection Trip” (wired into
monitoring interface 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
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

DI MOT COOLING ALARM (External) motor cooling alarm

DI /MOT COOLIING TRIP (External) motor cooling trip

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 Motor winding temperature phase W

W1
AI MOTOR WDG TEMP PHASE Motor winding temperature phase W

W2 2nd measurement (IOEC4 required)
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.

Pulse encoder The module allows a pulse encoder to be connected to the ACS 1000. A
interface module 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 output The ACS 1000 can be ordered with an increased output frequency of
frequency 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 for A motor space heater can be connected directly to a single-phase auxiliary
motor space heater 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
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
Motor starter for motor Motor cooling fan(s) or pump(s) can be connected directly to an auxiliary
cooling fan or pump 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 (three phase)
Overload current 400 VAC 480 VAC 575 VAC

rating 50/60 Hz 60 Hz 60 Hz
1 hp - 2 hp 1.5 hp - 3 hp
2.5 - 4.0 A
0.75 kW - 1.5 kW (1.1 kW - 2.2 kW) (1.1 kW - 2.2 kW)
2 hp - 3 hp 3 hp - 5 hp
4.0 - 6.3 A
1.5 kW - 2.2 kW (2.2 kW -3 kW) (2.2 kW - 3 kW)
3 hp - 5 hp 5 hp - 7.5 hp
6.3 - 10.0 A
2.2 kW - 4 kW (3 kW - 4 kW) (3 kW - 4 kW)
5 hp - 10 hp 7.5 hp - 10 hp
10.0 - 16.0 A
4 kW - 7.5 kW (4 kW -9 kW) (4 kW - 11 kW)
10 hp - 12 hp 10 hp - 15 hp
16.0 - 20.0 A
7.5 kW - 9 kW (9 kW -12.5 kW) (11 kW - 12.5 kW)
2 x (1 hp - 2 hp) 2 x (1.5 hp - 3 hp)

2 x (2.5 - 4.0 A)
2 x (0.75 kW - 1.5 kW) (2 x (1.1 kW - 2.2 kW)) (2 x (1.1 kW - 2.2 kW))
2 x (2 hp - 3 hp) 2 x (3 hp - 5 hp)
2 x (4.0 - 6.3 A)
2 x (1.5 kW - 2.2 kW) (2 x (2.2 kW -3 kW)) (2 x (2.2 kW - 3 kW))

Auxiliary voltage (three phase)
Overload current 400 VAC 480 VAC 575 VAC

rating 50/60 Hz 60 Hz 60 Hz
2 x (3 hp - 5 hp) 2 x (5 hp - 7.5 hp)

2 x (6.3 - 10.0 A)
2 x (2.2 kW - 4 kW) (2 x (3 kW - 4 kW)) 2 x (3 kW - 4 kW)
2 x (5 hp- 10 hp) 2 x 7.5 hp - 10 hp

2 x (10.0 - 16.0 A)
2 x (4 kW - 7.5 kW) (2 x (4 kW -9 kW)) (2 x (4 kW - 11 kW))
6.6 Converter cooling

Redundant cooling fan The redundant cooling fan is an option intended for applications where
(ACS 1000A) 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 cooling The redundant cooling fans are an option intended for applications where
fans (ACS 1000i) 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 cooling The water-cooled ACS 1000 can be equipped with a second pump [P2] in
pump (ACS 1000W) 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 The water-cooled ACS 1000 can be ordered with a redundant cooling fan,
(ACS 1000W) 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.
102
3-way valve The cooling unit of the ACS 1000 can be ordered with a 3-way valve in the
(ACS 1000W) 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 The material of the raw water circuit is stainless steel (AISI316).
(ACS 1000W)
Raw water connection Connecting flanges mounted to the right side of the ACS 1000. Counter
flanges (ACS 1000W) flanges are provided.
This option cannot be ordered in combination with the option braking
chopper.
Raw water shut-off Shut-off valves mounted between the connection flanges and their
valves (ACS 1000W) counter flanges.
Space heater for A space heater is typically required in places/countries with high ambient
tropicalized version 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 The air-cooled ACS 1000 can be supplied with air filter mats which have
(ACS 1000A/i) 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 bypass

The 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
Main supply
ACS 1000 frequency converter

12-pulse 3-level Output
Transformer rectifier inverter filter
MCB Sm1
U2
ACS 1000 control
Synchronized
bypass
control
MCB 1 Transformer 1
U11 M1
3-Ph
Sbp1
(if necessary)
Sm2
MCB 2 Transformer 2
U12
M2
3-Ph
Sbp2
(if necessary)
Figure 6-46 Synchronized bypass, single line diagram
Refer to Synchronization Bypass, Installation and Start-up Manual for

further information.
6.8 Auxiliary supply

The 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

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 interfaces

Optional control inputs / Optional I/O boards (IOEC3 and IOEC4) can be ordered for an extended
outputs 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 adapter A fieldbus module may be used for controlling and monitoring the
modules 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.
Temperature Configurable temperature measuring transducers for motor and trans-

transducers for PT100 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 disconnector

Input 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.
Disconnector The following configurations are possible:

configurations
• 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 / output The input and / or output disconnectors are located in an additional cabinet
disconnector 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 software

Additional PC-based software packages for commissioning, monitoring
and diagnostics are available as option:
6.11.1 DriveWindow
DriveWindow 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 Overview
This section provides an overview of mounting requirements such as
clearances and foundation plans as well as information on power
equipment installation.
Links to Other List of references to other documents in this chapter:

Documents
Table 1-2)
7.2 Environmental conditions

Environmental 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 Mounting
Space 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
Converter Above Below Left / right Front Back

type mm / (in.) mm /(in.) mm / (in.) mm / (in.) mm / (in.)
500(1)(2)(3) 0(1) 0(5) 1000(4) 0(6)

ACS 1000A
(20") (0") (0") (39.4") (0")
0/700(1)(2) 0(1) 0(5) 1000(4) 0(6)

ACS 1000W
(0")/(27.6")/ (0") (0") (39.4") (0")
700(1)(2)(3) 0(1) 0(5) 1000(4) 0(6)

ACS 1000i
(27.6") (0") (0") (39.4") (0")
(The dimensions given are minimum values)
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.
72 (2.8) 2928 (115.3)
37.5
(1.5)
875 (34.4)
37.5
62 (2.4) 72
12 (0.5)
20 (0.8)
Figure 7-50 Foundation plan with position of anchor holes: 12-pulse /

24-pulse, ACS 1000A
112
ABB Chapter 7 - Installation guidelines
52 (2) 585.5 (23) 2760 (108.6) 802.5 (31.6)
902
(35.5)
20
(0.8)
12 (0.5)
Figure 7-51 Foundation plan with position of anchor holes: 12-pulse,

ACS 1000W
844 (33.2)
38
(1.5)
902 (35.5)
38
74.5 (2.9) 74.5
Figure 7-52 Foundation plan with position of anchor holes: additional

cabinet for ACS 1000A and ACS 1000W
3300 (129.9)
1096.5
(43.2)
350 350 (13.8)
119.5 119.5 (4.7)
55 (2.2) 55 18 (0.7)
18
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.
Anchor holes
Figure 7-54 Cabinet mounting with bolts and lock washers
Floor levelling and • The ACS 1000 cabinet must be installed in upright position.
cable ducts
• 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.
112
7.4 Power equipment installation
7.4.1 General
The 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
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
The figures indicated in Table 7-14 are valid for transformer and motor
cables. The maximum cable diameter is 45 mm.
7.4.4 Transformer wiring diagram for 12-pulse ACS 1000
PE Transformer
Factory
ground
a1 b1 c1 a2 b2 c2
Shielding Armouring
1U1 1V1 1W1 2U1 2V1 2W1
Factory
ground
PE ACS 1000
Figure 7-57 Typical 3-line transformer wiring diagram.
7.4.5 Transformer wiring diagram for 24-pulse ACS 1000
PE Transformer
Factory
ground
a1 b1 c1 a2 b2 c2 a3 b3 c3 a4 b4 c4
Shielding Armouring
1U1 1V1 1W1 2U1 2V1 2W1 3U1 3V1 3W1 4U1 4V1 4W1
Factory
ground ACS 1000
PE
Figure 7-58 Typical 3-line transformer wiring diagram
112
7.4.6 Motor wiring diagram for 12 / 24-pulse ACS 1000
ACS 1000
Factory V2
ground U2 W2
PE
V W
U
Factory M
ground PE
Figure 7-59 Typical 3-line motor wiring diagram
112
ABB
Chapter 8 - Ordering information
8.1 General
This chapter provides assistance when selecting the appropriate
converter and the included options.

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

The 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 filter
The 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 applications

For 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 code

See Type Code, BHS103412 ZAB E01
8.4 Option list

See Chapter 6 - Options.
8.5 External system data

See Chapter 5 - Engineering information.
8.6 Technical data

See Technical data.
114
ABB
Index
Numerics cable ducts 106

cable entry 108
3-way valve 93
cable routing 107
cable termination 108
A CDP control panel, see control panel
ABB Advant Fieldbus 100, see fieldbus adapter charging fault 36
modules circuit breaker for motor space heater 91
acceleration and deceleration ramps 26 circuit diagram 39
accurate speed control 25 clearance, see space requirements
accurate torque control without speed feed- coated printed circuit boards 85
back 25 common mode choke 45, 48, 53, 58, 88
actual signal monitoring 32 communication fault 37
additional cabinet 48, 64, 66, 86, 87, 90 control cabling 84
air cooling 37 control devices 71
air cooling system ACS 1000W 60 control functions 21–30
air flow 45, 47 control inputs / outputs, optional 96
air-to-water heat exchangers, see heat ex- control interfaces 96
changer control modes 29
alarm handling 33 control panel 69, 70
Allen-Bradley DeviceNet, see fieldbus adapter control section ACS 1000A 49
modules control section ACS 1000i 53
AMC board 69 control section ACS 1000W 57
AMC controller 68 control software 74, 75
AMC operating system (AMCOS), see operat- structure 74
ing system control switches 71
AMCOS, see operating system control system, structure 68
application parameters 25 converter enclosure 63, 85, 103
automatic restart 28 converter information 38
auxiliary interfaces 96 converter section ACS 1000W 57
auxiliary power cables 84 converter selection 113
auxiliary power supply 95 cooling 92–93
auxiliary ride-through, see ride-through cooling unit, main components 61
air cooling fan 61
air-to-water heat exchanger 61
B control system monitoring 61
battery test 38 deionized cooling water treatment 61
bearing temperature 38 expansion vessel 61
braking chopper 90, 93, 96 stainless steel water-to-water heat ex-
braking resistor 90 changer 61
busbars 65 water temperature control valve 61
water-cooling pump 61
cooling water circuit 60
C cooling water treatment circuit 60
cabinet color 86 corrosion protected busbars 85
cabinet layout 44–49 critical speed 27
cabinet paint finish 86
Index 3BHS125029 ZAB E01 Rev. D 115 / 118

ABB
D fuseless design 17
data logger 32
deceleration ramps, see acceleration and de- G
celeration ramps ground fault 37
diagnostics 30, 32 grounding 65
Direct Torque Control (DTC) 16, 21
DTC block diagram 22
DTC performance 24 H
DTC versus vector control 22 Hand/Auto, see macros
methods 22 hardware modules 49–62
scalar control 24 heat exchanger 47, 59, 60, 61, 62, 93
disconnector configurations 98
door interlocking 64, 86
door locks 64 I
DriveMonitorTM 100 I/O board 72, 73, 87, 89, 94, 96
DriveWindow 99 I/O interfaces 72
DTC, see Direct Torque Control (DTC) IGCT 16, 17, 41, 43
comparison of semiconductors 44
input bridges 87
E input disconnector 97
electromagnetic compatibility (EMC) 64 cabinet 98
elementary diagram 39 dimensions 99
emergency off 31 input section ACS 1000i 56
enclosure type 63 input signal source selection, see signal source
environmental conditions 85, 103 selection
equipment grounding 84 Interbus S, see fieldbus adapter modules
Ethernet, see fieldbus adapter modules interlocking, see door interlocking
extended ambient temperature 85 internal cooling water circuit 60
extended grounding busbar 86 internal cooling water treatment circuit 60
extended motor monitoring interface 89 inverter section ACS 1000A 52
I/O signals 89 inverter section ACS 1000i 55
extended raw water temperature 85 inverter temperature 37
extended transformer monitoring interface 87 IOEC, see I/O board
I/O signals 88 IP rating 63, 85
external emergency off 38
external motor protection trip 38
external transformer protection trip 38 L
lifting arrangements 66
load capacity curves, see motor selection
F
local control 30
fault handler 75 local operation 30
fault handling 33
fault logger 32
fieldbus adapter modules 96 M
filter section ACS 1000W 58 macros 30
floor levelling 106 Main Circuit Breaker (MCB) 28, 29, 31, 33, 38,
flux optimization 27 40, 69, 77, 78, 82, 97, 107
flying start 27 control 77
full torque at zero speed 26 control fault 78
Function Chart Builder (FCB) 75 types 77
116 / 118 3BHS125029 ZAB E01 Rev. D Index

ABB
main state machine 75 programmable control locations 28
Master/Follower, see control modes programmable digital outputs 73
measurement loss 37 protection functions 33–38
Modbus, see fieldbus adapter modules PT100, see temperature transducers for PT100
monitored air filter ACS 1000A/i 93 pulse encoder interface 90
monitoring limit values 36
motor cables, see power cables selection
R
motor control 75
motor ID calculation 27 raw water circuit 93
motor overload 36 raw water connection 62
motor phase loss 36 raw water connection flanges 93
motor related functions 27 raw water cooling circuit 60
motor selection 79–82 raw water shut-off valves 93
motor software 75 rectifier section ACS 1000A 53
motor stall 34 redundant cooling fan ACS 1000A 92
motor starter for motor cooling fan / pump 91 redundant cooling fan ACS 1000i 92
motor winding 38 redundant cooling fan ACS 1000W 92
mounting 106 redundant cooling pump 92
reference signal processing, see signal pro-
cessing
N remote control 31
non-quadratic load applications 114 remote operation 30
ride-through 27
O
operating system 37, 74 S
operation 30 safety ground 65
operation modes 29 safety labels 65
optional control inputs / outputs 96 scalable analog inputs 73
output disconnector 98 scalar control 24
cabinet 98 semiconductor, see IGCT
dimensions 99 Sequential control, see control modes
output filter 114 short circuit in the rectifier bridge 36
overcurrent 37 short circuit of the inverter 37
overspeed 35 signal processing 28
overvoltage 36 signal source selection 28
software concept 74
software, see control software
P
space heater for tropicalized version 93
painting 63 space requirements 103
panel application software 75 spare terminals 97
parameter lock 38 speed control functions 25
PID control, see control modes Speed control, see control modes
power cable dimensions 83 split cabinet 86
power cables selection 82 start sequence 31
power loss ride-through, see ride-through stop sequence 31
power range 15 supply phase loss 37
power semiconductor, see IGCT synchronized bypass 93
process stop 38 single line diagram 95
Profibus DP, see fieldbus adapter modules
programmable analog outputs 73
Index 3BHS125029 ZAB E01 Rev. D 117 / 118

ABB
T
temperature transducers for PT100 97
Torque control, see control modes
torsional excitation, see motor selection
transformer cables, see power cables selection
transformer selection 79
tripping loop 34, 78
U
underload 35
undervoltage 35
V
Voltage Source Inverter (VSI) 41
3-level voltage source inverter principle 42
W
water cooling protection function 37
water cooling system 59
water-to-water heat exchanger, see heat ex-
changer
wiring diagram, motor 111
wiring diagram, transformer 110
118 / 118 3BHS125029 ZAB E01 Rev. D Index

ABB
Technical data
Converter types and ratings

Table 1 12-Pulse converter types and ratings
Converter input current *

Converter input voltage
Rated output current *
Rated motor voltage
Rated motor power

ACS 1000 type
3-phase
Weight
UNom
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

Rated motor voltage
Rated motor power

ACS 1000 type
3-phase
Weight
UNom
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
* Depending on the application of the converter, the output current printed on the
rating plate can be different from the value stated for the same converter in this
table.
2 (14) 3BHS213402 ZAB E01 Rev. D ACS 1000A

ABB
Table 2 24-Pulse converter types and ratings

Rated motor voltage
Rated motor power

ACS 1000 type
3-phase
Weight
UNom
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

Rated motor voltage
Rated motor power

ACS 1000 type
3-phase
Weight
UNom
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
table.
Cabinet design data

Length 3000 mm (9 ft 10 in)
Depth 900 mm (3 ft)

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
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 2000 78.7* 870 34.2’ 800++ 31.5 300 661
unit
Braking chopper 644+ 25.3 902 35.5 2005 78.9 460 1014
(placed on the right 2070* 81.5*
side)
Synchronous bypass 644+ 25.3 902 35.5 2005 78.9 460 1014
(placed on the left side) 2070* 81.5*
644+ 25.3 902 35.5 2005 78.9 300...600*** 661...1323***

Extra cabinet
844+ 33.2 902 35.5 2070* 81.5* 300...600*** 661...1323***
* ) 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 transformer +10% / -5%

secondary side voltage
(safe operation with reduced output power possible down to -25%)
variation

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 secondary Maximum length:

cables
• 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 overload 1 min/10 min: 110% of rated current

capacity
Motor cable length Maximum length: 1000 m (3281 ft), longer on request
Acceleration time 0…1800 s
Auxiliary power supply

The 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
A1 A2 A3
Aux. power consumption*

VAC Hz Back-up fuse rating
VA
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
*) Aux. power consumption values without any options
Table 5 1-phase auxiliary power supply for control system
A1 A2 A3
Aux. power consumption*

VA
120 50 / 60 430 500 620 max. 25 A if lcu > 10 kA

230
Table 6 1-phase auxiliary power supply for cabinet space heater
A1 A2 A3
Aux. power consumption

VA
120 50 / 60 300 max. 25 A if lcu > 10 kA

230
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)

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
Output power derating Mesh size Remark
0% 18 μm Standard
5% 12 μm Option
10% 10 μm Option
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).

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 active Restrictions apply according to IEC / EN 60721-3-3 class 3C2

substances
Mechanically active Restrictions apply according to IEC / EN 60721-3-3 class 3S2

substances
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 temperature
The derating factor for air-cooled converters with enclosure class IP21 is
as follows:
Above +40 °C (+104 °F) the rated output current is decreased by 1.5% for
each additional 1 °C (0.85 % for each 1 °F) up to the maximum permitted
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 filters

Depending 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
Mesh size Remark Derating in %
18 μm standard 0
12 μm option 5
10 μm option 10
Derating for redundant cooling fan

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

The rated output power is reduced by 1% for each additional 100 m
(330 ft) at sites higher than 2000 m (6600 ft) above sea level.
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 input
Rin = 210 kΩ for voltage input

ABB
Common mode voltage Maximum 48 V
Isolation voltage 350 VAC
Common mode > 80 dB at 50 Hz

rejection ratio
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
MCB control Switching
Continuous current
voltages (UMCB) current
24 VDC 8A 6A
24 VAC 8A 6A
48 VDC 1A 1A
48 VAC 8A 6A
120 VDC 0.4 A 0.4 A
120 VAC 8A 6A
230 VAC 8A 6A
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)

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 30 kV according to IEC / EN 60071-1 (UL 347)

(BIL Basic Impulse
Insulation Level)
Dielectric withstand 9.6 kV during 1 min. according to UL 347

voltage
Electromagnetic According to IEC / EN 61000-4-2:

compatibility
• Contact discharge: 4 kV
• Air discharge: 15 kV
According to IEC / EN 61000-4-4:
• 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- 15 kA

circuit current

ABB
Technical data

Table 1 12-pulse converter types and ratings
Converter Input current *

Converter Input voltage
Rated motor voltage
Rated motor power

ACS 1000 type
3-phase
Length
Weight
UNom
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
table.
ACS 1000W 3BHS213403 ZAB E01 Rev. D 1 (12)

ABB
Table 2 24-pulse converter types and ratings

Rated motor voltage
Rated motor power

ACS 1000 type
3-phase
Length
Weight
UNom
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
table.
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)
Redundant fan unit 650 25.6 865 34 312++ 12.3 100 220
24-pulse extension 844+ 33.2 902 35.5 2005 78.9 350 771
(placed on the left 2070* 81.5*
side)
Braking chopper 644+ 25.3 902 35.5 2005 78.9 460 1014
side)
(placed on the left 2070* 81.5*
side)
644+ 25.3 902 35.5 2005 78.9 300...600*** 661...1323***

Extra cabinet
844+ 33.2 902 35.5 2070* 81.5*

Primary side voltage Any medium AC voltage level at primary side of converter transformer
Converter transformer +10% / -5%

secondary side voltage (safe operation with reduced output power possible down to -25%)
variation

ABB
Phase shift Phase shift between transformer secondary windings:
Frequency 50/60 Hz
Voltage unbalance ± 2% between phases
Transformer secondary Maximum length:

cables
• 12-pulse:
• 30 m (98ft)
• 24-pulse:
• 20 m (66ft)

Static speed deviation 0.1% of nominal motor speed

capacity
Motor cable length Maximum length: 1000 m (3281 ft)

electronics.

ABB
W1 W2 W3
Aux. Power Consumption*

VAC Hz Back-up Fuse Rating
VA
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

VA
120 50 / 60 800 1100 1100 max. 25 A if lcu > 10 kA

230
W1 W2 W3
Aux. Power Consumption

VA
120 50 / 60 400 max. 25 A if lcu > 10 kA

230
Cooling
Cooling method Closed water-cooled system with additional closed air cooling circuit
Heat dissipation to Approximately 1 kW, based on 27 °C (80 °F) raw water and 32 °C (90 °F)
environment ambient air temperature; up to 7 kW if IP42
Raw water +4…+27 °C (+40…+80 °F)

temperature
Raw water 10 bar (144.2 lb/sq in)

design pressure
Extended raw water +27…+38 °C (+80...+100 °F), higher on request

temperature

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
standards:
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)



substances

substances
Sound pressure level < 70 dB (A)

< 75 dB (A) for cabinets with enclosure protection IP42

ABB
Transport

(200...2000 Hz)
Storage

Derating for raw water temperature

If 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
Cooling water Derating

Converter type
inlet temp. range in % 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
Cooling water Derating
Converter type
inlet temp. range in % per °C
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
Derating for frostproofing

If 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
Frostproofing Glycol concentration Derating in %
-10 °C 20% 4.5

-20 °C 34% 7
-30 °C 44% 9
-40 °C 52% 11.5
Analog inputs
individually scalable by parameter

rejection ratio
Accuracy ± 0.25% (of upper range value) at 25 °C (± 30 mV offset)

ABB
Analog outputs
Signal level 0…20 mA / 4…20 mA, individually scalable by parameter setting
Digital inputs


ABB
Digital outputs
Contact rating
Continuous current
24 VDC 8A 6A
24 VAC 8A 6A
48 VDC 1A 1A
48 VAC 8A 6A
120 VDC 0.4 A 0.4 A
120 VAC 8A 6A
230 VAC 8A 6A

Voltage 24 VDC +15% / -10%


ABB
Application Remotely operated Control Panel, Master/Follower link

Converter tests
Test voltages
Impulse test voltage 30 kV according to IEC / EN 60071-1 (UL 347)

(BIL Basic Impulse
Insulation Level)
Dielectric withstand 9.6 kV during 1 min. according to UL 347

voltage

compatibility

circuit current

ABB

ABB
Technical data

Table 1 Converter types and ratings
Converter Input voltage **
Converter input current **

Nominal motor voltage

Rated motor power
ACS 1000i type
3-phase
Weight
UNom
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
Converter Input voltage **
Converter input current **

Nominal motor voltage

Rated motor power
ACS 1000i type
3-phase
Weight
UNom
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
* The output current depends on the application of the converter. Therefore, the
output current printed on the rating plate can be different from the value stated in
this table.
**Converter input voltage and current depend on the voltage level of the medium
voltage power supply. Besides the shown input voltages, the ACS 1000i is
available 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

Frame size A1
2517 mm (8 ft 3 in) (including fan hood)
2617 mm (8 ft 7 in) (including redundant fan hood and/or IP42)

Frame size A2/A3
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
2 (14) 3BHS213404 ZAB E01 Rev. E ACS 1000i

ABB
Grounding busbar Cross section: 50 x 6 mm
Power cable entry Steel plates without entry holes

plates
(optional: aluminum, brass or stainless steel plates)
Redundant cooling fan 714 28.1 858 33.8 332++ 13.1 100 220
unit
Braking chopper 644+ 25.3 1121 44.1 2005 78.9 460 1014
side)
(placed on the left side) 2070* 81.5*
644+ 25.3 1121 44.1 2005 78.9 300...600*** 661...1323***

Extra cabinet
844+ 33.2 1121 44.1 2070* 81.5* 300...600*** 661...1323***

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.
Converter +10% / -10%

transformer voltage
(safe operation with reduced output power possible down to -25%)
variation
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

ABB

Static speed deviation 0.1% of nominal motor speed

capacity
Motor cable length Maximum length: 1000 m (3281 ft)

electronics.
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

VA
400 ± 10% 50 4500 5400 max. 50 A if lcu > 50 kA
60 6400 8000
480 60 6400 8000

ABB
A1 A2 A3

VA
120 50 / 60 430 500 620 max. 25 A if lcu > 10 kA

230
A1 A2 A3
Aux. Power Consumption

VA
120 50 / 60 300 max. 25 A if lcu > 10 kA
230
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
Derating of output power Mesh size Remark
0% 18 µm Standard
5% 12 µm Option
10% 10 µm Option
Redundant cooling fan The ACS 1000i does not require any derating.

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
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.
standards:
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).


substances

substances
Sound pressure level < 85 dB (A)

ABB
Transport

(200...2000 Hz)
Storage

Ambient temperature
The derating factor for air-cooled converters with enclosure class IP21 is
as follows:
Above +40 °C (+104 °F) the rated output current is decreased by 1.5% for
each additional 1 °C (0.85 % for each 1 °F) up to the maximum permitted
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 filters
Depending 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
Mesh size Remark Derating in %
18 μm standard 0
12 μm option 5
10 μm option 10
Installation site altitude

The rated output power is reduced by 1% for each additional 100 m
(330 ft) at sites higher than 2000 m (6600 ft) above sea level.
Analog inputs
individually scalable by parameter setting

rejection ratio
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

ABB
Digital inputs

Digital Outputs

ABB
Contact rating
Continuous current
24 VDC 8A 6A
24 VAC 8A 6A
48 VDC 1A 1A
48 VAC 8A 6A
120 VDC 0.4 A 0.4 A
120 VAC 8A 6A
230 VAC 8A 6A

Voltage 24 VDC +15% / -10%


ABB
Application Remote operated Control Panel, Master/Follower link

Converter tests
Test voltages
Impulse test voltage Figure 1 illustrates the different converter sections and the voltage levels
and applied to these sections for testing. The light grey areas represent
Dielectric withstand sections which have been tested with the Impulse Test Voltage or the
voltage Basic Impulse Insulation Level (BIL) respectively. Sections which have
been tested with the Dielectric Withstand Voltage are shaded darker.

ABB
Test voltages with open input disconnector

3 4 5 6
For 7.2 kV
28 kV
input voltage
66 kV** 7
1 2
For 12 kV 28 kV
input voltage
75 kV**
Test voltages with closed input disconnector

3 4 5 6
20 kV
For 7.2 kV 9.6 kV
input voltage
45 kV* 60 kV** 7
1 2
For 12 kV 28 kV
input voltage
60 kV** 30 kV
1 Input disconnector
2 Fused contactor
3 Transformer
4 Rectifier
5 DC link
6 Inverter * according to ANSI C57.12.01
7 Sine filter ** according to IEC / EN 60071.1
Figure 1 Test voltages

compatibility

ABB

circuit current

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
techniques - Radiated, radio-frequency, electromagnetic field immunity
test
techniques - Electrical fast transient/burst immunity test
techniques - Surge immunity test
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

Transport

Stationary use at weatherprotected locations
2 (2) 3BHS232441 ZAB E01 Rev. A

Contact us
© Copyright 2009 ABB. All rights reserved. Specifications subject to change without notice. 3BHS125029 ZAB E01 Rev. D.
ABB Switzerland Ltd
Medium Voltage Drives
CH-5300 Turgi
Phone: +41 58 589 27 95
Fax: +41 58 589 29 84
E-Mail: mvdrives@ch.abb.com
www.abb.com/drives

ABB ACS 1000 Tech Catalog RevD

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Technical catalog

Medium voltage AC drive

Chapter 2 - Functional description, operation 21

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

Chapter 4 - Control system and process interfaces 67

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

4.4 Customer I/O interfaces 72

Chapter 5 - Engineering information 77

ACS 1000 Technical catalog 3BHS125029 ZAB E01 Rev. D 5 / 118

Chapter 7 - Installation guidelines 103

7.1 Overview 103

Chapter 8 - Ordering information 113

8.1 General 113

6 / 118 3BHS125029 ZAB E01 Rev. D ACS 1000 Technical catalog

ACS 1000 Technical catalog 3BHS125029 ZAB E01 Rev. D 7 / 118

8 / 118 3BHS125029 ZAB E01 Rev. D ACS 1000 Technical catalog

ACS 1000 Technical catalog 3BHS125029 ZAB E01 Rev. D 9 / 118

10 / 118 3BHS125029 ZAB E01 Rev. D ACS 1000 Technical catalog

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

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

Document number Document title

3BHS223999 ZABE01 Rev. - ACS 1000A Terminal list

3BHS224056 ZABE01 Rev. - ACS 1000i Terminal list

ACS 1000 Technical catalog 3BHS125029 ZAB E01 Rev. D 11 / 116

Document number Document title

3BHS224400 ZABE01 Rev. - ACS 1000W Terminal list

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

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

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

3BHS103412 ZAB E01 Rev. I Type Code

3BHS205465 ZAB E01 Rev. A Wiring and Busbar Specification

1.2 The standard solution

12 / 116 3BHS125029 ZAB E01 Rev. D ACS 1000 Technical catalog

Figure 1-1 ACS 1000A

ACS 1000 Technical catalog 3BHS125029 ZAB E01 Rev. D 13 / 116

Figure 1-2 ACS 1000W

14 / 116 3BHS125029 ZAB E01 Rev. D ACS 1000 Technical catalog

Cement, mining and • Grinding mills

Chemical, oil and gas • Compressors

Metals • Blast furnace blowers

Pulp and paper • Fans and pumps

Power generation • GT starters

Water and waste • Pumps

1.2.1 ACS 1000 types

Rated motor Rated motor

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