VSD ACS 1000 Technical Catalogue

ACS 1000 Medium Voltage AC Drives
for speed and torque control of 315 to 5000 kW / 400 to 6700 hp squirrel cage induction motors
Technical Catalog
Effective: October 23, 2000
ABB Industrie AG. All Rights Reserved.
We reserve all rights to this document, also in the event of patent issue or registration of any other industrial property protection right. Misuse and in particular duplication and forwarding to third parties are not permitted. This document has been checked with care. However, should the user find any errors, they should please be reported to ABB Industrie AG. The data stated in this manual is for product description purposes and does not represent assured characteristics. As we aim to keep our products up to the most modern standard, differences may occur between entries in this technical catalog and the actual product.
ACS 1000 Technical Catalog
Table of Contents
Chapter 1 - Overview 1.1 1.2 1.3 1.4 1.5 Introduction The Standard Solution Key Technology Technical Benefits ACS 1000 Types 7 7 7 7 8 9
Chapter 2 - Main Features 2.1 2.2 2.3 2.4 2.5 2.6 IGCT Power Semiconductors Fuseless Design Direct Torque Control Input Stage Output Stage Elementary Diagram
11 11 11 12 13 13 14
Chapter 3 - Hardware Description 3.1 3.2 3.2.1 3.2.2 3.2.3 3.3 3.4 3.5 3.6 3.7 3.8 Electromagnetic Compatibility ACS 1000 Cabinet Layout Air-cooled Type Water-cooled Type Power Terminals Control Equipment Door Locks IP Ratings Lifting Arrangements Standard Color Additional Cabinets
17 17 17 17 19 20 21 22 23 23 23 23
Chapter 4 - User Interfaces 4.1 4.2 4.3 4.4 4.5 Overview CDP 312 Control Panel Standard I/Os Fieldbus Adapter Modules PC Tools
25 25 25 26 31 31
Chapter 5 - Parameters and Application Macros 5.1 5.2 5.3 Overview Suitable Applications for Different Macros Macro I/O interfaces
33 33 33 36
Chapter 6 - Standard Functions 6.1 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.3 6.3.1 6.3.2 6.3.3 6.4 6.4.1 General Standard Control Functions General Functions Main Circuit Breaker Control Local and Remote Control Diagnostics Programmable Digital and Analog Outputs Scalable Analog Inputs Input Signal Source Selections and Signal Processing Standard Protection Functions Programmable Fault Functions Pre-programmed Protection Functions Other Protection Functions Other Functions Customer Specific Options
39 39 39 39 42 42 43 43 44 44 45 45 47 49 49 50
Chapter 7 - Options 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 Environmental Conditions Converter Enclosure Input Section Motor Side Converter Cooling Converter Isolators and Bypass Auxiliary & Control Interfaces PC Tools
51 51 51 52 53 56 59 61 61
Chapter 8 - Selecting the Drive System 8.1 8.2 8.2.1 8.2.2 8.2.3 8.3 Overview Main Circuit Breaker Main Circuit Breaker Control Tripping Loop Main Circuit Breaker Features Converter Input Transformer Selection
63 63 63 63 64 65 68
8.4 8.4.1 8.4.2 8.4.3 8.5 8.5.1 8.5.2 8.5.3 8.5.4
Selection of the ACS 1000 Converter ACS 1000 Output Filter Non Quadratic Load Applications ACS 1000 Selection Tables Motor Selection Load Capacity Curves Selection Criteria Retrofit Torsional Excitation
69 69 69 70 73 73 74 74 75
Appendix A - Installation Guidelines Ambient Conditions Mounting Power Equipment Installation General Transformer Primary Cables Transformer Secondary Cables Motor Cables Power Cable Dimensions Equipment Grounding Auxiliary Power Cables Control Cables Cable Routing ACS 1000 Cable Entry and Termination Transformer Connection Diagram for 12-pulse ACS 1000 Transformer Connection Diagram for 24-pulse ACS 1000 Motor Connection Diagram for 12 / 24-pulse ACS 1000
77 77 77 80 80 81 81 82 82 82 82 83 83 84 85 85 86
Appendix B - Technical Data Transformer Connection / Converter Input Converter Output / Motor Connection Auxiliary Supply Environmental Aspects Derating of Drive Power Air-cooled Converters Water-cooled Converters Transportation and Storage Cooling Air-cooled Converters Water-cooled Converters
87 87 88 88 89 90 90 91 91 92 92 92
Protection Functions Analog Inputs Analog Outputs Digital Inputs Digital Outputs Auxiliary Power Output Reference Voltage Output DDCS Fiber Optical Link Enclosures
93 94 94 95 95 95 96 96 96
Appendix C - Dimensions and Weights
97
Appendix D - Applicable Codes and Standards CE Marking Low Voltage Directive Machinery Directive EMC Directive Emissions Immunity UL Marking Applicable Codes and Standards
101 101 101 101 102 102 102 103 103
Appendix E - ACS 1000 Type Code
105
Chapter 1 - Overview
1.1 Introduction
This Technical Catalog describes the main electrical, mechanical and environmental features of the ACS 1000 ABBs contribution to new solutions of medium-voltage AC drives. In addition, the Catalog looks at the various options available for the drive and offers advice on selecting a motor and drive combination. It also provides useful installation tips.
1.2
The Standard Solution

The ACS 1000 is a standard, medium-voltage AC drive, rated from 315 to 5000 kW (400 to 6700 hp) for motor voltages of 2.3, 3.3 and 4.0 kV. The drive has been designed as a standard product rather than an engineered drive. It is, therefore, a core product of ABB, forming part of the companys ACS family. As such, the drive uses standard components, software tools and design principles as employed in the low voltage ACS range. This vastly increases the reliability of the drive and offers users a consistent addition to the extensive ACS product range. As a standard solution the ACS 1000 has many of the benefits associated with engineered drives already included. This meets the most common system specifications with minimal engineering. In addition, because the drive is pre-engineered, shorter delivery times to end-users are possible. About 85% of all medium-voltage drives are applied in standard applications 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 worlds motors are fitted with drives. Industries, which can benefit from this approach, include oil and gas, mining, water, pulp & paper, cement and power generation.
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 the ultimate torque and speed performance. DTC allows the speed of any standard squirrel cage induction motor to be controlled without the need for expensive and fragile encoders or tachogenerator feedback devices.
For the first time in any AC drive, a new power semiconductor switching device is utilized. Known as IGCT (Integrated Gate Commutated Thyristor), the device provides an intrinsically less complex, more efficient and reliable drive. This is achieved by fast switching and inherently low losses which mean less cooling equipment is needed. IGCTs do not require snubber circuits and allow power bridge implementation with fewer power devices than conventional mediumvoltage drives. 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 LC filter results in a sinusoidal output voltage. This proves useful in retrofit applications, as the drive is compatible with existing squirrel cage motors without the need to derate it. There are no undue voltage rises stressing the motor insulation and voltage reflections are eliminated on long cable runs. Furthermore, DTC avoids any torque pulsations, which can be damaging to loads and their associated mechanical connections. The ACS 1000 is available for use with a separately mounted input 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 undertaken much development work to ensure that the converter adequately meets the requirements of the worlds harmonics standards, such as IEEE 519-1992. For details please refer to Appendix D - Applicable Codes and Standards. The ACS 1000 features a selection of pre-programmed and standardized application macros for the configuration of inputs, outputs, signal processing and other parameters.
1.5
ACS 1000 Types

The ACS 1000 is available as air-cooled and water-cooled types. The aircooled ACS 1000 covers rated power outputs from 400 HP to 2250 HP (315 kW to 1600 kW). For higher power output ratings ranging from 2500 HP to 6700 HP (1800 kW to 5000 kW), the converters are watercooled. The ACS 1000 converter is available for 3 different medium voltage levels. These are the standard motor voltages of 2.3 kV, 3.3 kV and 4.0 kV. For information on solutions for retrofit applications with motor voltages of up to 7.2 kV please contact your ABB representative. The table below provides an overview of the rated output power range, covering air and water-cooled converters for all three medium voltage levels. For further details, refer to Chapter 8 - Selecting the Drive System. Table 1-1
Motor Voltage (kV) 2.3 2.3 3.3 3.3 4.0 4.0 Air Water Air Water Air Water
Standard power ranges for ACS 1000 converters

Rated Motor Power Range** HP 400 - 2250 2500 - 4000 450 - 2250 2500 - 6700 400 - 2250 2500 - 6700 Max. cont. Power of ACS 1000 (kVA) 400 - 2000 2300 - 3600 400 - 2150 2400 - 5950 400 - 2000 2300 - 5800
Type of Cooling
Frame Size
A1 - A3 W1 - W2 A1 - A3 W1 - W3 A1 - A3 W1 - W3
** The power ratings apply to typical 4 pole motors. For those motors the frequency converter has a built-in overloadability of 10%. When selecting the frequency converter it should be observed that the rated current of the ACS 1000 must be higher than or equal to the rated motor current in order to achieve the rated motor power given in the table. Note: For air-cooled units (with enclosure class IP21) the load capacity (current and power) depends on the altitude and the ambient temperature at the installation site. In case of water-cooled units the load capacity depends on the cooling water temperature at the installation site. For details on the derating factors, see Appendix B - Technical Data.
10
Chapter 2 - Main Features

2.1 IGCT Power Semiconductors
ABB researched and designed the Integrated Gate Commutated Thyristor (IGCT) specifically for the medium voltage market. IGCTs provide high speed switching like IGBTs (Insulated Gate Bipolar Transistors) and at the same time provide high voltage blocking and low loss conduction like GTOs (Gate Turn-Off Thyristors). The result is a fast, low loss device that can be used at medium voltage levels without resorting to series topologies. It transcends both of the older technologies from which it evolved. IGCTs also provide other benefits: Freewheeling diode is integrated into the same package Snubber circuits are not required Gating circuitry is packaged with the power device High reliability (low total parts count) High power density (combination of low total parts count and low power losses) Self-protecting against destructive failures.
All these features combined provide a medium voltage power switching device with the best combination of performance, reliability, efficiency, and space effectiveness available in the market today.
2.2
Fuseless Design
The ACS 1000 features a fuseless protected medium voltage drive. The patented design uses the new power semiconductor switching device, IGCT, for circuit protection. The IGCT, which is placed between the DC-link and the rectifier, can, unlike conventional fuses, directly isolate the inverter of the drive system from the power supply side. This is achieved within 25 microseconds, which is 1000 times faster than the operational performance of fuses. Using the IGCT as an integrated protection device leads to a lower parts count within the drive system making the ACS 1000 a drive with outstanding reliability. The reason why IGCTs are capable of performing a protection function, unlike other power semiconductor devices, lies in their low onstate losses and their ability to turn off at high speed at medium voltage levels.
11
2.3
Direct Torque Control

Direct Torque Control (DTC) is a unique motor control method for AC drives. The inverter switching is directly controlled according to the motor core variables flux and torque. The measured motor current and DC-link voltage are inputs to an adaptive motor model which produces exact actual values of torque and flux every 25 microseconds. Motor torque and flux comparators compare actual values to the reference values produced by the torque and flux reference controllers. Depending on the outputs from the hysteresis controllers, the pulse selector directly determines the optimum inverter switch positions.
Mains Rectifier Internal torque reference Torque Control status signals Torque comparator Flux comparator Actual torque Switch Actual flux positions Adaptive motor model Internal flux reference Flux status Switch position commands DC bus Optimum pulse selector
Speed controller + acceleration compensator
Torque reference Speed reference PID
Torque reference controller
= ~ Inverter
ASIC
Flux reference controller

U f U T f f
Output filter
Actual speed DC bus voltage (4 measurements)
Inverter current
Filter current (3 measurements)
M 3~
Figure 2-1 DTC block diagram
12
How does DTC differ from PWM Flux Vector Drives?
In DTC, each switching instance is determined separately based on the values of flux and torque, rather than switching in a predetermined pattern as in conventional PWM flux vector drives. Table 2-1 DTC versus PWM Flux Vector controlled drives
DTC Switching based on core motor variables Flux and Torque Flux Vector Switching based on separate control of magnetising and torque producing components of current Mechanical speed is essential. Requires shaft speed and position (either measured or estimated) Inverter switching based on average references to a PWM modulator. This results in delays in response and wasted switchings. Torque Step Rise Time Closed Loop 10 to 20 msec. Sensorless 100 to 200 msec.
Shaft speed and position not required
Each inverter switching is determined separately (every 25 s).
Torque Step Rise Time (open loop) is less than 10 msec.
For more information on DTC, please refer to the Technical Guide No. 1 Direct Torque Control (3AFY 58056685 R0025).
2.4
Input Stage
The ACS 1000 features a 12-pulse diode rectifier input stage. This is adequate for most networks and normally meets the harmonic requirements demanded by standards such as IEEE 519. For networks that are more demanding, the ACS 1000 can be supplied optionally with a 24-pulse configuration for water-cooled and for air-cooled types.
2.5
Output Stage
As a standard the ACS 1000 is equipped with a low pass LC sine filter in its output stage. Current feedback is used to actively control filter operation. The low pass frequency is designed to be well below the lowest switching frequency used by the inverter output stage. This greatly enhances the purity of both the voltage and current waveforms applied to the motor. This in turn provides many important benefits: Harmonic heating is virtually eliminated. The drive may be used to supply standard medium voltage motors (existing or new) without applying thermal derating factors.
13
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 not limited by the ACS 1000 (normal voltage drop restrictions as found in any electrical installation still apply). Motor bearing failures attributable to capacitively coupled high 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 drive topologies.
2.6
Elementary Diagram
Figure 2-2 and Figure 2-3 show the elementary circuit diagram of the 12pulse and the 24-pulse versions of the ACS 1000. The 3-phase AC line voltage is supplied to the rectifier bridges through the 3-winding converter transformer. In order to obtain 12 or 24-pulse rectification, appropriate phase shift is necessary between the secondary windings of the transformer. The two fuseless rectifier bridges in the 12-pulse scheme (Figure 2-2) are connected in series, such that the DC voltages are added up. Therefore, the full DC bus current flows through both bridges. In the 24-pulse scheme, 2 such bridge arrangements are connected in parallel as shown in Figure 2-3.
(Option)
3 Main Circuit Breaker
Converter Transformer
NP
Medium Voltage Switchgear
Diode Rectifier
Protection Intermediate IGCTs DC Link
Three Level Inverter
Output Sine Filter
Squirrel Cage Induction Motor
Figure 2-2 Elementary diagram - ACS 1000, 12-pulse version
14
(Option)
3 Main Circuit Breaker
Converter Transformer
NP
Medium Voltage Switchgear
Diode Rectifier
Protection Intermediate IGCTs DC Link
Three Level Inverter
Output Sine Filter
Squirrel Cage Induction Motor
Figure 2-3 Elementary diagram - ACS 1000, 24-pulse version Each leg of the 3-phase inverter bridge consists of a combination of 2 IGCTs for 3-level switching operation: with the IGCTs the output is switched between positive DC voltage, neutral point (NP) and negative DC voltage. Hence both the output voltage and the frequency can be controlled continuously from zero to maximum, using Direct Torque Control. At the converter output a LC filter is used for reducing the harmonic content of the output voltage. With this filter, the voltage waveform applied to the motor is nearly sinusoidal (see Figure 2-4). Therefore, standard motors can be used at their nominal ratings. The filter also eliminates all high dv/dt effects and thus voltage reflections in the motor cables and stresses to the motor insulation are totally eliminated.
ACS 1000
Output voltage: 4.16kV Output frequency: 60Hz
Figure 2-4 Voltage and current waveforms at converter output
15
16
Chapter 3 - Hardware Description

3.1 Electromagnetic Compatibility
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 electromagnetic emissions. The design fulfils the requirements of international standards like UL 347A. For details please refer to Appendix D - Applicable Codes and Standards. Electromagnetic Compatibility (EMC) has been achieved by applying a cabinet design consisting of folded, galvanized sheet metal plates and minimizing the spacing between the rivets. The cabinets inside walls are not painted, because paint tends to reduce the effectiveness of metallic bonding which is paramount to successful EMC. Accordingly, only the front of the ACS 1000 cabinet is painted while all other walls are galvanized. However, the cabinet can be ordered optionally with the whole of the outside painted. EMC performance is further enhanced by the use of metal cable channels.
3.2
ACS 1000 Cabinet Layout
3.2.1
Air-cooled Type
The air-cooled type of the ACS 1000 is designed with inverter stacks, output filter and DC-link capacitor in one section (see Figure 3-1). This section experiences maximum air flow which is advantageous for the temperature sensitive capacitors. The construction of the inverter stacks allows easy exchange of IGCTs by means of a specially designed tool which is part of the supply. The middle section accommodates cooling fan, rectifier stack, protection IGCTs and filter reactor. The construction is such that the fan can be exchanged easily. The air intake is provided with an air filter in order to prevent dust and particles from entering into the converter. The air filter can be replaced from outside while the drive system is in operation.
17
Figure 3-1 The ACS 1000 air-cooled type (12 / 24-pulse) 1 2 3 4 Control section with separate power cable connection section Grounding switch and filter reactor section (24-pulse version with additional rectifier stack) Rectifier stack, protection IGCTs and cooling fan Inverter stacks, air intake, output filter and DC-link capacitors
18
3.2.2
Water-cooled Type
12-pulse Version The water-cooled type of the ACS 1000 (see Figure 3-2) is equipped with a closed circuit water cooling system. Part of the cooling system is a fan and an air-to-water heat exchanger to maintain cooling of all components which cannot be cooled by water. As with the air-cooled type, the construction of the inverter stacks allows easy exchange of IGCTs by means of a specially designed tool which is part of the supply.
Figure 3-2 The ACS 1000 water-cooled type (12-pulse) 1 2 3 4 5 Control section with separate power cable connection section Filter and DC components section (grounding switch, filter reactor and filter capacitors, DC-link capacitors, common mode choke) see item 2 Converter section (rectifier stack, protection IGCTs, inverter stacks) Cooling unit
19
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.
3.2.3
Power Terminals
The leftmost section (Figure 3-1 and Figure 3-2) contains the swing frame with the control equipment (see Section Control Equipment, page 21). Behind this swing frame and a protective separation door is the drives power terminal section with busbars for mains and motor cables. To provide optimum access to the power terminals, the swing frame can be opened more than 120. Please refer to Appendix A - Installation Guidelines for further details on cable entry and connection.
20
3.3
Control Equipment
The layout of the control cabinet is identical for all converter types. The control hardware (processor and communication boards) are mounted on the swing frame. Details can be seen in Figure 3-3. The customer I/Os are located behind the swing frame on the right side wall (see Figure 3-4). Terminals for customer control and protection signals as well as for auxiliary power supply are also located there.
Swing frame Electronic power supply board (EPS) AMC3 control board
Interface board
Pulse encoder Fieldbus interface IOEC1 board p-transmitters (air- cooled converters only)
Motor starters and circuit breakers Aux. supply transformer Batteries
Figure 3-3 Control section with open front door
21
IOEC2 board (standard) Terminals for aux. voltages, control signals and tripping loop Access door to power cable connection section IOEC3 board (standard for water-cooled converters)
IOEC4 board (optional)
Figure 3-4 Control section with swing frame removed
3.4
Door Locks
All doors are hinged and locked using carriage key locks. The doors of the power sections of the drive 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 drive unless the doors are closed and the safety grounding switch has been opened.
22
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 drives tripping loop. If any of the doors are opened during operation, the MCB will be tripped immediately.
3.5
IP Ratings
The standard ACS 1000 cabinet is rated IP21 for air-cooled and IP 31 for water-cooled types. Higher IP ratings are available as options. See Chapter 7 - Options for further details.
3.6
Lifting Arrangements
The cabinets are fitted with lifting lugs as standard.
3.7
Standard Color
The standard color is RAL 7035 (light grey). Other colors are available on request.
3.8
Additional Cabinets
The ACS 1000 cabinet system provides the flexibility to add further sections to the converter at any time. Sections can be added in width of 600, 800 and 1000 mm (24, 32 and 39 inches).
23
24
Chapter 4 - User Interfaces

4.1 Overview
The ACS 1000 can be controlled from several control locations: The detachable CDP 312 control panel mounted on the ACS 1000 front door of the control section External control devices, e.g. a supervisory control system, connected to the analog and digital I/O terminals on the standard I/O Boards (IOEC) Fieldbus adapter modules PC Tools (DriveWindow and DriveSupport) hooked up via a PC adapter to the ACS 1000 control board.
4.2
CDP 312 Control Panel

The CDP 312 Control Panel is the basic user interface for monitoring, adjusting parameters and controlling the ACS 1000 converter operation.
Enclosure class IP54 when attached to the Control Panel Mounting Platform
Control Panel Display
1 L -> CURRENT SPEED TORQUE
1242rpm I 76.00 A 1242.0rpm 86.00 %
Multilingual Alphanumeric Display (4 lines x 20 characters) Plain text messages available in several languages
ACT
PAR
FUNC
DRIVE
Control Panel Mode Selection keys Double Up Arrow, Up Arrow Enter Double Down Arrow, Down Arrow Local/Remote, Reset, Reference and Start keys Forward, Reverse and Stop keys
ENTER
Control Panel Keypad
LOC REM
RESET
REF
Figure 4-1 CDP 312 Control Panel
25
Using the CDP 312 panel it is possible to enter start-up data into the drive set a reference signal and give Start, Stop and Direction commands display actual values (three values can be read simultaneously) display and adjust parameters display information on the most recent forty fault events.
4.3
Standard I/Os
The standard I/O-boards offer a number of pre-programmed analog and digital I/Os which are sufficient for most applications. For a wider range of signal interfaces optional I/O-boards can be ordered for water and aircooled ACS 1000 to provide extended protection for transformer and motor, external cooling equipment (e.g. fans, chillers), on-line synchronization logic and other customer requirements. The air-cooled ACS 1000 is equipped with two I/O-boards (IOEC1 and IOEC2) as a standard with the option of two additional I/O-boards (IOEC3 and IOEC4). The water-cooled ACS 1000 is equipped with three I/Oboards (IOEC1, IOEC2, IOEC3) with the option of one aditional I/O-board (IOEC4). All I/O-boards are identical in design with the same number of I/Os. The analog and digital I/Os are floating and galvanically isolated with ratings as indicated in Table 4-1. While the function of digital and analog inputs are fixed and cannot be altered, the signals allocated to digital and analog outputs can be changed by setting the corresponding parameters accordingly. Table 4-1
Number 4 2 14 6
I/O Board configuration with number and type of I/O

Signal Type Analog Inputs Analog Outputs Digital Inputs Digital Outputs (AI) (AO) (DI) (DO) Ratings 0...20 mA / 4...20 mA or 0...10 V / 2...10 V scalable by parameter setting 0...20 mA / 4...20 mA scalable by parameter setting Opto-coupled, rated for 22...250 VAC or 22...150 VDC With switch-over contact (SPDT), rated for 250 VAC, 2 A
26
Standard I/Os are marked in the following tables with a dot ( ). The letter (W) indicates that these I/Os are standard for the water-cooled ACS 1000. A signal name beginning with a slash (/) indicates a signal which is true when its status is low.
i
Table 4-2
Type DI DI DI DI DI DI DI
I/O Signals: remote control interface

Signal Name Remarks Macro specific I/O * Macro specific I/O * Macro specific I/O * Macro specific I/O * Macro specific I/O * Macro specific I/O * Remote input to disable the possibility for a local/remote switch-over from the CDP 312 control panel Remote request for closing the main circuit breaker Remote request for opening the main circuit breaker Remote fault reset (some converter related faults cannot be reset remotely) Status output Drive Ready (i.e. MCB closed, DC-link charged, no lockout active) Status output Drive Running Status output Drive Alarm Status output Drive Tripped Local mode operation status indication Macro specific I/O Standard
STANDARD INPUT 1 STANDARD INPUT 2 STANDARD INPUT 3 STANDARD INPUT 4 STANDARD INPUT 5 STANDARD INPUT 6 DISABLE LOCAL
DI DI DI
REM ORD MCB CLOSE REM ORD MCB OPEN REMOTE RESET
DO
DRIVE READY
DO DO DO DO AI
DRIVE RUNNING DRIVE ALARM DRIVE TRIP LOCAL MODE REF VALUE 1
27
Table 4-2
Type AI AO AO
I/O Signals: remote control interface (continued)

Signal Name Remarks Macro specific I/O Actual speed monitoring output Actual current / torque monitoring output (programmable) Standard
REF VALUE 2 SHAFT SPEED ACT VAL MOT CURRENT ACT VAL / MOT TORQUE ACT VAL
* see Chapter 6 - Standard Functions
Table 4-3
Type DI DI DI
I/O Signals: main circuit breaker

Signal Name Remarks Status feedback from the main circuit breaker Status feedback from the main circuit breaker Status feedback from the main circuit breaker, showing that the breaker is faulty, drawn-out or in test position Drive command to close the main circuit breaker (pulse signal or maintained) Drive command to open the main circuit breaker (pulse signal or maintained) Hardware tripping loop to the main circuit breaker (signal active when low) Standard
MCB IS CLOSED MCB IS OPEN MCB IS AVAILABLE
DO
MCB ORD CLOSE
DO
/MCB ORD OPEN
DO
/MCB ORD TRIP
Table 4-4
Type DI
I/O Signals: transformer

Signal Name Remarks Initiates a main circuit breaker trip (included in hardwired tripping loop) Transformer oil level alarm indication W Standard
/EXT TRAFO PROT TRIP
DI
OIL LEVEL ALARM
28
Table 4-4
Type DI
I/O Signals: transformer (continued)

Signal Name Remarks Transformer oil temperature alarm indication Transformer winding temperature alarm indication Transformer oil temperature trip indication Transformer winding temperature trip indication Transformer alarm indication from Buchholz relay Transformer trip indication from Buchholz relay Temperature measurement of transformer oil Temperature measurement of transformer winding W Standard W
OIL TEMP ALARM, or
TRAFO WDG TEMP ALARM DI /OIL TEMP TRIP, or /TRAFO WDG TEMP TRIP DI DI AI BUCHHOLZ ALARM /BUCHHOLZ TRIP OIL TEMP, or TRAFO WDG TEMP
W W W
Table 4-5
Type DI
I/O Signals: motor

Signal Name Remarks Initiates a main circuit breaker trip (included in hardwired tripping loop) (External) motor protection alarm indication (External) motor cooling alarm indication (External) motor cooling trip indication Motor vibration alarm indication Motor vibration trip indication Motor overspeed trip (included in hardwired tripping loop) Motor winding temperature Motor winding temperature Motor winding temperature W W W W W W Standard
/EXT MOT PROT TRIP
DI DI DI DI DI DI
EXT MOT PROT ALARM MOT COOLING ALARM /MOT COOLING TRIP VIBRATION SV ALARM /VIBRATION SV TRIP /OVERSPEED TRIP
AI AI AI
MOT WDG TEMP PH U MOT WDG TEMP PH V MOT WDG TEMP PH W
29
Table 4-5
Type AI AI
I/O Signals: motor (continued)

Signal Name Remarks Motor bearing temperature of driven end Motor bearing temperature of non-driven end Standard W W
BRG TEMP DE BRG TEMP NDE
Table 4-6
Type DI
I/O Signals: process

Signal Name Remarks Remote process stop input to stop the drive (signal active when low) Emergency OFF (signal active when low) from process side to trip the main circuit breaker instantaneously (included in hardwired tripping loop) Standard
/PROCESS STOP
DI
/INT/EXT EMERGENCY OFF
Table 4-7
Type DI
I/O Signals: Others

Signal Name Remarks Trip from external voltage unbalance relay (signal active when low) Alarm indication from external water cooling unit Trip (active when low) from external water cooling unit Alarm signal from braking chopper Trip signal from braking chopper Status input Status input Status input Status input Temperature measurement of outside air Standard
/SUPPL VOLT UNBALANCE
DI DI DI DI DI DI DI DI AI
EXT WTR COOLING ALARM /EXT WTR COOLING TRIP BRAKE CHOP FAN ALARM BRAKE CHOP TEMP TRIP INPUT ISOLATOR OPEN INPUT ISOLATOR CLOSED OUTPUT ISOLATOR OPEN OUTPUT ISOLATOR CLOSED OUTSIDE AIR TEMP
30
4.4
Fieldbus Adapter Modules

A fieldbus module may be used for controlling and monitoring the ACS 1000 instead of using the conventional hard-wired I/Os. There are several fieldbus adapter modules available for the ACS 1000. For further details, see Chapter 7 - Options.
4.5
PC Tools
DriveWindow offers several functions for commissioning and monitoring ABB products. All the functions are available from the Menubar or the Toolbar of the program. In DriveWindow the user has the choice between two special displays and six different tools. For further details, see Chapter 7.8 PC Tools.
31
32
Chapter 5 - Parameters and Application Macros

5.1 Overview
Parameters allow the user specific configuration of the ACS 1000. They can be set using the CDP 312 control panel. The application macros consist of pre-programmed parameter sets that are adapted for a specific application. They offer pre-set signal interfaces for opening/closing the main circuit breaker, starting/stopping the drive system and setting reference values. Depending on the process, the appropriate macro can be selected, thus enabling a quick and easy start-up of the ACS 1000. Using an application macro has the advantage that the number of individual parameters to be set during start-up is minimized. All parameters have factory-set default values. Leaving them unchanged, a good system performance is achieved in typical situations. These default values can be left unchanged or they can be set individually according to the needs of the customer. The ACS 1000 can be operated with one of the following standard macros: Factory Speed Control Hand/Auto PID Control Torque Control Sequential Control Master/Follower User 1 User 2
5.2
Suitable Applications for Different Macros

Factory The Factory Macro is the default-set macro. It covers most of the common applications, such as: Pump, fan and other industrial processes with a square torque characteristic Conveyors and other industrial drives requiring constant torque.
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Speed Control
The Speed Control Macro is essentially the same as the Factory Macro. The only difference to the Factory Macro is that a loading of the Speed Control Macro will not affect the currently set motor control parameters (when loading the Factory Macro all parameters will be reset to their default value). The Hand/Auto Macro is suitable for applications where the speed has to be controlled automatically by a process control system and manually by an external control panel. The active control location is selected via a digital input. The macro is also recommended when the drive has to be controlled from two external control stations. The active control station for starting /stopping and setting of the reference value is selected via a digital input.
Hand/Auto
PID Control
The PID Macro is intended for the use with closed loop control systems such as pressure control, level control and flow control. For example: Booster pumps of municipal water supply systems Booster pumps of district heating systems Automatic level control of water reservoirs Speed control of different types of material handling systems where the material flow has to be regulated.
The PID-controller is incorporated into the ACS 1000 software. It is activated by selecting the PID Macro. A process reference value is set via an analog input or by using the control panel of the ACS 1000. The actual process value is connected to a dedicated analog input. The internal PID-controller of the ACS 1000 eliminates the need of a separate PID-controller (no additional installation and wiring required).
ACS 1000 converter
Reference
Level Transducer Actual Value
Pump
Figure 5-1 Example of an application with PID control loop
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Torque Control
The macro is intended for processes requiring torque control, e.g. mixers and slave drives. The torque reference comes from a process automation system or a control panel. The Sequential Control Macro is aimed for processes where different constant speed settings and/or different acceleration/deceleration ramps are required in addition to an adjustable speed reference value. The different settings can be selected automatically by a process control system or they can be activated manually by selector switches which are connected to the corresponding digital inputs. The Master/Follower Macro is designed for applications with several ACS 1000 where the motor shafts are coupled to each other by gearing, chain, belt etc. Thanks to the Master/Follower macro the load can be evenly distributed between the drives or depending on the process at some other ratio. The User Macro 1 and 2 allows to save a complete set of customized parameters and to recall it at a later instant or to download it to another ACS 1000.
Sequential Control
Master/Follower
User 1 / User 2
35
5.3
Macro I/O interfaces

The following tables give an overview of the pre-set digital and analog inputs and outputs, regarding opening/closing the main circuit breaker, starting/stopping the drive system, setting reference values and status feedback signals. All other customer interface signals are the same for each application macro, see Chapter 4 - User Interfaces. All macro specific I/Os are available on the standard IOEC boards. Only the PID macro requires IOEC 4 board. Table 5-1 Macro specific digital and analog inputs
I/Os DI I/O functions MCB open/close commands Start/ stop commands Selection of direction Selection of 2 accel/decel ramps Selection of 2 const. speeds Process stop or run enable 2 speed reference values Selection of hand/auto mode MCB open/close commands in hand mode MCB open/close commnands in auto mode Start/ stop commands in hand mode Start/stop commands in auto mode Selection of 1 const. speed Process stop or run enable Speed reference value in hand mode Speed reference value in auto mode MCB open/close commands Start/stop commands Selection of direction Selection of reference value Selection of 2 accel/decel ramps Selection of 3 const. speeds Process stop or run enable Reference value Actual value, process feedback Actual value process feedback MCB open/close commands Start/stop commands Selection of speed/torque control Selection of 2 accel/decel ramps Selection of 1 constant speed Process stop or run enable Speed reference value Torque reference value
Macro Factory Speed
AI Hand/Auto DI
AI PID DI
AI
Torque
DI
AI
36
Table 5-1
Macro specific digital and analog inputs (continued)

I/Os DI I/O functions MCB open/close commands Start/stop commands Selection of 2 accel/decel ramps Selection of 7 const. speeds Process stop or run enable Reference value MCB open/close command Start/stop command Selection of 1 accel/decel ramp Selection of 3 const. speeds Process stop or run enable Speed reference value Depends on application
Macro Sequential
AI Master Follower DI
AI User 1 / User 2
The pre-set digital and analog outputs available for external use are the same for each macro. Table 5-2 Macro specific digital and analog outputs
I/Os DO Drive ready Drive running Drive alarm Drive trip Motor frequency Motor torque Motor speed Motor torque filtered I/O functions
Macro Factory Speed PID Torque Sequential Master/Follower
AO
37
38
Chapter 6 - Standard Functions

6.1 General
The ACS 1000 is configured and customized by means of application parameters. These parameters can be altered by the user, either by means of the integrated CDP 312 control panel or by using a PC and the DriveWindow software package, as described in Chapter 7 - Options. Control and monitoring functions of the ACS 1000 can be activated by setting parameters one by one or by invoking an Application Macro (see Chapter 5 - Parameters and Application Macros) which is optimized for a particular application. Therefore some of the functions described in this chapter will be configured automatically if an application macro is selected. This chapter provides information about the standard control, monitoring and protection functions for the ACS 1000. A description of the basic I/O devices and the application macros of the ACS 1000 can be found in Chapter 4 - User Interfaces and Chapter 5 - Parameters and Application Macros.
6.2
Standard Control Functions
6.2.1
General Functions
Based on the nameplate data all ACS 1000 internal motor control parameters will be automatically calculated. This procedure is usually performed once during commissioning. However, the procedure can be repeated whenever required (e.g. when the ACS 1000 will be hooked up to another motor). A motor fed by the ACS 1000 can develop short-term motor nominal torque at start-up without any pulse encoder or tachogenerator feedback. This feature is essential for constant torque applications. However, if permanent operation at zero speed is required, a pulse encoder has to be used. 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.
Motor ID Calculation
Full Torque at Zero Speed
Enhanced Flying Start
39
Flux Optimization
Flux optimization of the ACS 1000 reduces the total energy consumption and motor noise level when the drive operates below the nominal load. The total efficiency (ACS 1000 and motor) can be improved by 1...10%, depending on the load torque and speed. This function is activated by parameters. If the incoming supply voltage is cut off the ACS 1000 will continue to operate in an active but non-torque producing mode by utilizing the kinetic energy of the rotating motor and load. The ACS 1000 will be fully active as long as the motor rotates and generates energy to the ACS 1000. Power loss ride through can be enabled by parameters. The auxiliary ride through function guarantees correct fault indication and proper trip sequencing, in the event that the auxiliary power source feeding the drive is lost. The function is activated by a parameter. During ride through the power for the control circuits of the ACS 1000 is supplied by internal batteries. The ride through time is limited to 1 sec. ACS 1000 provides two user-selectable acceleration and deceleration ramps. It is possible to adjust the acceleration/deceleration times (0...1800 s) and select the ramp shape. Switching between the two ramps can be controlled via a digital input. The available ramp shape alternatives are: Linear: Suitable for drives requiring long acceleration/deceleration where S-curve ramping is not required. S1: Suit. for short acc./dec. times. S2: Suit. for medium acc./dec. times S3: Suit. for long acc./dec. times. S-curve ramps are ideal for conveyors carrying fragile loads, or other applications where a smooth transition is required when changing from one speed to another.
Linear S1 Motor speed
Power Loss RideThrough
Auxiliary Ride Through
Acceleration and Deceleration Ramps
S2 S3
1 1.25
2 t (s)
Critical Speed
There is a Critical Speed function available for applications where it is necessary to avoid certain motor speeds or speed bands, for example due to mechanical resonance problems. The ACS 1000 makes it possible to set up five different speed settings or speed bands which will be avoided during operation.
40
Each critical speed setting allows the user to define a low and a high speed limit. If the speed reference signal requires the ACS 1000 to operate within this speed range the Critical Speeds function will keep the ACS 1000 operating at the low (or high) limit until the reference is out of the critical speed range. The motor is accelerated/decelerated through the critical speed band according to the acceleration or deceleration ramp. Constant Speeds
Motor speed (rpm) 1560 1380
690 540 Speed reference (rpm) s 1 Lows1 High 540 690 s2 Low s2 High 1380 1560
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. The static speed control error is typically +0.1% (10 % of nominal slip) of the motor nominal speed, which satisfies most industrial applications. The ACS 1000 can perform precise torque control without any speed feedback from the motor shaft. With torque rise time less than 10 ms at 100% torque reference step compared to over 100 milliseconds in frequency converters using sensorless flux vector control, the ACS 1000 is unbeatable. By applying a torque reference instead of a speed reference, the ACS 1000 will maintain a specific motor torque value; the speed will be adjusted automatically to maintain the required torque.
T (%) TN 100 90 Tref Tact
Accurate Speed Control Accurate Torque Control without Speed Feedback
10 < 10 ms t(s)
TN = rated motor torque Tref = torque reference Tact = actual torque
Table 6-1
Typical performance figures for torque control, when Direct Torque Control is used
ACS 1000 no Pulse Encoder + 4 %* < 10 ms ACS 1000 with Pulse Encoder +3% < 10 ms
Torque Control Linearity error Torque rise time
* When operated around zero frequency, the error may be bigger.
41
6.2.2
Main Circuit Breaker Control

All functions regarding the control of the main circuit breaker (opening, closing, tripping, monitoring) are included in the ACS 1000. For detailed information see Chapter 8 - Selecting the Drive System, Main Circuit Breaker, page 63.
6.2.3
Local and Remote Control

Operation of the ACS 1000 is possible either in local or remote control mode. Local/remote control is selected directly on the CDP 312 control panel by pushing the LOC/REM push-button. A capital L on the display indicates local control:.
LOC REM
1 L -> 0.0 rpm 0 Status RdyForMCBOn MotSpeed 0.00 rpm Power 0.0 %
Remote control is indicated with a blank:
LOC REM
1 -> 0.0 rpm 0 Status RdyForMCBOn MotSpeed 0.00 rpm Power 0.0 %
Local Control
If the converter is in local control, local operation using the push-buttons on the converter front door and the CDP 312 control panel is possible. In local operation mode no remote control command will be accepted. If remote control is selected, local operation from the push-buttons on the converter front door and from the CDP 312 control panel is not possible. Instead all commands for closing and opening the main circuit breaker or starting and stopping the drive are received via digital inputs from a remote control station. The speed reference value is given as an analog input signal. Alternatively all remote control signals can be exchanged via an optional fieldbus interface. Changing the control mode from local to remote and vice versa can be disabled by setting digital input DISABLE LOCAL (see also Table 4-2).
Remote Control
42
6.2.4
Diagnostics
Actual Signal Monitoring Three signals can be displayed simultaneously on the control panel. Actual signals to be displayed can be selected in parameter group 1 to 5, Actual Signals. For example: Fault History ACS 1000 output frequency, current, voltage and power Motor speed and torque DC Link voltage Active control location (Local / External 1 / External 2) Reference values ACS 1000 inverter air temperature Cooling water temperature, pressure and conductivity Operating time counter (h), kWh counter Digital I/O and analog I/O status PID controller actual values (if the PID Control Macro is selected)
1 L -> 600.0 rpm 1 Status Running MotSpeed 600.00 rpm Power 75.0 %
The Fault History contains information on the forty most recent faults detected by the ACS 1000. Faults are displayed in alphanumeric characters.
6.2.5
Programmable Digital and Analog Outputs

Four digital outputs on the IOEC 2 board can be programmed individually. Each output has floating change-over contacts and can be allocated to an internal binary control or status signal via parameter setting. Examples are: ready, running, fault, warning, motor stall, motor temperature alarm / trip, ACS 1000 temperature alarm / trip, reverse rotation selected, external control selected, preset speed limits, intermediate circuit voltage limits, preset motor current limit, reference limits, loss of reference signal, motor operating at reference speed, process PID controller actual value limits (low, high) etc.
Programmable Digital Outputs
If optional boards IOEC 3 and/or IOEC 4 are installed, a maximum of 12 additional digital outputs (6 on each board) are available.
43
Programmable Analog Outputs
Two programmable analog outputs on each IOEC board are at the users disposal. Depending on the setting of the corresponding parameters, the analog output signals can represent for example: motor speed, process speed (scaled motor speed), output frequency, output current, motor torque, motor power, DC bus voltage, output voltage, application block output (process PID controller output), active reference, reference deviation (difference between the reference and the actual value of the process PID controller).
The selected analog output signals can be inverted and filtered. The minimum signal level can be set to 0 mA, 4 mA or 10 mA.
6.2.6
Scalable Analog Inputs

Each analog input can be adapted individually to the type and range of the connected input signal: signal type: voltage or current (selectable by DIP switches) signal inversion: if a signal is inverted, the maximum input level corresponds to the minimum signal value and vice versa minimum level: 0 mA (0 V), 4 mA (2 V) or by input tuning function (actual input value is read and set as minimum) maximum level: 20 mA (10 V) or by input tuning function (actual input value is read and set as maximum) signal filtering time constant: adjustable between 0.01..10 s.
The offset of the analog inputs can be calibrated automatically or manually.
6.2.7
Input Signal Source Selections and Signal Processing

The ACS 1000 can receive the Start/Stop/Direction commands and the reference value from the integrated control panel and the Closing/Opening commands for the main circuit breaker from the push buttons on the control section door. Alternatively it is possible to predefine two separate external control 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 7 - Options. Reference Signal Processing The ACS 1000 can handle a variety of speed reference schemes in addition to the conventional analog input signal and control panel signals. The ACS 1000 reference can be given using two digital inputs:
Two Programmable Control Locations
44
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 41). 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.
6.3
Standard Protection Functions

The ACS 1000 offers several programmable fault functions and other nonuser adjustable pre-programmed protection functions.
6.3.1
Programmable Fault Functions

Motor Winding Temperature The motor can be protected from overheating by activating the motor winding temperature monitoring function. The ACS 1000 standard solution offers three analog inputs for measuring and monitoring the motor winding temperature. Values for alarm and trip levels can be set. Motor Stall The ACS 1000 protects the motor if a stall condition is detected. The 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 drive responds with an alarm or a trip when a stall is detected. The protection is activated if all the following conditions are fulfilled simultaneuously: 1 2 The output frequency is below the set stall frequency. The drive is in torque limit. The torque limit level is a basic setup parameter that sets maximum drive output torque. Although it indirectly effects operation of the motor stall protection, it should not be considered a motor stall parameter. The frequency and torque levels from conditions 1 and 2 have been present for a period longer than the set stall time.
Torque Stall region Tm.a
Stall Frequency
f (Hz)
Figure 6-1 Stall region of the motor
45
Underload
Loss of motor load may indicate a process malfunction. The ACS 1000 provides an underload function to protect the machinery and the process in such a serious fault condition. This monitoring function checks if the motor load is above the specified load curve. 5 different load curves can be selected by the customer. Monitoring limits: underload curve and underload time can be chosen as well as the drive response to the underload condition (alarm / trip indication and stop the drive / no reaction).
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
0 100% 110% 120% 130% 140% 10% 20% 30% 40% 50% 60% 70% 80% 90%
Speed
Figure 6-2 Load curves for underload function The protection is activated if all the following conditions are fulfilled simultaneously: 1 2 Overspeed The motor load is below the underload curve selected by the user (see Figure 6-2). The motor load has been below the selected underload curve longer than the time set by the user (Underload time).
The motor speed as determined by DTC is monitored. If the motor speed exceeds the maximum permitted motor speed (user adjustable) a trip is initiated. In addition, an input for connection of an external motor overspeed trip is available. A converter trip is also initiated, if the external motor overspeed trip is activated (signal active when low). In order to detect a loss of the mains power supply, the positive and negative DC link voltage levels are monitored. If these voltage levels drop below 70% of their nominal levels an undervoltage alarm is initiated and power loss ride through is activated (provided it is selected). If the DC link voltage levels drop below 65% of their nominal values an undervoltage trip is initiated.
Undervoltage
46
6.3.2
Pre-programmed Protection Functions

The phase loss function monitors the status of the motor cable connections. The function is useful especially during motor starting: the ACS 1000 detects if any of the motor phases are not connected and refuses to start. The phase loss function also monitors the motor connection status during normal operation. The motor operating frequency must be above a minimum level in order for this feature to function. Should a motor phase loss be detected a trip is initiated. Motor Overload The 3-phase RMS value of the motor current is monitored and compared with three adjustable thresholds. A pickup delay for each threshold can also be set. In case an overload is detected an alarm message will be displayed and the converter will be shut down. 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. To provide ultimate reliability the second overvoltage trip is implemented both in software and redundantly in hardware (140%). A short circuit in the rectifier bridge is detected by monitoring the DC link voltage. If a short circuit is detected, a trip is initiated and the drive is disconnected from the supply voltage. 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. 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. The overcurrent trip limit for the ACS 1000 is 2.2 x IN RMS of the nominal inverter current. If this level is exceeded, a trip is initiated. In order to insure that the inverter section does not exceed the temperature limits, the current is monitored and limited to the maximum permitted level. The operating condition of the cooling circuit is monitored. If any of the monitored signals such as water temperature, water pressure or conductivity exceed a preset limit, a trip is initiated. In addition, the status of the
Motor Phase Loss
Overvoltage
Short Circuit in the Rectifier Bridge Charging Fault
Supply Phase Loss Overcurrent Inverter Temperature
Cooling Circuit
47
cooling water pumps, the water level in the expansion vessel and the auxiliary fan are monitored. Short Circuit of the Inverter Ground Fault The inverter is monitored to ensure that a short circuit condition does not exist. If a short circuit is detected a trip is initiated. The current in the output filter ground leg is monitored and compared with two thresholds. The first threshold is set to a fixed percentage of the peak value of the nominal inverter current. The second threshold is adjustable and compared with the RMS value of the ground current. If the ground current exceeds one of the thresholds a corresponding alarm message will be displayed and the drive will be shut down. Ground faults will be detected in the area between the ACS 1000 transformer secondary side and the motor. Operating System The operating system of the microprocessor board monitores different functions within the control software and will initiate a trip if a malfunction is detected. Such faults are displayed as Control SW fault. Should one of these faults be detected during operation, the drive should be restarted. Except for the measurement boards all communication links are realized by DDCS (Distributed Drive Control System). If one of these links fails a trip is initiated. 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 The back-up batteries are checked periodically by applying a known load and by measuring the resulting voltage drop. If the charge of the batteries is deficient, a fault message is displayed and either a normal stop or an alarm is initiated. During commissioning an identification run has to be carried out. The nominal data for identification of the system parameters has to be entered. If incorrect values are used and therefore the system parameters cannot be determined, a trip is initiated. In this case the identification run has to be repeated after the correct data has been entered.
Communication Fault
Measurement Loss
ID-Run Fault
48
6.3.3
Other Protection Functions

External Motor Protection Trip If the customer uses an external motor protection relay, it can be connected to a pre-defined protection input of the ACS 1000. The motor protection input is integrated into the tripping loop by a normally closed (NC) contact. If the customer uses an external transformer protection relay, it can be connected to a pre-defined protection input of the ACS 1000. The transformer protection input is integrated into the tripping loop by a normally closed (NC) contact. An optional signal input is available to connect a line unbalance protection relay for initiation of a converter trip. A process stop button or relay can be connected to a pre-defined input of the ACS 1000. The actual process stop input must be closed during normal operation. If the digital input opens, the drive control initiates a stop command. The stop mode (ramp stop, stop at torque limit, or coast stop) can be selected by a parameter. When the drive is stopped the main circuit breaker is opened. The normally closed (NC) contacts of external emergency-off buttons can be wired into the tripping loop. For further details see Chapter 4 - User Interfaces.
External Transformer Protection Trip
Line Unbalance Protection Relay Process Stop
External Emergency Off
6.4
Other Functions
Automatic Restart The ACS 1000 can automatically reset itself after an undervoltage has occurred. This function is activated by two parameters one to enable the automatic restart function and one to select the undervoltage waiting time (adjustable between 0 and 600 s). If the automatic restart feature is activated and an undervoltage is detected in the DC-link, the waiting time is started. If the voltage recovers within the selected time, the fault will be reset automatically and the converter resumes normal operation. If the waiting time has elapsed and the voltage has not recovered the converter is tripped and the MCB is opened.
Monitoring of Limit Values
The values of several user selectable signals can be monitored for adjustable low and high limits. Adjustable limits can be set for: two speed values, a current value, two torque values, two reference values and two actual values of the PID controller. The digital status of the active limit appears on the control panel display and can also be allocated to digital output.
ACS 1000 Information
The software version and the serial number of the ACS 1000 can be displayed on the CDP 312 control panel.
49
Parameter Lock
The user can prevent unwanted parameter changes by activating the Parameter Lock.
6.4.1
Customer Specific Options

Information on additional user specific options that can be implemented in the ACS 1000 is given in Chapter 7 - Options.
50
Chapter 7 - Options
7.1 Environmental Conditions
Above 40 C the converter output power must be derated by 1.5% per 1 C and filter capacitors, suitable for high operating temperatures, are supplied. For certain environmental conditions (e.g. salty air in combination with increased ambient temperature and high humidity) corrosion protected bus bars can be chosen instead of the standard type. This choice is relevant for all power and grounding bus bars of the converter. 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.
Extended Ambient Temperature: 50 C Corrosion Protected Bus Bars
Coated PCBs
7.2
Converter Enclosure
The standard IP classes of the converter enclosures are given in Appendix A - Installation Guidelines. The following IP ratings are optional: Door Interlocking IP22, IP31, IP32 and IP42 (for air-cooled converters) IP54 (for water-cooled converters)
Converter Enclosure
The ACS 1000 is equipped with an electromechanical door interlocking system as standard. Alternative optional interlocking: Kirk key interlocking
If this option is required, contact your ABB representative. Cabinet Color The standard color for the ACS 1000 converter is RAL 7035, Light Grey. Other RAL colors are available optionally and must be specified explicitly when ordered. The standard converter has painted front doors. Optionally, the entire cabinet exterior is available with painted surfaces (see also Cabinet Color). The water-cooled ACS 1000 can be delivered with a shipping split for easy transportation. All materials necessary for joining the two parts are supplied with the drive.
Cabinet Paint Finish
Split Cabinet
51
Chapter 7 - Options
Extended Grounding Busbar
The standard grounding busbar which is located in the power cable termination section of the ACS 1000 can be an extended throughout the medium voltage sections of the ACS 1000.
7.3
Input Section
Input Bridges The following input rectifier bridges are available: 12-pulse diode rectifier (standard) This type is sufficient for most network conditions to fulfill the network harmonic requirements according to IEEE 519-1992. It is the ideal solution for a small converter footprint and if an outdoor transformer can be used. 24-pulse diode rectifier with integrated or external transformer configuration This type is recommended if superior network behavior is required. The 24-pulse diode rectifier is applicable if outdoor transformers are not required. In this case there is no need for an oil pit and no additional cabling between transformer and converter is needed which can substantially reduce construction and installation costs.
Motor and Transformer Protection Extended Transformer Monitoring Interface
Refer to Sections Extended Motor Monitoring Interface, page 53 and Extended Transformer Monitoring Interface, page 52. In addition to the standard signal Transformer Protection Trip (wired into tripping loop) the signals according to Table 7-1 can be included optionally in the signal interface between the transformer and the ACS 1000. Note: This option requires the IOEC 3 board. The option is standard for water-cooled converters (see Chapter 4 - User Interfaces, I/O Signals: transformer, page 28). Table 7-1
Type DI DI
I/O signals for extended transformer monitoring

Signal Name OIL LEVEL ALARM OIL TEMP ALARM, or Remarks Transformer oil level alarm indication Transformer oil temperature alarm indication Transformer winding temperature alarm indication Transformer oil temperature trip indication Transformer winding temperature trip indication
TRAFO WDG TEMP ALARM DI /OIL TEMP TRIP, or /TRAFO WDG TEMP TRIP
52
Chapter 7 - Options
Table 7-1
Type DI DI AI
I/O signals for extended transformer monitoring (continued)

Signal Name BUCHHOLZ ALARM /BUCHHOLZ TRIP OIL TEMP, or TRAFO WDG TEMP Remarks Transformer alarm indication from Buchholz relay Transformer trip indication from Buchholz relay Temperature measurement of transformer oil Temperature measurement of transformer 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. Line Unbalance Protection Relay Common Mode Choke A signal from a line unbalance protection relay can be monitored by wiring it into the tripping loop of the ACS 1000. If the signal is low the main circuit breaker is tripped immediately. This option is needed if the cable length between the converter transformer 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 versions.
The DC link 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.
7.4
Motor Side
In addition to the standard signal Motor Protection Trip (wired into tripping loop) the signals according to Table 7-2 can be included optionally in the signal interface between the motor and the ACS 1000. Note: This option requires the IOEC 3 board. The option is standard for water-cooled converters (see Chapter 4 - User Interfaces, I/O Signals: motor, page 29),
Extended Motor Monitoring Interface
53
Chapter 7 - Options
Table 7-2
Type DI DI DI DI DI DI AI AI
I/O signals for extended motor monitoring

Signal Name EXT MOT PROT ALARM MOT COOLING ALARM /MOT COOLING TRIP VIBRATION SV ALARM /VIBRATION SV TRIP /OVERSPEED TRIP BRG TEMP DE BRG TEMP NDE Remarks (External) motor protection alarm indication (External) motor cooling alarm indication (External) motor cooling trip indication Motor vibration alarm indication Motor vibration trip indication Motor overspeed trip (included in hardwired tripping loop) Motor bearing temperature of driven end Motor bearing temperature of nondriven end
The analog inputs are suitable for actual values in the range of 0..20 mA / 4..20 mA (or 0..10 V / 2..10 V) and are monitored by the ACS 1000 for alarm and trip levels. Ex-Zone Signal Interface for Motor Measurements (Zener Barriers) For motor installations in hazardous areas (Ex-Zone) all interface signals from the motor have to be connected to Zener Barriers mounted in the converter. This applies to the winding temperature and bearing temperature measurements as well as to all digital signals e.g. external motor protection alarm and trip and external overspeed trip. If this option is required, contact your ABB representative. Pulse Encoder Interface Module The Module allows a pulse encoder to be connected to the ACS 1000. A pulse encoder is advantageous in applications where the flying start function is used. The actual frequency of a rotating motor can be detected faster and rapid start-up by the converter can be achieved. It is also recommended if a highly accurate read-out of the speed is required. 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)
54
Chapter 7 - Options
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 Frequency Braking Chopper The ACS 1000 can be ordered with an increased output frequency of 82.5 Hz as a maximum. This option requires an optimized sine filter configuration. Effective motor braking and short deceleration times can be achieved by using resistor braking. For resistor braking, the ACS 1000 converter must be equipped with a braking chopper and a braking resistor. Braking choppers are available for all ACS 1000 types. The choppers can be ordered factory-installed or as add-on kits. The operation of the braking chopper is controlled by the ACS 1000 control system. The braking chopper hardware is located in an additional cabinet. The input currents of the braking chopper are monitored for overcurrent and unbalance in order to detect any defective component in the circuit. In case a short circuit or an unsymmetry in the braking chopper is detected a converter trip is initiated. Braking chopper and braking resistors are each monitored for overtemperature by means of thermal models. Alarm and trip levels are determined and set during commissioning. For more information about braking chopper and braking resistor, see the resistor specification or contact your ABB representative. Braking Resistor The braking resistor has to be specified individually for each project by ABB Industrie AG. For further information contact your ABB representative. A motor space heater can be connected directly to a single-phase auxiliary power circuit breaker, installed in the converter cabinet. Based on the power rating of the heater, one of the circuit breaker sizes as indicated in Table 7-3 can be used.
Circuit Breaker for Motor Space Heater
55
Chapter 7 - Options
Table 7-3
Power ratings for different circuit breaker sizes

Auxiliary Voltage (single phase)
Circuit Breaker Rating 0.5 A 1.0 A 2.0 A 3.0 A 4.0 A 5.0 A 6.0 A 10.0 A
120 V 60 W 120 W 240 W 360 W 480 W 600 W 720 W 1200 W
240 V 120 W 240 W 480 W 720 W 960 W 1200 W 1440 W 2400 W
400 V 200 W 400 W 800 W 1200 W 1600 W 2000 W 2400 W 4000 W
Motor Starter for Motor Cooling Fan / Pump
A motor cooling fan or pump can also be connected directly to an auxiliary motor starter installed in the converter. Based on the power rating of the cooling fan or pump, one of the following motor starter sizes can be chosen: Table 7-4 Power ratings for different starter sizes
Auxiliary Voltage (three phase) Overload Current Rating 2.5 - 4.0 A 4.0 - 6.3 A 6.3 - 10.0 A 400 V 750 W - 1500 W (1.0 - 2.0 hp) 1500 W - 2200 W (2.0 - 3.0 hp) 2200 W - 4000 W (3.0 - 5.4 hp) 480 V 1100 W - 2000 W (1.5 - 2.7 hp) 2000 W - 3000 W (2.7 - 4.0 hp) 3000 W - 4000 W (4.0 - 5.4 hp) 575 V 1200 W - 2600 W (1.6 - 3.5 hp) 2600 W - 3600 W (3.5 - 4.8 hp) 3600 W - 6000 W (4.8 - 8.0 hp)
7.5
Converter Cooling
The redundant cooling fan is an option intended for applications where enhanced reliability of the installation is required. The redundant fan unit is supplied as a separate unit to be mounted on top of the ACS 1000 converter. If delivered together with the ACS 1000, both fans are already mounted in the unit. As add-on kit, only the redundant fan is supplied and the standard fan must be transferred from the converter cabinet to the redundant fan unit.
Redundant Cooling Fan (Air-cooled ACS 1000)
56
Chapter 7 - Options
With this option continuous operation of the drive is guaranteed even if one fan fails. Switch-over from the faulty to the stand-by device takes place automatically. To replace the faulty unit the converter must be stopped. The replacement of a fan takes about 30 minutes.
Control Box
Rectifier
Inverter
Figure 7-1 Standard cooling fan unit
Air Duct
Control Box
Rectifier
Inverter
Figure 7-2 Redundant cooling fan unit (functional principle) If this option is ordered the derating of the drive output power needs to be considered (see Appendix B - Technical Data, Environmental Aspects, page 89). Redundant Cooling Fan (Water-cooled ACS 1000) The water-cooled ACS 1000 can be ordered with a redundant cooling fan, if continuous operation is required in case a fan fails. The redundant fan unit is supplied as a separate unit and is mounted on top of the ACS 1000. If the redundant fan unit is ordered and delivered together with the ACS 1000, the cut-outs on the roof and the mounting holes are already prepared. If the redundant fan is purchased separately, the roof cut-outs and the mounting holes have to be prepared on side. The water-cooled ACS 1000 can be equipped with a second pump [P2] in the cooling water circuit. This option is needed when continuous operation of the drive is required in case of a pump failure in the cooling unit. The redundant pump is installed in the cooling unit of the ACS 1000. The cooling unit of the ACS 1000 can be ordered with a three-way valve [B14] in the raw water circuit. This option is recommended, if the raw water flow must be kept at a constant rate. If the cooling unit is equipped with a three-way valve, the water-to-water heat exchanger [E1] is bypassed and
Redundant Cooling Pump (Water-cooled ACS 1000) Three-way Valve (Water-cooled ACS 1000)
57
Chapter 7 - Options
the total raw water flow is kept constant even if the water flow in the heat exchanger varies.
Cooling Unit (Watercooled ACS 1000)
From the cooling water circuit below the interface connections towards the ACS 1000 and the raw water supply can be seen. The components shown are part of the ACS 1000 cooling unit.
Pressure AI 1.3
B11 P I
Conductivity AI 1.4
B12 Q I
B13 T I
Temperature AI 1.2
ACS 1000 CABINET

Valve identification:
open (normal operation)
V5
to converter nipple
V13 8 PA
12 PA
closed (normal operation) Non-return valve Control valve

M V11 5 l/min 12 PA V14 C A make-up water ISO-R1/2 water to water heat exchanger V3 P1 M M12 V4 M P2 130 l/min
12 PA
expansion vessel
C2
B10
Z2 (microfilter)
Z1 (strainer)
raw water inlet nipple 33 mm E1 air to water heat exchanger E2 V82
from converter nipple 40 mm S1
C1
ion exchanger vessel M V1 M11
OPTION
B14
24 l/min
V2
controlled by: DO 3.3 DO 3.4
raw water outlet nipple 33 mm
V80
V81
OPTION
COOLING UNIT
Figure 7-3 Cooling unit of the water-cooled ACS 1000 Space Heater for Tropicalized Version A space heater is typically required in places/countries with high ambient humidity. It is switched on automatically when the converter is not in operation in order to prevent condensation. The heater consists of several heating elements with a rated power of 100 W each. Monitored Air Filter (Air-cooled ACS 1000) The air-cooled ACS 1000 can be supplied with air filter mats which have a finer mesh than the standard air filter mat. There are filter mats available with a 10 m and a 12 m 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.
58
Chapter 7 - Options
If the ACS 1000 is ordered with an air filter with finer mesh the derating of the drive output power needs to be considered (see Appendix B - Technical Data, Environmental Aspects, page 89)
7.6
Converter Isolators and Bypass

The synchronized bypass (Figure 7-4) allows for automatic synchronization of a motor with the line after a soft start. Two versions are available: synchronized bypass for 1 motor synchronized bypass for up to 4 motors.
Synchronized Bypass
The bypass cabinet which is attached to the left hand side of the ACS 1000 houses the following control hardware: the interface for external commands and feedback signals the signal interface(s) for the control of motor and bypass breakers the control unit for synchronizing and switching coordination the optional voltage measuring equipment.
For dimensions and weight of the bypass cabinet see Table C-4 Dimensions and weights of the ACS 1000 and optional equipment. Note:The bypass switchgear is not included in the scope of this option. Note:The ACS 1000 does not support manual or automatic bypass functions. All bypass related interlocks and the controls for the bypass switches have to be realized externally to the drive. Only an output disconnector switch can be monitored via digital inputs, if IOEC 4 board is installed. These inputs are used to interlock the drive.
59
Chapter 7 - Options
Mains Supply
MCB
Transformer
ACS1000 Frequency Converter

12 Pulse Rectifier Three Level Inverter Output Filter
= =
Sm1
U2 ACS 1000 Control
Synchronized Bypass Controls
MCB 1
Transformer 1 U11
M1
Sbp1 Sm2
3-Ph
(if necessary)
Mains Supply
MCB 2
Transformer 2 U12 Sbp2
M2
3-Ph
(if necessary)
Figure 7-4 Synchronized bypass, single line diagram Input Isolator Used in addition to the main circuit breaker, the input isolator provides a visible break between the transformer and the rectifier section when the input isolator is in the open position. The input isolator is located in an additional cabinet next to the converter. If this option is required, contact your ABB representative. Output Isolator The output isolator is normally used in combination with a converter bypass and provides the possibility to isolate the converter visibly from the motor. The output isolator is located in an additional cabinet next to the converter. If this option is required, contact your ABB representative.
60
Chapter 7 - Options
7.7
Auxiliary & Control Interfaces

Fieldbus Adapter Modules A fieldbus module may be used for controlling and monitoring the converter instead of using conventional hard-wired I/Os. There are several fieldbus adapter modules available for the ACS 1000: Profibus DP Profibus FMS Modbus Modbus+ Allen-Bradley Device Net ABB Advant Fieldbus 100 ABB Procontic CS31 Interbus S
The fieldbus is connected to the adapter module via a twisted pair bus (RS 485) or via BNC-connectors (for ABB AF100). The adapter communicates with the ACS 1000 control board via a fast (4 Mbit/s) Duplex Fiber Optic Link. All fieldbus modules require 24 VDC power. In all cases power is supplied by the ACS 1000 internal control power supply (EPS). Spare Terminals As an option, 30 spare terminals can be provided. These terminals are not wired up. A higher number of spare terminals is available on request.
7.8
PC Tools
DriveWindow DriveWindow offers several advanced, yet easy-to-use tools for commissioning and control of the ACS 1000. The parameter and signal tool with a full set of device specific data either in online or offline mode to check, study and change the parameters The monitor tool as a graphic interface for monitoring digital and analog signals The data logger as a versatile way of tracing fast and accurate events The fault logger displaying a fault history The application tools presenting the pin values in order to debug application software and force constants
61
Chapter 7 - Options
With its component structure, enhanced flexibility is achieved to allow working with several different types of products through different target and communication drivers (The look and feel of the DriveWindow program remains the same even when the product changes).
DriveSupport
The DriveSupport tool offers an advanced level of servicing, maintaining and trouble shooting of a drive system. Versatile features are provided for: Diagnosing faults and warnings Testing and verifying possible causes of faults Locating of faulty components Performing step-by step replacement procedures Recording maintenance activities.
The DriveSupport works on-line together with the DriveWindow tool.
62
Chapter 8 - Selecting the Drive System

8.1 Overview
The excellent performance of the ACS 1000 makes it suitable for most variable speed drive applications. In order to dimension and configure an ACS 1000 drive system, the driven load has to be clearly specified and an appropriate motor must be selected. The driven load together with the selected motor basically determines the size of the ACS 1000 as well as the size of the required converter input transformer.
8.2
Main Circuit Breaker
8.2.1
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 pre-set time, the closing command is reset and a trip of the MCB is initiated. The MCB is opened by : an MCB OPEN command, either given from the push button on the ACS 1000 or from a remote control station via digital inputs or through a fieldbus adapter the hardwired tripping loop (see Tripping Loop, page 64).
The opening command from the converter to the MCB - pulse or steady state signal - is reset as soon as the status feedback MCB IS OPEN has been received. If the feedback signal has not arrived after a preset time the command MCB ORDER TRIP is initiated to open the MCB. The MCB ORDER TRIP is a steady state true signal. When in low status it directly opens the MCB. MCB Control Fault All opening and closing commands to the MCB are monitored for time-out An alarm or fault message comes up on the display of the CDP 312 control panel if there is something wrong in connection with the control of the MCB.
63
8.2.2
Tripping Loop
General The tripping loop is a hardwired control circuit provided to trip the MCB directly either via the tripping coil or via the opening coil. Depending on which coil is available, the tripping coil or the opening coil has to be connected to the tripping loop. Signals from customer devices can (but do not have to) be wired into this loop. Each of these signals is monitored by a digital input. These signals can be connected to a terminal strip in the control section of the ACS 1000. If one or several of the signals are not used a jumper must be put across the corresponding terminals.
Customer side
control voltage provided by customer emergency off
(one or more emergency off connected in series)
Control section of ACS 1000

22...250 VAC 22...150 VDC
X 300 1 2
*
3 4
transformer protection trip
*
5 6
motor protection trip
*
8
overspeed trip
*
9 10
supply voltage unbalance trip optional IOEC board 3 required
*
11
jumper when signal is not used
12
MCB tripping coil

13
Figure 8-1 Tripping loop: principle diagram
64
ACS 1000 Tripping Loop Signals
The following ACS 1000 contacts are wired to the tripping loop: the digital output "MCB ORDER TRIP" the emergency-off button on the ACS 1000 front door.
The digital output "MCB ORDER TRIP" is initiated: Customer Signals if the grounding isolator is closed or not not completely opened after an off command and there is no feedback signal within a programmable time lapse when switching off the main circuit breaker and a signal discrepancy between off command and feedback signal is detected by main circuit interface board of the ACS 1000 in case of a trip.
The following signals from customer devices can (but do not need to) be wired to the tripping loop terminals: external emergency-off transformer protection trip motor protection trip overspeed trip supply voltage unbalance.
The following signals require the optional IOEC 3 board: overspeed trip supply voltage unbalance.
8.2.3
Main Circuit Breaker Features

The MCB has to be specified according to the rated primary voltage and current of the converter transformer. It should also meet the specific drive requirements (some items require proper coordination with the instrumentation and protection equipment). The MCB must be capable: to connect and maintain nominal load currents and clear short-circuit currents to tolerate the transformer inrush current without tripping to clear transformer secondary short circuits within 250 ms (the time includes the pick-up time of the protection relay and the opening time of the MCB) close in response to a close command open within 160 ms in response to an open command (signal active when high) open within 160 ms in response to a trip command (signal active when low)
General Requirements for MCB
65
provide a status output which indicates MCB closed provide a status output which indicates MCB open provide a status output which indicates MCB not available (vacuum circuit breaker in test position or vacuum controller disconnect switch in open position).
Types of MCBs
The following types of MCBs can be used: vacuum or gas insulated (SF6) circuit breakers load disconnectors with fuse vacuum or gas insulated (SF6) controllers / medium voltage starters.
MCB Control Signal Interface
A possible signal interface between the ACS 1000 and a vacuum controller or vacuum circuit breaker is indicated in the schematic diagrams below.
vacuum cir cuit breaker 52
MCB not available clo se command open command
trip sig nals
MCB open
MCB clo sed
50 51
51N
AC tim e resid ua l overcurrent rela y in stantaneous / AC tim e overcurrent relay
ACS 1000
Figure 8-2 Connection scheme with vacuum circuit breaker
66
tripping loop
non lo ad-break dis connector fast actin g current lim it in g fuse vacuum contactor trip sig nals
MCB not available
clo se command
open command
MCB clo sed
MCB open
50 51
51N
AC tim e resid ua l overcurrent rela y in stantaneous / AC tim e overcurrent relay
ACS 1000
Figure 8-3 Connection scheme with vacuum controller MCB Instrumentation and Protection Equipment Appropriate current transformers and protection relaying must be provided to protect transformer and transformer primary cables. The intended approach for protection is shown in Figure 8-4. As shown in the figure the protection can be considered to consist of three areas. The first area identified as Transformer Primary Fault Protection is an instantaneous trip area that protects against short circuits in the transformer primary windings or in the cables supplying the transformer primary. The lower level of the trip threshold should be adjusted high enough to insure that nuisance tripping does not occur due to transformer inrush currents. The second area identified as Transformer Secondary Fault Protection is a short delay trip area that protects against short circuits in the transformer secondary windings, the cables from the transformer secondaries to the ACS 1000, or in the input rectifier stages of the ACS 1000. The short time delay provided should be adjustable and should be set long enough to insure that the protection does not trip due to transformer inrush current. The trip level should be adjusted low enough to insure that tripping will occur within 100 ms (including MCB delay time) even if transformers with high input impedance are used. The final area identified as Overload Protection should provide long term overload protection with an inverse time characteristic. This area is intended to protect the transformer and cables from long term overload conditions.
tripping loop
67
The protection described can be provided with individual protection relays or with a single microprocessor based unit. Required current transformers should be sized in accordance with the rated current levels of the transformer. Basic protection configuration and connection should be as previously shown in Figure 8-2 and Figure 8-3.
Transformer primary fault protection
x 20
Transformer secondary fault protection
x 10
Overload protection
Adjustable time delay
x1 10 ms 200 ms 1s 10 s 100 s
Figure 8-4 Sample protection scheme
8.3
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 24pulse rectifier bridge are to be designed to provide a 15 phase shift. A second purpose of the transformer is to provide sufficient impedance to limit the line harmonics to acceptable levels. The transformer may be an oil-immersed or a dry type. Based on installation requirements of the application, the transformer may be located remote from the ACS 1000 drive equipment or nearby, even integration into the drive is possible. For requirements regarding the maximum cable length between transformer and ACS 1000 see Appendix B - Technical Data . The transformer may be supplied from ABB or alternatively from a third party supplier in accordance with the specifications provided by ABB. The design of the transformer must take into account site-specific line conditions (voltage, short circuit capacity, existing harmonics, etc.) to insure compliance with harmonic standards invoked by the specifications. Transformer quality is critical with respect to effecting proper limitation of harmonic currents and voltages.
68
When determining the power rating of the transformer, power and efficiency of the motor, power factor and efficiency of the ACS 1000 converter and harmonic loading of the transformer must all be considered. For selecting an appropriate ABB ACS 1000 transformer or for specifiying a generic transformer, please contact your ABB representative.
8.4
Selection of the ACS 1000 Converter

The rating tables for selecting the ACS 1000 can be found in this chapter. In general the ACS 1000 converter is selected according to the rated motor power. The rated output current of the ACS 1000 should be checked to insure that it is higher than or equal to the rated motor current. If a motor with 6 or more poles is used, the nominal motor current usually increases as compared to a motor with fewer poles. This may result in a different output filter configuration (see ACS 1000 Output Filter below). In such cases, please contact your ABB representative for further assistance before making a final drive selection. When determining the appropriate size of the ACS 1000 converter for a particular application the following factors need to be considered: ambient temperature temperature of the cooling media installation site altitude frostproofing of the cooling water the presence of a redundant cooling fan type of air filter.
Please refer to Appendix B - Technical Data for details on environmental aspects.
8.4.1
ACS 1000 Output 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.
8.4.2
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 drive selection. To determine the appropriate ACS 1000 please contact your ABB representative.
69
8.4.3
ACS 1000 Selection Tables

ACS 1000 rated for 2.3 kV have output ratings based on horsepower (HP). Equivalent output ratings in kilowatt (kW) are approximate and listed for reference only. Note: The load capacity (current and power) decreases if the environmental conditions at site do not comply with the limits given in Appendix B - Technical Data, Environmental Aspects, page 89. The resulting derating factors are specified in Appendix B - Technical Data, Derating of Drive Power, page 90.
Selection Table for Air / Water-cooled ACS 1000 with 2.3 kV Motors
Table 8-1
Motor Voltage (kV) 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3
ACS 1000 ratings for 2.3 kV motors, 50 Hz and 60 Hz supply (12/24-pulse)

Type of Cooling Max. cont. Converter Power (kVA) 400 400 450 550 650 750 800 900 1150 1350 1550 1800 2000 2300 2700 3100 3600 Rated Motor Power** (HP) 400 450 500 600 700 800 900 1000 1250 1500 1750 2000 2250 2500 3000 3500 4000 _ 315 355 450 500 560 630 710 900 1120 1250 1400 1600 1800 2250 2500 2800 Equival. Motor Power** (kW) Rated Output Current (A) 100 100 113 138 163 188 201 226 289 339 389 452 502 577 678 778 904 Frame Size
Converter Type*
ACS10x2-A1-A0-00 ACS10x2-A1-B0-00 ACS10x2-A1-C0-00 ACS10x2-A1-D0-00 ACS10x2-A1-E0-00 ACS10x2-A1-F0-00 ACS10x2-A1-G0-00 ACS10x2-A1-H0-00 ACS10x2-A2-J0-00 ACS10x2-A2-K0-00 ACS10x2-A3-L0-00 ACS10x2-A3-M0-00 ACS10x2-A3-N0-00 ACS10x2-W1-P0-00 ACS10x2-W1-Q0-00 ACS10x2-W2-R0-00 ACS10x2-W2-S0-00
Air Air Air Air Air Air Air Air Air Air Air Air Air Water Water Water Water
A1 A1 A1 A1 A1 A1 A1 A1 A2 A2 A3 A3 A3 W1 W1 W2 W2
*, ** See note at end of this Section on page 72
70
Selection Table for Air / Water-cooled ACS 1000 with 3.3 kV Motors Table 8-2
Motor Voltage (kV) 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
ACS 1000 rated for 3.3 kV have output ratings based on kilowatt (kW). Equivalent output ratings in horsepower (HP) are approximate and listed for reference only.

Type of Cooling Max. cont. Converter Power (kVA) 400 450 500 550 600 700 750 850 950 1100 1200 1350 1500 1700 1900 2150 2400 2700 3000 3350 3750 4250 4750 5350 5950 Rated Motor Power** (HP) 450 500 550 600 700 750 800 900 1000 1250 1350 1500 1650 1750 2000 2250 2500 3000 3350 3500 4000 4500 5000 6000 6700 Equival. Motor Power** (kW) 315 355 400 450 500 560 630 710 800 900 1000 1120 1250 1400 1600 1800 2000 2250 2500 2800 3150 3550 4000 4500 5000 Rated Output Current (A) 70 79 87 96 105 122 131 149 166 192 210 236 262 297 332 376 420 472 525 586 656 744 831 936 1041 Frame Size
Converter Type*
ACS10x3-A1-A0-00 ACS10x3-A1-B0-00 ACS10x3-A1-C0-00 ACS10x3-A1-D0-00 ACS10x3-A1-E0-00 ACS10x3-A1-F0-00 ACS10x3-A1-G0-00 ACS10x3-A1-H0-00 ACS10x3-A2-J0-00 ACS10x3-A2-K0-00 ACS10x3-A2-L0-00 ACS10x3-A2-M0-00 ACS10x3-A2-N0-00 ACS10x3-A2-P0-00 ACS10x3-A3-Q0-00 ACS10x3-A3-R0-00 ACS10x3-W1-S0-00 ACS10x3-W1-T0-00 ACS10x3-W1-U0-00 ACS10x3-W2-V0-00 ACS10x3-W2-W0-00 ACS10x3-W2-X0-00 ACS10x3-W3-Y0-00 ACS10x3-W3-Z0-00 ACS10x3-W3-10-00
Air Air Air Air Air Air Air Air Air Air Air Air Air Air Air Air Water Water Water Water Water Water Water Water Water
A1 A1 A1 A1 A1 A1 A1 A1 A2 A2 A2 A2 A2 A2 A3 A3 W1 W1 W1 W2 W2 W2 W3 W3 W3
*, ** See note at end of this Section on page 72
71
Selection Table for Air / Water-cooled ACS 1000 with 4.0 kV Motors Table 8-3
Motor Voltage (kV) 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0
ACS 1000 rated for 4.0 kV have output ratings based on horsepower (HP). Equivalent output ratings in kilowatt (kW) are approximate and are listed for reference only.

Type of Cooling Max. cont. Converter Power (kVA) 400 400 450 550 650 750 800 900 1150 1350 1550 1800 2000 2300 2700 3100 3600 4000 4500 4900 5300 5800 Rated Motor Power** (HP) 400 450 500 600 700 800 900 1000 1250 1500 1750 2000 2250 2500 3000 3500 4000 4500 5000 5500 6000 6700 _ 315 355 450 500 560 630 710 900 1120 1250 1400 1600 1800 2250 2500 2800 3150 3550 4000 4500 5000 Equival. Motor Power** (kW) Rated Output Current (A) 58 58 65 79 94 108 115 130 166 195 224 260 289 332 390 447 520 577 650 707 765 837 Frame Size
Converter Type*
ACS10x4-A1-A0-00 ACS10x4-A1-B0-00 ACS10x4-A1-C0-00 ACS10x4-A1-D0-00 ACS10x4-A1-E0-00 ACS10x4-A1-F0-00 ACS10x4-A1-G0-00 ACS10x4-A1-H0-00 ACS10x4-A2-J0-00 ACS10x4-A2-K0-00 ACS10x4-A3-L0-00 ACS10x4-A3-M0-00 ACS10x4-A3-N0-00 ACS10x4-W1-P0-00 ACS10x4-W1-Q0-00 ACS10x4-W2-R0-00 ACS10x4-W2-S0-00 ACS10x4-W2-T0-00 ACS10x4-W2-U0-00 ACS10x4-W3-V0-00 ACS10x4-W3-W0-00 ACS10x4-W3-X0-00
Air Air Air Air Air Air Air Air Air Air Air Air Air Water Water Water Water Water Water Water Water Water
A1 A1 A1 A1 A1 A1 A1 A1 A2 A2 A3 A3 A3 W1 W1 W2 W2 W2 W2 W3 W3 W3
* "x" stands for: "1" = 12-pulse rectifier (air / water-cooled ACS 1000)
"2" = 24-pulse rectifier (air-cooled ACS 1000)
** The power ratings apply to typical 4 pole motors. For those motors the
ACS 1000 has a built-in overloadability of 10%. When selecting the ACS 1000 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.
72
8.5
Motor Selection
8.5.1
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: Curve 2: Typical continous load capacity curve of an IEC34 selfventilated motor, controlled by the ACS 1000. Load capacity of the ACS 1000, rated for normal use (i.e. 100% continous, 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 1.1 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.0
Curve 2 ACS 1000 Loadability
Curve 1 Motor Loadability
10 600 300 200 150
20 1200 600 400 300
30 1800 900 600 450
40 2400 1200 800 600
50 3000 1500 1000 750
60 3600 1800 1200 900
70
80
90
100
f (Hz) n (rpm)
p = T = TN = n = f =
number of poles load torque rated motor torque speed output frequency of ACS 1000
p=2 p=4
0 0
2100 1400 1050
2400 1600
n (rpm) n (rpm) n (rpm)
p=6 0 p=8 0
Figure 8-5 Load capacity curves
73
8.5.2
Selection Criteria
Generally speaking the motor must be selected and sized as required by the load. Supplying an additional power margin to compensate for PWM inverter operation is not required with the ACS 1000 due to its sinusoidal output waveform. After the motor has been selected (or if an existing motor is being applied) the following parameters are relevant to select the converter and the transformer: load characteristic (the most common characteristic is square torque; for other loads like constant torque or constant power applications, please contact your ABB representative) overloadability requirements motor voltage number of motor poles shaft power (nominal) shaft speed (nominal) rated current (nominal) motor efficiency motor power factor.
Special attention must be paid to the motor cooling in variable speed applications. If the motor is self-ventilated, long-time operation at low speeds will usually require some derating to compensate for the reduced cooling. Depending on the mechanical configuration of the motor, load, gear-box and shaft there may be some critical speeds within the operating speed range of the drive. The critical speeds have to be known and if they have to be avoided the appropriate parameter settings have to be made. Special attention has to be paid to variable speed applications using twopole motors, since there is usually a critical motor speed below its rated speed. For more information see Chapter 6 - Standard Functions, Critical Speed.
8.5.3
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.
74
Although from an electrical point of view no restrictions exist for variable speed operation with retrofit motors, attention should be paid to possible motor and load restrictions such as insufficient lubrication or reduced cooling at low speed, critical speed areas within the targeted operating range that need to be avoided, etc. Also the maximum (i.e. rated) speed of the motor should under no circumstances be increased without authorization from the manufacturer of each component of the drive train concerned.
8.5.4
Torsional 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 arrangements.
75
76
Appendix A - Installation Guidelines

Ambient Conditions
Ambient conditions may require to derate the drive due to the presence of elevated air temperature, altitude, or cooling water temperature. Sufficient air flow must be available. Other ambient factors such as relative humidity, air contamination, shock and vibration must also be in compliance with stated maximum permissible levels. See Appendix B - Technical Data for load capacity derating factors and other requirements related to ambient conditions. Converter Enclosure The standard IP protection classes for the converter enclosure according to IEC 529 are: IP21 (for air-cooled converters) IP31 (for water-cooled converters).
Higher IP-protection classes for the converter enclosure are optional. Please refer to Chapter 7 - Options.
Mounting
Space Requirements All units must be mounted in an upright position with adequate free space provided in accordance with Table A-1. Table A-1 Required free space in front and above converter
Type of Cooling Air Water Above mm / (in.) 500 (1)(2)(3) (20") 0 / 700 (1)(2) (0")/(27.6") Below mm / (in.) 0 (1) (0") 0 (1) (0") Left / Right mm / (in.) 0 (5) (0") 0 (5) (0") Front mm / (in.) 1000 (4) (39.4") 1000 (4) (39.4") Back mm / (in.) 0 (6) (0") 0 (0")
(The dimensions given are minimum values) Notes: 1 Dimensions do not include space for cable entry which can be from top or from below. 2 Dimensions are above the blower hood or above the redundant fan unit. 3 This is a general recommendation to ensure proper air flow.
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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.
500 mm / 20 in.
400 mm / 15.75 in.
Front view
Top view
1000 mm / 39.4 in.
1000 mm / 39.4 in. Water-cooled ACS 1000
Air-cooled ACS 1000
Figure A-1 ACS 1000 free space requirements For cabinet dimensions refer to Appendix C - Dimensions and Weights.
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The foundation plans for the ACS 1000 12-pulse, air and water-cooled, are given in Figure A-2 and Figure A-3.
2846 78
37.5
2856
78
20
12
Figure A-2 Foundation plan with position of anchoring holes: ACS 1000 12-pulse, air-cooled
585.5 2760/3260 * 1080.5 802.5
800
685
181
70
432
50
20
12
Figure A-3 Foundation plan with position of anchoring holes: ACS 1000 12-pulse, water-cooled
800
38
79
The cabinet should be fixed with anchor bolts and lock washers (recommended size M12, not part of supply) as shown in Figure A-4 below. The anchor holes in the base mounting channels can be accessed through the cabinet.
anchoring holes
Figure A-4 Cabinet mounting with bolts and lock washers Floor Levelling and Cable Ducts The ACS 1000 cabinet must be installed in upright position. The maximum allowable overall unevenness is 5 mm. If the floor is uneven, it must be levelled. The floor must be of non-flammable material, with smooth and nonabrasive surface, protected against humidity diffusion and able to support the weight of the converter (min. 1000 kg/m2). Cable ducts must be of non-flammable material, with non-abrasive surface and protected against humidity, dust and penetration of animals.
Power Equipment Installation
General
The connection from the mains supply to the ACS 1000 drive consists of six basic elements: Main circuit breaker / controller Instrumentation and protection equipment Transformer primary cables Transformer Transformer secondary cables Cable termination - ACS 1000.
Recommendations for the installation of each of these elements are given below. All applicable manufacturer s instructions and local regulations must be followed when installing this equipment. If any specific instruction
80
as stated in this manual appears to be in conflict with the requirements, please contact your local ABB representative for further assistance. For information regarding Main Circuit Breaker / Controller, Instrumentation and Protection Equipment refer to Chapter 6 - Standard Functions and Chapter 8 - Selecting the Drive System.
Transformer Primary 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.
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 cables rated for 6kV/10 kV are common. In order to insure compliance with EMC requirements and to provide a low impedance, high frequency path through which the common mode currents can flow, a shielded cable is recommended. Shields should be terminated and grounded at the shortest possible way at both cable termination points. The ACS 1000 includes a vertical ground bus within the cable termination section in order to facilitate above requirement. A non-shielded cable with a continuous corrugated aluminum armor may be used as an alternative to the shielded cable described above. Steel wire armored or interlocked aluminum armored cable should not be used. Cable terminal ends with electrical contact all around its periphery to the armor should be used to terminate the cable ends to the ground. The ampacity rating of the cable should be in consistency with 125% of the transformer nominal output current and the settings of the protection equipment in order to allow for the harmonic content. Derating of cable ampacity in accordance with maximum expected ambient temperature, raceway fill factors and any other factors required by local electrical codes
81
should be applied. Installation should be in compliance with standard industrial practice for medium voltage equipment. If required by local electrical code, an equipment safety ground wire should be supplied separately. The ampacity of this conductor shall be in accordance with the code. For information regarding the maximum length of the transformer secondary cables see Appendix B - Technical Data.
Motor Cables
There are no special requirements to be considered for the motor cables. The maximum cable length is limited to 1000 m (3281 ft). A voltage rating consistent with the voltage present at the motor must be selected. The ampacity rating should be consistent with the size of the motor being supplied and the overload settings of the motor protection software. Derating of cable ampacity in accordance with maximum expected ambient temperature, raceway fill factors, and any other factors required by local electrical codes should be applied. Installation should comply with standard industrial practice for medium voltage equipment. Cable screening is not required for the motor cables, since the converter output voltage and current are sinusoidal. Therefore no measures against common mode currents are needed. If required by local electrical code an equipment safety ground wire should be supplied separately. The ampacity of this conductor shall be in accordance with the code. Motor cables are terminated within the ACS 1000 cabinet in the same way as the transformer secondary cables (see Figure A-5).
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.
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.
Auxiliary Power Cables

A 3-phase cable without neutral connector is required for auxiliary power supply. Type and ratings are to be selected according to local regulations. For ratings see also Appendix B - Technical Data.
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Control Cables
Control cables should be in accordance with Table A-2. Cable shields should be terminated on the ACS 1000 end only. Either single or multiple twisted pair cables may be used. Table A-2 Control cable requirements
Signal Type Analog In Analog Out Digital In Digital Out General Cable Type Twisted pair(s) - Overall Shield Twisted pair(s) - Overall Shield Twisted pair(s) Twisted pair(s) Cross-Section (I/O Termination) 0.5 to 2.5 mm2 / AWG 20 to AWG 12 0.5 to 2.5 mm2 / AWG 20 to AWG 12 0.5 to 2.5 mm2 / AWG 20 to AWG 12 0.5 to 2.5 mm2 / AWG 20 to AWG 12
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 recommendations of the cable manufacturer. For best EMC performance, shielded three phase cables are recommended. If single phase cables are used, the cables with the three different phases must be grouped close together to ensure best EMC performance. Phase interchange must be accomplished according to local regulations. For high power ratings, a maximum of two cables per motor phase can be accommodated by the gland plates of the ACS 1000. If the cross-section of the cable shielding is less than 50% of the cross-section of one phase, an additional grounding wire should be laid along the power cables to avoid excessive heat losses in the cable shieldings. Please refer to the local regulations for further details.
Cable Termination Grounding Wire Control Cables
Cables must be terminated with connectors according to the cable manufacturer s requirements. Routing of the grounding connection must comply with local regulations. 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.
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ACS 1000 Cable Entry and Termination

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. Figure A-5 shows a typical example of how transformer and motor cables are connected to the internal bus system of the ACS 1000. Cables can be entered through the cabinet roof or from the bottom. If the cable entry is from below, the gland plates mounted on top of the cable termination section must be relocated to the bottom and the bottom cover plate must be fixed to the top of the cabinet.
2U1 Front side of cabinet 2V1 2W1 U2 V2 W2 1U1 1V1 1W1
Side view
Front view
Figure A-5 Principle of power cable entry (water-cooled type)
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Transformer Connection Diagram for 12-pulse ACS 1000

PE Factory Ground
Transformer
a1
b1
c1
a2
b2
c2
Shielding
Armouring
1U1
Factory Ground
1V1
1W1
2U1
2V1
2W1
PE
ACS 1000
Figure A-6 Typical 3-line transformer connection diagram.
Transformer Connection Diagram for 24-pulse ACS 1000

PE Factory Ground
Transformer
a1
b1
c1
a2
b2
c2
a3
b3
c3
a4
b4
c4
Shielding
Armouring
1U1 1V1 1W1

Factory Ground PE
2U1 2V1 2W1
3U1 3V1 3W1
4U1 4V1 4W1
ACS 1000
Figure A-7 Typical 3-line transformer connection diagram
85
Motor Connection Diagram for 12 / 24-pulse ACS 1000
ACS 1000
Factory Ground PE
V2 U2 W2
V U
Factory Ground PE
Figure A-8 Typical 3-line motor connection diagram
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Appendix B - Technical Data

Transformer Connection / Converter Input
Primary Side Voltage Secondary Side Voltage Any medium voltage level can be applied to the primary side of the converter input transformer. Transformer secondary side / converter input voltages (no load) for 12 / 24-pulse ACS 1000: 1327 VAC, 10% for 2.3 kV motors 1903 VAC, 10% for 3.3 kV motors 2305 VAC, 10% for 4.0 kV motors
Safe operation with reduced output power is possible down to -25%. Phase Shift Phase shift between transformer secondary windings: Frequency Range Voltage Unbalance Fundamental Power Factor Total Power Factor Transformer Secondary Cables 30 for 12-pulse ACS 1000 15 for 24-pulse ACS 1000
50 / 60 Hz max. 2% (Umax - Umin ) / Uavg cos 1 > 0.97 cos T > 0.95 Depending on the presence of a Common Mode Choke (CMC) in the ACS 1000, the maximum permitted length for the transformer secondary cables is as follows: Table B-1 ACS 1000 without CMC
ACS 1000 Types Air-cooled Water-cooled Air-cooled Water-cooled Rectifier Type 12-pulse 12-pulse 24-pulse 24-pulse Max. cable length 30 m (98 ft) 30 m (98 ft) 20 m (66 ft) 20 m (66 ft)
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Table B-2 ACS 1000 with CMC

ACS 1000 Types Air-cooled Water-cooled Air-cooled Water-cooled Rectifier Type 12-pulse 12-pulse 24-pulse 24-pulse Max. cable length 200 m (656 ft) 200 m (656 ft) Not available with CMC 150 m (492 ft)
Converter Output / Motor Connection

Nominal Voltage Operational Voltage Frequency Frequency Resolution Short Term Overload Capacity Field Weakening Point Switching Frequency Maximum Motor Cable Length Acceleration Time Deceleration Time Efficiency UNom: 2.3 kVAC, 3.3 kVAC, 4.0 kVAC UOut: 0UNom, 3-phase, sinusoidal, symmetrical 0...66 Hz for UNom = 2.3 kV, 3.3 kV and 4.0 kV 0.01 Hz 1 min/10 min: 110% of rated current 4566 Hz 1 kHz (3-level inverter, operating at 2 x 500 Hz) 1000 m (3281 ft) 01800 s 01800 s Approximately 98% (with nominal input voltage and DC-link under full load)
Auxiliary Supply
Auxiliary Voltage Level 400 VAC, 50 or 60 Hz, 3 phase 10% or 480 VAC, 60 Hz, 3 phase 10% or 575 VAC, 60 Hz, 3 phase 10%
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Auxiliary Power Consumption
Table B-3 Auxiliary power consumption

Air-cooled Types all types ACS1012-W1 ACS1013-W1 ACS1012-W2 ACS1013-W2 ACS1013-W3 ACS1014-W2 ACS1014-W3 ACS1014-W1 Water-cooled Types Power consumption 7.3 kW * 4.3 kW * 4.6 kW *
4.9 kW *
*) without optional heaters / coolers
Environmental Aspects
Ambient Temperature The permitted temperature range for the ACS 1000 is: +1+40 C (34104 F) for air-cooled types Note: If the temperature is higher than +40 C (+104 F) the output power of the air-cooled ACS 1000 types decreases. For derating factors see section Derating of Drive Power, page 90. Contamination Levels +1+50 C (34122 F) for water-cooled types
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.
Installation Site Altitude
The maximum possible installation site altitude for the ACS 1000 is: 5500 m (18045 ft) above sea level for 2.3 kV motor voltage 4000 m (13124 ft) above sea level for 3.3 kV motor voltage 3000 m (9843 ft) above sea level for 4.0 kV motor voltage.
Note: If the installation site is more than 2000 m (6562 ft) above sea level the derating of the output power needs to be considered for the air-cooled ACS 1000 types. For derating factor see section Derating of Drive Power, page 90. Water-cooled types do not have a derating for the installation site altitude.
89
Relative Humidity
The permitted ranges for relative humidity are: 595%, no condensation is allowed 560%, if corrosive gases are present.
Vibration
The ACS 1000 can be exposed to the following maximum values for vibration: 0.3 mm (29 Hz) 1 m/s2 (2200 Hz), sinusoidal (according to IEC 721-3-3). < 75 dB (A) for air-cooled types < 70 dB (A) for water-cooled types.
Sound Pressure Level
Derating of Drive Power
Air-cooled Converters
Ambient Temperature The derating factor for air-cooled converters with enclosure class IP21 is as follows: Above +40 C (+104 F) the rated output current is decreased by 1.5 % for each additional 1 C (0.85 % for each 1 F) up to the maximum permitted temperature of +50 C (+122 F). Example: If the ambient temperature is 50 C the derating factor is calculated as 100% - 1.5 %/C 10 C = 85%. Hence, the maximum output current is 85% of the rated value. Derating for Air Filters Depending on the mesh size of the filter mat the derating factors as stated in Table B-4 apply to the rated output power: Table B-4 Derating factors for air filters:
Mesh Size 18 m 12 m 10 m Remark Standard Option Option Derating in % 0 5 10
Derating for Redundant Cooling Fan Installation Site Altitude
If a redundant cooling fan is installed the derating factor for the rated output power is 7.5 %. 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.
90
Water-cooled Converters
Derating for Raw Water Temperature If the raw water temperature exceeds 27 C (81 F) the derating factors as stated in Table B-5 apply to the rated output power: Table B-5 Derating factors for raw water temperature
Converter Type ACS1012-W1 ACS1012-W2 ACS1013-W1 ACS1013-W2 ACS1013-W3 ACS1014-W1 ACS1014-W2 ACS1014-W3 Rated motor Power (kW) 18002250 25002800 20002500 28004000 45005000 18002250 25003550 40005000 Cooling Water Inlet Temp. Range 27C to max. 38C 27C to max. 38C 27C to max. 38C 27C to max. 38C 27C to max. 38C 27C to max. 38C 27C to max. 38C 27C to max. 38C Derating in % / K 0 0 0 0 0.4 0.6 0 1.35
Derating for Frostproofing
If glycol is added to the make-up water,the derating factors as stated in Table B-6 apply to the rated output power: Table B-6 Derating factors for glycol
Frostproofing - 10C - 20C - 30C - 40C Glycol Concentration 20 % 34 % 44 % 52 % Derating in % 4.5 7 9 11.5
Transportation and Storage

Temperature Relative Humidity Vibration (Storage) Vibration (Seismic) Shock (Storage and Transportation) -40+70 C (-40+158 F) Less than 95%, no condensation allowed Max. 0.3 mm (2..9 Hz), max.1 m/s2 (2..200 Hz), sinusoidal (IEC 721-3-1) Max. 9 mm (535 Hz), max. 18 m/s2, sinusoidal (IEEE 344) Max. 100 m/s2, 11 ms, (IEC 721-3-2 / 2M2), Spectrum I
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Cooling
Air-cooled Converters
Cooling Method Power Losses Cooling Air Flow Air cooling with internal fan < 2 % of nominal output power 1.7 m3/s (3600 cu ft/min) for ACS 1000 - A1 2.5 m3/s (5300 cu ft/min) for ACS 1000 - A2/A3
Water-cooled Converters
Cooling Method Heat Dissipation to Environment Raw Water Temperature Raw Water Pressure Extended Raw Water Temperature Raw Water Flow Water-cooled closed loop system with superimposed closed circuit air cooling. approx. 1 kW +4+27 C (+40+80 F) 110 bar (14.22144.2 lb/sq in) +27+38 C Water Quality
80 l/min (21.1 gal/min for ACS 1000 - W1) or l/min (39.6 gal/min for ACS 1000 - W2/W3)
150
Table B-7 Make-up water (drinking water) quality requirements

Parameter pH conductivity hardness chloride (Cl) copper (Cu) total dissolved solids (TDS) suspended solids Value 6 8.5 < 300 S / cm 3 10 dH < 100 mg/l < 0.1 mg/l < 300 mg/l < 5 mg/l
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Table B-8 Raw water (industrial water) quality requirements

Parameter pH conductivity hardness chloride (Cl) 69 < 500 S / cm 3 15 dH < 300 mg/l above 300 mg/l titanium stabilized exchanger plates are required recommended: < 300 mg/l up to 1000 mg/l are possible, provided above limits for hardness and chloride are not exceeded < 10 mg/l Value
total dissolved solids (TDS)
suspended solids
Protection Functions
The drive provides a wide range of protection, fault and alarm functions including: Motor temperature monitoring Motor stall Underload Overspeed Undervoltage Battery condition monitoring Motor phase loss Overvoltage Short circuit in the rectifier bridge Charging fault Supply phase loss Overcurrent Short circuit of the inverter Measurement loss Communication fault Cooling circuit monitoring (water-cooled converters) Earth fault monitoring
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Analog Inputs
Analog Input (AI) Floating, galvanically isolated inputs Common Mode Voltage Isolation Voltage Common Mode Rejection Ratio Resolution Accuracy Protection Input Updating Time Terminal Block Size Signal Level: 020 mA / 420 mA or 010 V / 210 V, individually scalable by parameter setting Input Resistance: Rin = 100 for current input Rin = 210 k for voltage input
max. 48 V 350 VAC > 80 dB at 50 Hz 0.1% (12 bit)
0.25% (Full Scale Range) at 25 C (30 mV offset)

No internal damage up to 250 VAC/DC input voltage (for voltage inputs) 100 ms (with standard application software) Cables 0.52.5 mm2 (up to AWG12)
Analog Outputs
Analog Output (AO) Signal Level Isolation Voltage Resolution Accuracy Max. Load Impedance Protection Output Updating Time Terminal Block Size Floating, galvanically isolated outputs 020 mA / 420 mA individually scalable by parameter setting 350 VAC 0.03% (12 bit)
0.25% (Full Scale Range) at 25 C ( 50 A offset)

250 No internal damage up to 250 VAC/DC input voltage, short circuit proof 250 ms (with standard application software) Cables 0.52.5 mm2 (up to AWG12)
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Digital Inputs
Digital Input (DI) Signal Level Logical Thresholds Input Current Filtering Time Constant Isolation Isolation Test Voltage Floating, galvanically isolated inputs (opto-coupled) 22250 VAC / 22150 VDC < 12 VAC/DC 0, > 20 VAC/DC 1
at 24 V: 13 mA at 250 V, 10 mA 20 ms Individually isolated (for 1minute) 2300 VAC input / input 1350 VAC input / logic 1350 VAC input / ground
Input Updating Time Terminal Block Size
250 ms (with standard application software) Cables 0.52.5 mm2 (up to AWG12)
Digital Outputs
Digital Output (DO) Switching Capacity With switch-over contact (SPDT) Contacts Isolation Voltage Output Updating Time Terminal Block Size AC: 6 A switching, 4 A steady state up to 250 V DC: at 24 V: 8 A, at 48 V: 1A, at 120 V: 0.4 A
Encapsulated Contacts 4 kVAC, 1 minute 250 ms (with standard application software) Cables 0.52.5 mm2 (up to AWG12)
Auxiliary Power Output

Voltage Maximum Current Protection Terminal Block Size 24 VDC +15% / -10% 180 mA (per I/O-board) Short circuit proof Cables 0.52.5 mm2 (up to AWG12)
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This voltage can be used for the digital inputs of ACS 1000 and / or to supply external measurement transmitters for analog inputs. An external 120 VAC / 240 VAC supply can be used instead of the internal 24 VDC supply.
Reference Voltage Output

Voltage Maximum Current Protection Terminal Block Size 10 VDC 10% 10 mA Short circuit proof Cables 0.52.5 mm2 (up to AWG12) This reference voltage can be employed to supply external potentiometers used for reference values.
DDCS Fiber Optical Link

High speed, DDCS protocol fiber optic serial data bus. Connectors Fiber Optic Cable A pair of fiber optic connectors (transmitter and receiver) Plastic core optic fiber, 1 mm (0.04 in), max. length 10 m (33 ft), min. bend radius 25 mm (1 in) (short-term) or 35 mm (1.4 in) (long-term)
Enclosures
Standard Enclosure Classes IP21 (for air-cooled types) IP31 (for water-cooled types)
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Dimensions and weights of the basic ACS 1000 cabinets are given in Table C-1 to Table C-3. The dimensions and weights of additional equipment and converter options are given in Table C-4. Table C-1 Dimensions and weights of 12/24-pulse ACS 1000 air-cooled and 12-pulse ACS 1000 water-cooled (24-pulse ACS 1000 water-cooled see Table C-4) motor voltage 2.3 kV
Motor Voltage (kV) Converter Type Type of Cooling Length (mm) 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 ACS1012-A1-A0-00 ACS1012-A1-B0-00 ACS1012-A1-C0-00 ACS1012-A1-D0-00 ACS1012-A1-E0-00 ACS1012-A1-F0-00 ACS1012-A1-G0-00 ACS1012-A1-H0-00 ACS1012-A2-J0-00 ACS1012-A2-K0-00 ACS1012-A3-L0-00 ACS1012-A3-M0-00 ACS1012-A3-N0-00 ACS1012-W1-P0-00 ACS1012-W1-Q0-00 ACS1012-W2-R0-00 ACS1012-W2-S0-00 Air Air Air Air Air Air Air Air Air Air Air Air Air Water Water Water Water 4700 155 902 30 2002 67 3680 8100 4200 1310 902 30 2002 67 3300 7260 3000 910 900 30 2005 67 * 2000 4410 3000 910 900 30 2005 67 * 1750 3860 3000 910 900 30 2005 67 * 1600 3530 (ft/in) Dimensions and Weights
Depth (mm) (ft/in)
Height (mm) (ft/in)
Weight** (kg) (lbs)
*) without air-exhaust fan cover (see Table C-4) **) approximate values
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Table C-2 Dimensions and weights of 12/24-pulse ACS 1000 air-cooled and 12-pulse ACS 1000 water-cooled (24-pulse ACS 1000 water-cooled see Table C-4) motor voltage 3.3 kV
Motor Voltage (kV) Converter Type Type of Cooling Length (mm) 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 ACS1013-A1-A0-00 ACS1013-A1-B0-00 ACS1013-A1-C0-00 ACS1013-A1-D0-00 ACS1013-A1-E0-00 ACS1013-A1-F0-00 ACS1013-A1-G0-00 ACS1013-A1-H0-00 ACS1013-A2-J0-00 ACS1013-A2-K0-00 ACS1013-A2-L0-00 ACS1013-A2-M0-00 ACS1013-A2-N0-00 ACS1013-A2-P0-00 ACS1013-A3-Q0-00 ACS1013-A3-R0-00 ACS1013-W1-S0-00 ACS1013-W1-T0-00 ACS1013-W1-U0-00 ACS1013-W2-V0-00 ACS1013-W2-W0-00 ACS1013-W2-X0-00 ACS1013-W3-Y0-00 ACS1013-W3-Z0-00 ACS1013-W3-10-00 Air Air Air Air Air Air Air Air Air Air Air Air Air Air Air Air Water Water Water Water Water Water Water Water Water 4700 155 902 30 2002 67 3680 8100 4200 1310 902 30 2002 67 3300 7260 3000 910 900 30 2005 67 * 2000 4410 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 910 910 (ft/in) Dimensions and Weights
Depth (mm) 900 900 900 900 900 900 900 900 900 900 900 900 900 900 30 30 (ft/in)
Height (mm) 2005 2005 2005 2005 2005 2005 2005 2005 2005 2005 2005 2005 2005 2005 67 * 67 * (ft/in)
Weight** (kg) 1600 1600 1600 1600 1600 1600 1600 1600 1750 1750 1750 1750 1750 1750 3860 3530 (lbs)
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Table C-3 Dimensions and weights of 12/24-pulse ACS 1000 air-cooled and 12-pulse-ACS 1000 water-cooled (24-pulse ACS 1000 water-cooled see Table C-4) motor voltage 4.16 kV
Motor Voltage (kV) Converter Type Type of Cooling Length (mm) 4.16 4.16 4.16 4.16 4.16 4.16 4.16 4.16 4.16 4.16 4.16 4.16 4.16 4.16 4.16 4.16 4.16 4.16 4.16 4.16 4.16 4.16 ACS1014-A1-A0-00 ACS1014-A1-B0-00 ACS1014-A1-C0-00 ACS1014-A1-D0-00 ACS1014-A1-E0-00 ACS1014-A1-F0-00 ACS1014-A1-G0-00 ACS1014-A1-H0-00 ACS1014-A2-J0-00 ACS1014-A2-K0-00 ACS1014-A3-L0-00 ACS1014-A3-M0-00 ACS1014-A3-N0-00 ACS1014-W1-P0-00 ACS1014-W1-Q0-00 ACS1014-W2-R0-00 ACS1014-W2-S0-00 ACS1014-W2-T0-00 ACS1014-W2-U0-00 ACS1014-W3-V0-00 ACS1014-W3-W0-00 ACS1014-W3-X0-00 Air Air Air Air Air Air Air Air Air Air Air Air Air Water Water Water Water Water Water Water Water Water 4700 155 902 30 2002 67 3680 8100 4200 1310 902 30 2002 67 3300 7260 3000 910 900 30 2005 67 * 2000 4410 3000 910 900 30 2005 67 * 1750 3860 3000 910 900 30 2005 67 * 1600 3530 (ft/in) Dimensions and Weights
Depth (mm) (ft/in)
Height (mm) (ft/in)
Weight** (kg) (lbs)
99
Table C-4 Dimensions and weights of the ACS 1000 and optional equipment
Description ACS 1000 Type Air-exhaust fan cover Redundant cooling fan unit Braking chopper (placed on the right side) Synchronous bypass (placed on the left side) 24-pulse extension (placed on the left side) Redundant fan unit Watercooled Watercooled Air-cooled Air-cooled Length (mm) 654 2000 644 644 844 650 (ft/in) 2 2"** 6 7""* 2 1" 2 1" 2 9""* 2 2" Dimensions and Weights Depth (mm) 733 870 902 902 902 865 (ft/in) 2 5" 210"" 3 3 3 210"" Height (mm) 278 800 2005/ 2070* 2005/ 2070* 2005/ 2070* 312 6 7"/ 6 10"* 6 7"/ 6 10"* 6 7"/ 6 10"* 1 ** (ft/in) Weight** (kg) 300 460 460 350 100 (lbs) 660 1012 1012 770 220
*) including lifting lugs **) approx. values
100
Appendix D - Applicable Codes and Standards

CE Marking
The ACS 1000 frequency converter is marked with a CE symbol. The CE marking indicates that the ACS 1000 complies with the basic technical requirements and conformity valuation criteria and is an essential requirement of the relevant EC Directives. The CE marking is mainly for the benefit of authorities throughout the Common European Market.
Low Voltage Directive

Low Voltage Directive73/23 EEC modified by 93/68 EEC. This directive concerns all electrical equipment with nominal voltage levels of 50..1000 VAC and 75..1500 VDC. The aim of the directive is to protect against electrical, mechanical, fire and radiation hazards. It tries to insure that safe products are placed on the market. Compliance with the Low Voltage Directive The ACS 1000 fully complies with the Low Voltage Directive as far as enclosure, auxiliary supply and I/O ports are concerned. The Declaration of Conformity will be enclosed in the ACS 1000 delivery. The Low Voltage Directive is not applicable for the medium-voltage section of the ACS 1000. However, the medium-voltage section fulfills the requirements of the standard EN 50178 (Electronic equipment for use in power installations).
Machinery Directive
89/392 EEC modified by 91/368; 93/44, 93/68 and 98/37EEC. This directive concerns all combinations of mechanically joined components, where at least one part is moving.
101
Compliance with the Machinery Directive
On its own, the ACS 1000 does not have a functional value to the user: It always needs its motor coupled to the driven load before it can function effectively. Therefore, the Machinery Directive is not applicable for the ACS 1000.
EMC Directive
89/336 EEC modified by 91/263; 92/31; 93/68 and 93/97EEC. EMC stands for Electromagnetic Compatibility. It is the ability of electrical/ electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other neighboring electrical equipment or system.
Emissions
The source of high-frequency emission of frequency converters is fast switching of IGCTs and control electronics. The high-frequency emission can propagate by conduction and radiation.
Immunity
Electrical equipment should be immune to high-frequency and lowfrequency phenomena. High-frequency phenomena include electrostatic discharge (ESD), fast transient burst, radiating electromagnetic field, conducting radio frequency disturbance and electrical surge. Typical low frequency phenomena are mains voltage harmonics, notches and imbalance. Compliance with the EMC Directive The EMC Directive applies to the ACS 1000 as far as the enclosure, the auxiliary supply and the I/O ports are concerned. The Declaration of Conformity for industrial environment signed by ABB is enclosed in the ACS 1000 delivery. The two applicable standards, EN 50081-2 (Emissions) and EN 50082-2 (Immunity) have been met. As far as the medium-voltage ports are concerned the EMC Directive is not applicable. The standard IEC 1800-3: Adjustable speed electrical power drive systems - Part 3: EMC product standard including specific test methods, states: For supply voltages higher than 1000 VAC rms, EMC requirements result from agreement between manufacturer / supplier and user. In order to make sure that the whole system is electromagnetically compatible within its surrounding the installation regulations have to be strictly observed. Following the grounding regulations, instructions for cable entries as well as for cable laying is extremely important. The ACS 1000 is installed with screened control and main power supply cables that are specified in Appendix A - Installation Guidlines. The installation of the ACS 1000 shall be performed as described in the ACS 1000 Users Manual.
102
UL Marking
The ACS 1000 is UL and Canadian UL listed under "Power Conversion Equipment", File E176716.
Applicable Codes and Standards

The ACS 1000 Converter complies with the following codes and standards: IEC 22B/88/CD Draft revision of IEC 146-2: Self-commutated convertors including direct DC convertors and IEC 146-3: Semiconductors direct DC convertors DC chopper convertors Semiconductor convertors Degrees for protection provided by enclosures (IP-Code) Insulation coordination for equipment within low-voltage systems Classification of environmental conditions Part 3: Storage Classification of environmental conditions Part 3: Transportation Classification of environmental conditions Part 3: Stationary use at weatherprotected locations Electrostatic immunity test - contact discharge 4 kV - air discharge 8 kV Fast Transient immunity test - Aux-Supply Power-Ports: 2 kV, 5 kHz - Signal-Ports: 2 kV, 5 kHz Surge immunity test - Aux-Supply Power Ports - Line to Line 2 kV - Line to Earth 4 kV - Signal-Ports 1 kV Electromagnetic compatibility (EMC)
IEC 146-1-1 IEC 529 IEC 664-1 IEC 721-3-1 A1
IEC 721-3-2 A2
IEC 721-3-3 A1
IEC 1000-4-2
IEC 1000-4-4
IEC 1000-4-5
EN 50081-2
103
generic emission standard part 2: Industrial environment EN 50082-2 Electromagnetic compatibility (EMC) generic immunity standard part 2: Industrial environment Electronic equipment for use in power installations Suppression of Radio disturbances caused by electrical appliances and systems - Aux-Supply Power-Ports conducted emission 0.15 - 30 MHz Class A Radio frequency common mode - Aux-Supply Power-Ports - Signal-Ports AM 0.15 - 80 MHz 10 V (rms) High Voltage Industrial Control Equipment Medium Voltage Power Conversion Equipment Proposed first edition of the standard Power Conversion Equipment Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems
EN 50178 EN55011; A2
ENV 50141
UL 347 UL 347A
UL 508C IEEE 519
104

1
A C S 1
Product Category
A = AC Drive
2/3
Product Type
CS = Standard xx = OEM
ACS Product Family

1 = ACS 1000
Variation
0 = Standard 1 = Non-Standard Options included (to be specified separately)
Input Bridge
0 = 6-Pulse Rectifier 1 = 12 Pulse Rectifier 3 = 12-Pulse Rect. with Integrated Transformer 2 = 24 Pulse Rectifier 4 = 24-Pulse Rect. with Integrated Transformer
Voltage Rating
2 = 2.3 kV 3 = 3.3 kV 4 = 4.0 kV 6 = 6.6 kV
8/9
Frame Size
A1, A2 and A3 for Air Cooled Converters W1, W2 and W3 for Water Cooled Converters See Option Sheet
10
Sub-Frame Size
See ACS 1000 rating tables
11
Extended Ambient Air / Raw Water Temperature

0 = None x = extended ambient air / raw water temperature
See Option Sheet
12
Maximum Output Frequency

0 = 66 Hz (Standard) 2 = 82.5 Hz x = Other options will follow later
13
Field Weakening
0 = 1 : 1.1 (Standard) 4 = max. FW 1 : 1.5 1 = max. FW 1 : 1.2 2 = max. FW 1 : 1.3 3 = max. FW 1 : 1.4
14
Filter Equipment
F = Sine Filter and Common Mode Choke S = Sine Filter (without Common Mode Choke)
15
Output Filter Choke

Output Filters are motor specifically selected
16/17
Output Filter Capacitor

Output Filters are motor specifically selected
18
Auxiliary Voltage Rating (indicated values +/- 10%)

1 = 400 VAC / 50 Hz 2 = 480 VAC / 60 Hz 3 = 575 VAC / 60 Hz 4 = 400 VAC / 60 Hz
Example: ACS 1014-A1-B0-00-F101-2 Note: The ACS 1000 is identified by the type code which represents all standard features and available options by one of the 36 digits. The type code is also printed on the name plate of each drive. Options, presently not available, are shaded on the type code sheet. The example of the type code sheet shows only a part of the type code. For the complete type code please use the software based ACS 1000 configurator tools or contact the factory.
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106

VSD ACS 1000 Technical Catalogue

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ACS 1000 Medium Voltage AC Drives

Effective: October 23, 2000

ABB Industrie AG. All Rights Reserved.

ACS 1000 Technical Catalog

ACS 1000 Technical Catalog

ACS 1000 Technical Catalog

8.4 8.4.1 8.4.2 8.4.3 8.5 8.5.1 8.5.2 8.5.3 8.5.4

ACS 1000 Technical Catalog

Appendix C - Dimensions and Weights

101 101 101 101 102 102 102 103 103

Appendix E - ACS 1000 Type Code

ACS 1000 Technical Catalog

The Standard Solution

ACS 1000 Technical Catalog

ACS 1000 Technical Catalog

ACS 1000 Types

Standard power ranges for ACS 1000 converters

ACS 1000 Technical Catalog

ACS 1000 Technical Catalog

Chapter 2 - Main Features

ACS 1000 Technical Catalog

Chapter 2 - Main Features

Direct Torque Control

Speed controller + acceleration compensator

Torque reference Speed reference PID

Torque reference controller

Flux reference controller

Actual speed DC bus voltage (4 measurements)

Filter current (3 measurements)

Figure 2-1 DTC block diagram

ACS 1000 Technical Catalog

Chapter 2 - Main Features

How does DTC differ from PWM Flux Vector Drives?

Shaft speed and position not required

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

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

ACS 1000 Technical Catalog

Chapter 2 - Main Features

3 Main Circuit Breaker

Medium Voltage Switchgear

Protection Intermediate IGCTs DC Link

Three Level Inverter

Output Sine Filter

Squirrel Cage Induction Motor

Figure 2-2 Elementary diagram - ACS 1000, 12-pulse version

ACS 1000 Technical Catalog

Chapter 2 - Main Features

3 Main Circuit Breaker

Medium Voltage Switchgear

Protection Intermediate IGCTs DC Link

Three Level Inverter

Output Sine Filter

Squirrel Cage Induction Motor

Output voltage: 4.16kV Output frequency: 60Hz

Figure 2-4 Voltage and current waveforms at converter output

ACS 1000 Technical Catalog

Chapter 2 - Main Features

ACS 1000 Technical Catalog

Chapter 3 - Hardware Description

ACS 1000 Cabinet Layout

ACS 1000 Technical Catalog

Chapter 3 - Hardware Description

ACS 1000 Technical Catalog

Chapter 3 - Hardware Description