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.

2

ACS 1000 Technical Catalog

Table of Contents Chapter 1 - Overview

7

1.1 1.2 1.3 1.4 1.5

7 7 7 8 9

Introduction The Standard Solution Key Technology Technical Benefits ACS 1000 Types

Chapter 2 - Main Features

11

2.1 2.2 2.3 2.4 2.5 2.6

11 11 12 13 13 14

IGCT Power Semiconductors Fuseless Design Direct Torque Control Input Stage Output Stage Elementary Diagram

Chapter 3 - Hardware Description

17

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

17 17 17 19 20 21 22 23 23 23 23

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

Chapter 4 - User Interfaces

25

4.1 4.2 4.3 4.4 4.5

25 25 26 31 31

ACS 1000 Technical Catalog

Overview CDP 312 Control Panel Standard I/Os Fieldbus Adapter Modules PC Tools

3

Chapter 5 - Parameters and Application Macros

33

5.1 5.2 5.3

33 33 36

Chapter 6 - Standard Functions

39

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

39 39 39 42 42 43 43 44

6.3 6.3.1 6.3.2 6.3.3 6.4 6.4.1

4

Overview Suitable Applications for Different Macros Macro I/O interfaces

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

44 45 45 47 49 49 50

Chapter 7 - Options

51

7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8

51 51 52 53 56 59 61 61

Environmental Conditions Converter Enclosure Input Section Motor Side Converter Cooling Converter Isolators and Bypass Auxiliary & Control Interfaces PC Tools

Chapter 8 - Selecting the Drive System

63

8.1 8.2 8.2.1 8.2.2 8.2.3 8.3

63 63 63 64 65 68

Overview Main Circuit Breaker Main Circuit Breaker Control Tripping Loop Main Circuit Breaker Features Converter Input Transformer Selection

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

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

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

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

ACS 1000 Technical Catalog

69 69 69 70 73 73 74 74 75

77 77 77 80 80 81 81 82 82 82 82 83 83 84 85 85 86

87 87 88 88 89 90 90 91 91 92 92 92

5

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

101

CE Marking Low Voltage Directive Machinery Directive EMC Directive Emissions Immunity UL Marking Applicable Codes and Standards

101 101 101 102 102 102 103 103

Appendix E - ACS 1000 Type Code

6

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ACS 1000 Technical Catalog

Chapter 1 - Overview 1.1

Introduction This Technical Catalog describes the main electrical, mechanical and environmental features of the ACS 1000 – ABB’s contribution to new solutions 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 company’s 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 world’s 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.

ACS 1000 Technical Catalog

7

Chapter 1 - Overview

•

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 world’s 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.

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ACS 1000 Technical Catalog

Chapter 1 - Overview

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

Standard power ranges for ACS 1000 converters

Type of Cooling

(kV)

Rated Motor Power Range** HP

Max. cont. Power of ACS 1000 (kVA)

Frame Size

2.3

Air

400 - 2250

400 - 2000

A1 - A3

2.3

Water

2500 - 4000

2300 - 3600

W1 - W2

3.3

Air

450 - 2250

400 - 2150

A1 - A3

3.3

Water

2500 - 6700

2400 - 5950

W1 - W3

4.0

Air

400 - 2250

400 - 2000

A1 - A3

4.0

Water

2500 - 6700

2300 - 5800

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.

ACS 1000 Technical Catalog

9

Chapter 1 - Overview

10

ACS 1000 Technical Catalog

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.

ACS 1000 Technical Catalog

11

Chapter 2 - Main Features

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

Speed controller + acceleration compensator Torque Control status signals

Internal torque reference

reference Speed

DC bus

Torque comparator

Torque reference controller

Torque

Optimum pulse selector

Flux comparator

PID

Flux reference controller U f U T

f f

= ~ Inverter

Flux status Actual torque Switch Actual flux positions Adaptive motor model

reference

Switch position commands

ASIC

Output filter

Internal flux reference

Actual speed

Inverter current

DC bus voltage (4 measurements)

Filter current (3 measurements)

M 3~

Figure 2-1 DTC block diagram

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ACS 1000 Technical Catalog

Chapter 2 - Main Features

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

Flux Vector

Switching based on core motor variables Flux and Torque

Switching based on separate control of magnetising and torque producing components of current

Shaft speed and position not required

Mechanical speed is essential. Requires shaft speed and position (either measured or estimated)

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

Inverter switching based on average references to a PWM modulator. This results in delays in response and wasted switchings.

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

Torque Step Rise Time Closed Loop 10 to 20 msec. Sensorless 100 to 200 msec.

For more information on DTC, please refer to the Technical Guide No. 1 Direct Torque Control (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: •

ACS 1000 Technical Catalog

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

Chapter 2 - Main Features

2.6

•

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.

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

Medium Voltage Switchgear

Converter Transformer

M

NP

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

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ACS 1000 Technical Catalog

Chapter 2 - Main Features

(Option)

3

Converter Transformer

M

NP

Main Circuit Breaker

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

ACS 1000 Technical Catalog

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Chapter 2 - Main Features

16

ACS 1000 Technical Catalog

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 cabinet’s 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

3.2.1

ACS 1000 Cabinet Layout

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.

ACS 1000 Technical Catalog

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Chapter 3 - Hardware Description

1

2

3

4

Figure 3-1 The ACS 1000 air-cooled type (12 / 24-pulse)

18

1

Control section with separate power cable connection section

2

Grounding switch and filter reactor section (24-pulse version with additional rectifier stack)

3

Rectifier stack, protection IGCTs and cooling fan

4

Inverter stacks, air intake, output filter and DC-link capacitors

ACS 1000 Technical Catalog

Chapter 3 - Hardware Description

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.

1

2

3

4

5

Figure 3-2 The ACS 1000 water-cooled type (12-pulse) 1

Control section with separate power cable connection section

2

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

3

see item 2

4

Converter section (rectifier stack, protection IGCTs, inverter stacks)

5

Cooling unit

ACS 1000 Technical Catalog

19

Chapter 3 - Hardware Description

24-pulse Version

3.2.3

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.

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 drive’s 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.

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ACS 1000 Technical Catalog

Chapter 3 - Hardware Description

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

ACS 1000 Technical Catalog

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Chapter 3 - Hardware Description

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.

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ACS 1000 Technical Catalog

Chapter 3 - Hardware Description

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 drive’s 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).

ACS 1000 Technical Catalog

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Chapter 3 - Hardware Description

24

ACS 1000 Technical Catalog

Chapter 4 - User Interfaces 4.1

Overview The ACS 1000 can be controlled from several control locations:

4.2

•

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.

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

1 L -> CURRENT SPEED TORQUE

Control Panel Display

ACT

PAR

1242rpm I 76.00 A 1242.0rpm 86.00 %

FUNC

DRIVE

ENTER

Control Panel Keypad

LOC

RESET

REF

REM

Multilingual Alphanumeric Display (4 lines x 20 characters) Plain text messages available in several languages

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

Figure 4-1 CDP 312 Control Panel

ACS 1000 Technical Catalog

25

Chapter 4 - User Interfaces

Using the CDP 312 panel it is possible to

4.3

•

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.

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

26

I/O Board configuration with number and type of I/O Signal Type

Ratings

4

Analog Inputs

(AI)

0...20 mA / 4...20 mA or 0...10 V / 2...10 V scalable by parameter setting

2

Analog Outputs

(AO)

0...20 mA / 4...20 mA scalable by parameter setting

14

Digital Inputs

(DI)

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

6

Digital Outputs

(DO)

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

ACS 1000 Technical Catalog

Chapter 4 - User Interfaces

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

ACS 1000 Technical Catalog

I/O Signals: remote control interface Signal Name

Remarks

DI

STANDARD INPUT 1

Macro specific I/O *

DI

STANDARD INPUT 2

Macro specific I/O *

DI

STANDARD INPUT 3

Macro specific I/O *

DI

STANDARD INPUT 4

Macro specific I/O *

DI

STANDARD INPUT 5

Macro specific I/O *

DI

STANDARD INPUT 6

Macro specific I/O *

DI

DISABLE LOCAL

Remote input to disable the possibility for a local/remote switch-over from the CDP 312 control panel

DI

REM ORD MCB CLOSE

Remote request for closing the main circuit breaker

DI

REM ORD MCB OPEN

Remote request for opening the main circuit breaker

DI

REMOTE RESET

Remote fault reset (some converter related faults cannot be reset remotely)

DO

DRIVE READY

Status output “Drive Ready” (i.e. MCB closed, DC-link charged, no lockout active)

DO

DRIVE RUNNING

Status output “Drive Running”

DO

DRIVE ALARM

Status output “Drive Alarm”

DO

DRIVE TRIP

Status output “Drive Tripped”

DO

LOCAL MODE

Local mode operation status indication

AI

REF VALUE 1

Macro specific I/O

Standard

27

Chapter 4 - User Interfaces

Table 4-2 Type

I/O Signals: remote control interface (continued) Signal Name

Remarks

AI

REF VALUE 2

Macro specific I/O

AO

SHAFT SPEED ACT VAL

Actual speed monitoring output

AO

MOT CURRENT ACT VAL / MOT TORQUE ACT VAL

Actual current / torque monitoring output (programmable)

Standard

* see Chapter 6 - Standard Functions

Table 4-3 Type

Signal Name

Remarks

DI

MCB IS CLOSED

Status feedback from the main circuit breaker

DI

MCB IS OPEN

Status feedback from the main circuit breaker

DI

MCB IS AVAILABLE

Status feedback from the main circuit breaker, showing that the breaker is faulty, drawn-out or in test position

DO

MCB ORD CLOSE

Drive command to close the main circuit breaker (pulse signal or maintained)

DO

/MCB ORD OPEN

Drive command to open the main circuit breaker (pulse signal or maintained)

DO

/MCB ORD TRIP

Hardware tripping loop to the main circuit breaker (signal active when low)

Table 4-4 Type

28

I/O Signals: main circuit breaker Standard

I/O Signals: transformer Signal Name

Remarks

DI

/EXT TRAFO PROT TRIP

Initiates a main circuit breaker trip (included in hardwired tripping loop)

DI

OIL LEVEL ALARM

Transformer oil level alarm indication

Standard

W

ACS 1000 Technical Catalog

Chapter 4 - User Interfaces

Table 4-4 Type DI

DI

I/O Signals: transformer (continued) Signal Name

Standard W

OIL TEMP ALARM, or

Transformer oil temperature alarm indication

TRAFO WDG TEMP ALARM

Transformer winding temperature alarm indication

/OIL TEMP TRIP, or

Transformer oil temperature trip indication Transformer winding temperature trip indication

W

/TRAFO WDG TEMP TRIP DI

BUCHHOLZ ALARM

Transformer alarm indication from Buchholz relay

W

DI

/BUCHHOLZ TRIP

Transformer trip indication from Buchholz relay

W

AI

OIL TEMP, or

Temperature measurement of transformer oil Temperature measurement of transformer winding

W

Remarks

Standard

TRAFO WDG TEMP

Table 4-5 Type

ACS 1000 Technical Catalog

Remarks

I/O Signals: motor Signal Name

DI

/EXT MOT PROT TRIP

Initiates a main circuit breaker trip (included in hardwired tripping loop)

DI

EXT MOT PROT ALARM

(External) motor protection alarm indication

W

DI

MOT COOLING ALARM

(External) motor cooling alarm indication

W

DI

/MOT COOLING TRIP

(External) motor cooling trip indication

W

DI

VIBRATION SV ALARM

Motor vibration alarm indication

W

DI

/VIBRATION SV TRIP

Motor vibration trip indication

W

DI

/OVERSPEED TRIP

Motor overspeed trip (included in hardwired tripping loop)

W

AI

MOT WDG TEMP PH U

Motor winding temperature

AI

MOT WDG TEMP PH V

Motor winding temperature

AI

MOT WDG TEMP PH W

Motor winding temperature

29

Chapter 4 - User Interfaces

Table 4-5 Type

Signal Name

Remarks

Standard

AI

BRG TEMP DE

Motor bearing temperature of driven end

W

AI

BRG TEMP NDE

Motor bearing temperature of non-driven end

W

Remarks

Standard

Table 4-6 Type

I/O Signals: process Signal Name

DI

/PROCESS STOP

Remote process stop input to stop the drive (signal active when low)

DI

/INT/EXT EMERGENCY OFF

Emergency OFF (signal active when low) from process side to trip the main circuit breaker instantaneously (included in hardwired tripping loop)

Table 4-7 Type

30

I/O Signals: motor (continued)

I/O Signals: Others Signal Name

Remarks

DI

/SUPPL VOLT UNBALANCE

Trip from external voltage unbalance relay (signal active when low)

DI

EXT WTR COOLING ALARM

Alarm indication from external water cooling unit

DI

/EXT WTR COOLING TRIP

Trip (active when low) from external water cooling unit

DI

BRAKE CHOP FAN ALARM

Alarm signal from braking chopper

DI

BRAKE CHOP TEMP TRIP

Trip signal from braking chopper

DI

INPUT ISOLATOR OPEN

Status input

DI

INPUT ISOLATOR CLOSED

Status input

DI

OUTPUT ISOLATOR OPEN

Status input

DI

OUTPUT ISOLATOR CLOSED

Status input

AI

OUTSIDE AIR TEMP

Temperature measurement of outside air

Standard

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Chapter 4 - User Interfaces

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.

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Chapter 4 - User Interfaces

32

ACS 1000 Technical Catalog

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:

5.2

•

Factory

•

Speed Control

•

Hand/Auto

•

PID Control

•

Torque Control

•

Sequential Control

•

Master/Follower

•

User 1

•

User 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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Chapter 5 - Parameters and Application Macros

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).

Hand/Auto

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.

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

34

ACS 1000 Technical Catalog

Chapter 5 - Parameters and Application Macros

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.

Sequential Control

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.

Master/Follower

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.

User 1 / User 2

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.

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Chapter 5 - Parameters and Application Macros

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

Macro Factory Speed

Hand/Auto

PID

Torque

36

I/Os

I/O functions

DI

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

AI

2 speed reference values

DI

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

AI

Speed reference value in hand mode Speed reference value in auto mode

DI

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

AI

Reference value Actual value, process feedback Actual value process feedback

DI

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

AI

Speed reference value Torque reference value

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Chapter 5 - Parameters and Application Macros

Table 5-1

Macro specific digital and analog inputs (continued)

Macro Sequential

Master Follower

I/Os

I/O functions

DI

MCB open/close commands Start/stop commands Selection of 2 accel/decel ramps Selection of 7 const. speeds Process stop or run enable

AI

Reference value

DI

MCB open/close command Start/stop command Selection of 1 accel/decel ramp Selection of 3 const. speeds Process stop or run enable

AI

Speed reference value

User 1 / User 2

Depends on application

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

Macro Factory Speed PID Torque Sequential Master/Follower

ACS 1000 Technical Catalog

I/Os

I/O functions

DO

Drive ready Drive running Drive alarm Drive trip

AO

Motor frequency Motor torque Motor speed Motor torque filtered

37

Chapter 5 - Parameters and Application Macros

38

ACS 1000 Technical Catalog

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

6.2.1

Standard Control Functions

General Functions

Motor ID Calculation

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).

Full Torque at Zero Speed

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.

Enhanced Flying Start

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

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Chapter 6 - Standard Functions

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.

Power Loss RideThrough

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.

Auxiliary Ride Through

The auxiliary ride through function guarantees correct fault indication and proper trip sequencing, in the event that the auxiliary power source feeding the 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.

Acceleration and Deceleration Ramps

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.

Motor speed

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.

Critical Speed

40

S1

Linear

S2 S3

1 1.25

2 t (s)

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.

ACS 1000 Technical Catalog

Chapter 6 - Standard Functions

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.

Motor speed (rpm) 1560 1380

690 540 Speed reference (rpm) s 1 Lows1 High 540 690

s2 Low s2 High 1380 1560

Constant Speeds

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

Accurate Speed Control

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

Accurate Torque Control without Speed Feedback

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.

T (%) TN 100

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.

90

Tref Tact

10 t(s)

< 10 ms

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

Torque Control

ACS 1000 no Pulse Encoder

ACS 1000 with Pulse Encoder

Linearity error

+ 4 %*

+3%

Torque rise time

< 10 ms

< 10 ms

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

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Chapter 6 - Standard Functions

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.

Remote Control

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).

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Chapter 6 - Standard Functions

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.

1 L -> 600.0 rpm 1 Status Running MotSpeed 600.00 rpm Power 75.0 %

For example:

Fault History

6.2.5

•

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)

The Fault History contains information on the forty most recent faults detected by the ACS 1000. Faults are displayed in alphanumeric characters.

Programmable Digital and Analog Outputs

Programmable Digital 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.

If optional boards IOEC 3 and/or IOEC 4 are installed, a maximum of 12 additional digital outputs (6 on each board) are available.

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Chapter 6 - Standard Functions

Programmable Analog Outputs

Two programmable analog outputs on each IOEC board are at the user’s disposal. Depending on the setting of the corresponding parameters, the analog output signals can represent for example: •

motor speed, process speed (scaled motor speed), output frequency, output current, motor torque, motor power, DC 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

Two Programmable Control Locations

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

44

The ACS 1000 reference can be given using two digital inputs:

ACS 1000 Technical Catalog

Chapter 6 - Standard Functions

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

The output frequency is below the set stall frequency.

2

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.

3

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

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Chapter 6 - Standard Functions

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 curve 3

0.4

curve 4 curve 5

0.3

0.2

0.1

140%

130%

120%

110%

100%

90%

80%

70%

60%

50%

40%

30%

20%

10%

0

Speed

Figure 6-2 Load curves for underload function The protection is activated if all the following conditions are fulfilled simultaneously:

46

1

The motor load is below the underload curve selected by the user (see Figure 6-2).

2

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

Overspeed

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

Undervoltage

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.

ACS 1000 Technical Catalog

Chapter 6 - Standard Functions

6.3.2

Pre-programmed Protection Functions

Motor Phase Loss

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.

Overvoltage

The levels of the positive and negative DC link voltage are monitored to detect whether an improper overvoltage condition develops. If these voltage levels rise above 130% of their nominal levels an overvoltage trip is initiated. On rare occasions, a combination of conditions can result in the motor entering a self excitation mode that can cause the DC link voltage to continue to rise, despite the fact that a trip has been initiated. If this condition occurs and if the DC link voltage levels rise above 135% of their nominal levels, a second overvoltage trip is initiated that causes the inner 6 IGCT’s 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%).

Short Circuit in the Rectifier Bridge

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

Charging Fault

Supply Phase Loss Overcurrent

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.

Inverter Temperature

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.

Cooling Circuit

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

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Chapter 6 - Standard Functions

cooling water pumps, the water level in the expansion vessel and the auxiliary fan are monitored. Short Circuit of the Inverter

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

Ground Fault

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

Communication Fault

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.

Measurement Loss

On the ADCVI board (analog digital conversion for voltage and current) analog signals are converted into digital signals. The digital signals are then transmitted via PPCC (fiber-optic bus system) to the interface board which is the main interface to the converter control system. In order to guarantee proper operation of the protection functions included in the converter, the status of the communication is monitored on the interface board. If a fault is detected a trip is initiated.

48

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.

ID-Run Fault

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.

ACS 1000 Technical Catalog

Chapter 6 - Standard Functions

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.

External Transformer Protection Trip

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.

Line Unbalance Protection Relay

An optional signal input is available to connect a line unbalance protection relay for initiation of a converter trip.

Process Stop

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.

External Emergency Off

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.

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.

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Chapter 6 - Standard Functions

Parameter Lock

6.4.1

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

Customer Specific Options Information on additional user specific options that can be implemented in the ACS 1000 is given in Chapter 7 - Options.

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ACS 1000 Technical Catalog

Chapter 7 - Options 7.1

Environmental Conditions

Extended Ambient Temperature: 50 °C

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.

Corrosion Protected Bus Bars

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.

Coated PCBs

7.2

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.

Converter Enclosure

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)

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

Cabinet Paint Finish

Split Cabinet

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.

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Extended Grounding Busbar

7.3

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.

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

Refer to Sections Extended Motor Monitoring Interface, page 53 and Extended Transformer Monitoring Interface, page 52.

Extended Transformer Monitoring Interface

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

I/O signals for extended transformer monitoring Signal Name

DI

OIL LEVEL ALARM

Transformer oil level alarm indication

DI

OIL TEMP ALARM, or

Transformer oil temperature alarm indication

TRAFO WDG TEMP ALARM

Transformer winding temperature alarm indication

/OIL TEMP TRIP, or

Transformer oil temperature trip indication Transformer winding temperature trip indication

DI

/TRAFO WDG TEMP TRIP

52

Remarks

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Table 7-1 Type

I/O signals for extended transformer monitoring (continued) Signal Name

Remarks

DI

BUCHHOLZ ALARM

Transformer alarm indication from Buchholz relay

DI

/BUCHHOLZ TRIP

Transformer trip indication from Buchholz relay

AI

OIL TEMP, or

Temperature measurement of transformer oil Temperature measurement of transformer winding

TRAFO WDG TEMP

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

Extended Motor Monitoring Interface

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),

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Table 7-2 Type

I/O signals for extended motor monitoring Signal Name

Remarks

DI

EXT MOT PROT ALARM

(External) motor protection alarm indication

DI

MOT COOLING ALARM

(External) motor cooling alarm indication

DI

/MOT COOLING TRIP

(External) motor cooling trip indication

DI

VIBRATION SV ALARM

Motor vibration alarm indication

DI

/VIBRATION SV TRIP

Motor vibration trip indication

DI

/OVERSPEED TRIP

Motor overspeed trip (included in hardwired tripping loop)

AI

BRG TEMP DE

Motor bearing temperature of driven end

AI

BRG TEMP NDE

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:

54

•

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)

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•

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

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

Braking Chopper

Effective motor braking and short deceleration times can be achieved by using resistor braking. For resistor braking, the ACS 1000 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

Circuit Breaker for Motor Space Heater

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.

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Table 7-3

Power ratings for different circuit breaker sizes Auxiliary Voltage (single phase)

Motor Starter for Motor Cooling Fan / Pump

Circuit Breaker Rating

120 V

240 V

400 V

0.5 A

60 W

120 W

200 W

1.0 A

120 W

240 W

400 W

2.0 A

240 W

480 W

800 W

3.0 A

360 W

720 W

1200 W

4.0 A

480 W

960 W

1600 W

5.0 A

600 W

1200 W

2000 W

6.0 A

720 W

1440 W

2400 W

10.0 A

1200 W

2400 W

4000 W

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

7.5

480 V

575 V

2.5 - 4.0 A

750 W - 1500 W (1.0 - 2.0 hp)

1100 W - 2000 W (1.5 - 2.7 hp)

1200 W - 2600 W (1.6 - 3.5 hp)

4.0 - 6.3 A

1500 W - 2200 W (2.0 - 3.0 hp)

2000 W - 3000 W (2.7 - 4.0 hp)

2600 W - 3600 W (3.5 - 4.8 hp)

6.3 - 10.0 A

2200 W - 4000 W (3.0 - 5.4 hp)

3000 W - 4000 W (4.0 - 5.4 hp)

3600 W - 6000 W (4.8 - 8.0 hp)

Converter Cooling

Redundant Cooling Fan (Air-cooled ACS 1000)

56

400 V

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.

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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.

Redundant Cooling Pump (Water-cooled ACS 1000)

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.

Three-way Valve (Water-cooled 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

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.

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the total raw water flow is kept constant even if the water flow in the heat exchanger varies.

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

Conductivity AI 1.4

B11 P I

to converter nipple

B12

B13

Q

T

ACS 1000 CABINET

I

I

V5

Temperature AI 1.2

Valve identification: V13

open (normal operation) closed (normal operation)

8 PA

B10

C2

Non-return valve

12 PA

expansion vessel

Control valve M

Z2 (microfilter)

L

V11 5 l/min

Z1 (strainer)

12 PA C1 S1

raw water inlet nipple 33 mm

V14 C

E1

A

ion exchanger vessel M

M11

V82 V3

V1

130 l/min

P1 M

air to water heat exchanger E2

make-up water ISO-R1/2 water to water heat exchanger

12 PA

from converter nipple 40 mm

OPTION

M12

V2

B14 V4 M

P2

V80

OPTION

V81

24 l/min

Cooling Unit (Watercooled ACS 1000)

controlled by: DO 3.3 DO 3.4

raw water outlet nipple 33 mm

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 µm and a 12 µm fine mesh. The optional air filter mats should be selected if the air contamination level exceeds IEC 721-3-3, Class 3C2 (for chemical gases) or IEC 721-3-3, Class 3S1 (for solid particles). Air filter mats with finer mesh are monitored by measuring the pressure difference across the filter. An alarm is displayed if the filter is clogged. The filter mat which is mounted at the converter air intake can be changed while the converter is in operation.

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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

Synchronized 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.

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.

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Mains Supply

Transformer

MCB

ACS1000 Frequency Converter 12 Pulse Rectifier

Three Level Inverter

Output Filter

Sm1

= =

U2 ACS 1000 Control

Synchronized Bypass Controls

MCB 1

Transformer 1

M1

U11 Sbp1

(if necessary)

Sm2

Mains Supply

MCB 2

3-Ph

Transformer 2

M2

U12 Sbp2

(if necessary)

3-Ph

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.

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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

7.8

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.

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

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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.

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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

8.2.1

Main Circuit Breaker

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.

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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

Control section of ACS 1000 22...250 VAC 22...150 VDC

X 300 1 2

*

emergency off (one or more emergency off connected in series)

3 4

*

transformer protection trip

5 6

*

motor protection trip

8

*

overspeed trip

9 10

*

supply voltage unbalance trip

11

optional IOEC board 3 required

*

jumper when signal is not used

12

MCB tripping coil 13

Figure 8-1 Tripping loop: principle diagram

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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:

8.2.3

•

overspeed trip

•

supply voltage unbalance.

Main Circuit Breaker Features

General Requirements for MCB

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)

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Types of MCBs

MCB Control Signal Interface

•

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).

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.

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 trip sig nals

50 51

51N

AC tim e resid ua l overcurrent rela y in stantaneous / AC tim e overcurrent relay

tripping loop

open command

MCB clo sed

clo se command

MCB open

MCB not available

52

ACS 1000

Figure 8-2 Connection scheme with vacuum circuit breaker

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non lo ad-break dis connector fast actin g current lim it in g fuse vacuum contactor

50 51

51N

AC tim e resid ua l overcurrent rela y in stantaneous / AC tim e overcurrent relay

tripping loop

clo se command

open command

MCB clo sed

MCB open

MCB not available

trip sig nals

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.

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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.

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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.

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8.4.3

ACS 1000 Selection Tables

Selection Table for Air / Water-cooled ACS 1000 with 2.3 kV Motors

Table 8-1 Motor Voltage (kV)

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.

ACS 1000 ratings for 2.3 kV motors, 50 Hz and 60 Hz supply (12/24-pulse)

Converter Type*

Type of Cooling

Max. cont. Converter Power (kVA)

Rated Motor Power** (HP)

Equival. Motor Power** (kW)

Rated Output Current (A)

Frame Size

2.3

ACS10x2-A1-A0-00

Air

400

400

_

100

A1

2.3

ACS10x2-A1-B0-00

Air

400

450

315

100

A1

2.3

ACS10x2-A1-C0-00

Air

450

500

355

113

A1

2.3

ACS10x2-A1-D0-00

Air

550

600

450

138

A1

2.3

ACS10x2-A1-E0-00

Air

650

700

500

163

A1

2.3

ACS10x2-A1-F0-00

Air

750

800

560

188

A1

2.3

ACS10x2-A1-G0-00

Air

800

900

630

201

A1

2.3

ACS10x2-A1-H0-00

Air

900

1000

710

226

A1

2.3

ACS10x2-A2-J0-00

Air

1150

1250

900

289

A2

2.3

ACS10x2-A2-K0-00

Air

1350

1500

1120

339

A2

2.3

ACS10x2-A3-L0-00

Air

1550

1750

1250

389

A3

2.3

ACS10x2-A3-M0-00

Air

1800

2000

1400

452

A3

2.3

ACS10x2-A3-N0-00

Air

2000

2250

1600

502

A3

2.3

ACS10x2-W1-P0-00

Water

2300

2500

1800

577

W1

2.3

ACS10x2-W1-Q0-00

Water

2700

3000

2250

678

W1

2.3

ACS10x2-W2-R0-00

Water

3100

3500

2500

778

W2

2.3

ACS10x2-W2-S0-00

Water

3600

4000

2800

904

W2

*, ** See note at end of this Section on page 72

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Selection Table for Air / Water-cooled ACS 1000 with 3.3 kV Motors Table 8-2 Motor Voltage (kV)

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.

ACS 1000 ratings for 3.3 kV motors, 50 Hz and 60 Hz supply (12/24-pulse)

Converter Type*

Type of Cooling

Max. cont. Converter Power (kVA)

Rated Motor Power** (HP)

Equival. Motor Power** (kW)

Rated Output Current (A)

Frame Size

3.3

ACS10x3-A1-A0-00

Air

400

450

315

70

A1

3.3

ACS10x3-A1-B0-00

Air

450

500

355

79

A1

3.3

ACS10x3-A1-C0-00

Air

500

550

400

87

A1

3.3

ACS10x3-A1-D0-00

Air

550

600

450

96

A1

3.3

ACS10x3-A1-E0-00

Air

600

700

500

105

A1

3.3

ACS10x3-A1-F0-00

Air

700

750

560

122

A1

3.3

ACS10x3-A1-G0-00

Air

750

800

630

131

A1

3.3

ACS10x3-A1-H0-00

Air

850

900

710

149

A1

3.3

ACS10x3-A2-J0-00

Air

950

1000

800

166

A2

3.3

ACS10x3-A2-K0-00

Air

1100

1250

900

192

A2

3.3

ACS10x3-A2-L0-00

Air

1200

1350

1000

210

A2

3.3

ACS10x3-A2-M0-00

Air

1350

1500

1120

236

A2

3.3

ACS10x3-A2-N0-00

Air

1500

1650

1250

262

A2

3.3

ACS10x3-A2-P0-00

Air

1700

1750

1400

297

A2

3.3

ACS10x3-A3-Q0-00

Air

1900

2000

1600

332

A3

3.3

ACS10x3-A3-R0-00

Air

2150

2250

1800

376

A3

3.3

ACS10x3-W1-S0-00

Water

2400

2500

2000

420

W1

3.3

ACS10x3-W1-T0-00

Water

2700

3000

2250

472

W1

3.3

ACS10x3-W1-U0-00

Water

3000

3350

2500

525

W1

3.3

ACS10x3-W2-V0-00

Water

3350

3500

2800

586

W2

3.3

ACS10x3-W2-W0-00

Water

3750

4000

3150

656

W2

3.3

ACS10x3-W2-X0-00

Water

4250

4500

3550

744

W2

3.3

ACS10x3-W3-Y0-00

Water

4750

5000

4000

831

W3

3.3

ACS10x3-W3-Z0-00

Water

5350

6000

4500

936

W3

3.3

ACS10x3-W3-10-00

Water

5950

6700

5000

1041

W3

*, ** See note at end of this Section on page 72

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Chapter 8 - Selecting the Drive System

Selection Table for Air / Water-cooled ACS 1000 with 4.0 kV Motors Table 8-3 Motor Voltage (kV)

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.

ACS 1000 ratings for 4.0 kV motors, 50 Hz and 60 Hz supply (12/24-pulse)

Converter Type*

Type of Cooling

Max. cont. Converter Power (kVA)

Rated Motor Power** (HP)

Equival. Motor Power** (kW)

Rated Output Current (A)

Frame Size

4.0

ACS10x4-A1-A0-00

Air

400

400

_

58

A1

4.0

ACS10x4-A1-B0-00

Air

400

450

315

58

A1

4.0

ACS10x4-A1-C0-00

Air

450

500

355

65

A1

4.0

ACS10x4-A1-D0-00

Air

550

600

450

79

A1

4.0

ACS10x4-A1-E0-00

Air

650

700

500

94

A1

4.0

ACS10x4-A1-F0-00

Air

750

800

560

108

A1

4.0

ACS10x4-A1-G0-00

Air

800

900

630

115

A1

4.0

ACS10x4-A1-H0-00

Air

900

1000

710

130

A1

4.0

ACS10x4-A2-J0-00

Air

1150

1250

900

166

A2

4.0

ACS10x4-A2-K0-00

Air

1350

1500

1120

195

A2

4.0

ACS10x4-A3-L0-00

Air

1550

1750

1250

224

A3

4.0

ACS10x4-A3-M0-00

Air

1800

2000

1400

260

A3

4.0

ACS10x4-A3-N0-00

Air

2000

2250

1600

289

A3

4.0

ACS10x4-W1-P0-00

Water

2300

2500

1800

332

W1

4.0

ACS10x4-W1-Q0-00

Water

2700

3000

2250

390

W1

4.0

ACS10x4-W2-R0-00

Water

3100

3500

2500

447

W2

4.0

ACS10x4-W2-S0-00

Water

3600

4000

2800

520

W2

4.0

ACS10x4-W2-T0-00

Water

4000

4500

3150

577

W2

4.0

ACS10x4-W2-U0-00

Water

4500

5000

3550

650

W2

4.0

ACS10x4-W3-V0-00

Water

4900

5500

4000

707

W3

4.0

ACS10x4-W3-W0-00

Water

5300

6000

4500

765

W3

4.0

ACS10x4-W3-X0-00

Water

5800

6700

5000

837

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.

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8.5

8.5.1

Motor Selection

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:

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

p = T = TN = n = f =

number of poles load torque rated motor torque speed output frequency of ACS 1000

p=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.).

Curve 2 ACS 1000 Loadability

Curve 1 Motor Loadability

0

10

20

30

40

50

60

0

600

1200

1800

2400

3000

3600

0

300

600

900

1200

1500

0

200

400

600

800

1000

1200

1400

0

150

300

450

600

750

900

1050

70

80

90

100

f (Hz) n (rpm)

p=4 1800

2100

2400

n (rpm)

p=6 1600

n (rpm)

p=8 n (rpm)

Figure 8-5 Load capacity curves

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Chapter 8 - Selecting the Drive System

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.

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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.

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Chapter 8 - Selecting the Drive System

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ACS 1000 Technical Catalog

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

Above mm / (in.)

Below mm / (in.)

Left / Right mm / (in.)

Front mm / (in.)

Back mm / (in.)

Air

500 (1)(2)(3) (20")

0 (1) (0")

0 (5) (0")

1000 (4) (39.4")

0 (6) (0")

Water

0 / 700 (1)(2) (0")/(27.6")

0 (1) (0")

0 (5) (0")

1000 (4) (39.4")

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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Appendix A - Installation Guidelines

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.

Air-cooled ACS 1000

1000 mm / 39.4 in. Water-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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Appendix A - Installation Guidelines

The foundation plans for the ACS 1000 12-pulse, air and water-cooled, are given in Figure A-2 and Figure A-3. 78

2856

78

20

37.5

800

2846

12

Figure A-2 Foundation plan with position of anchoring holes: ACS 1000 12-pulse, air-cooled 585.5

2760/3260 *

802.5

181

70

800

685

38

1080.5

432

20

50

12

Figure A-3 Foundation plan with position of anchoring holes: ACS 1000 12-pulse, water-cooled

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Appendix A - Installation Guidelines

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. 1’000 kg/m2).

•

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

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

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Appendix A - Installation Guidelines

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

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Appendix A - Installation Guidelines

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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Appendix A - Installation Guidelines

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

General Cable Type

Cross-Section (I/O Termination)

Analog In

Twisted pair(s) - Overall Shield

0.5 to 2.5 mm2 / AWG 20 to AWG 12

Analog Out

Twisted pair(s) - Overall Shield

0.5 to 2.5 mm2 / AWG 20 to AWG 12

Digital In

Twisted pair(s)

0.5 to 2.5 mm2 / AWG 20 to AWG 12

Digital Out

Twisted pair(s)

0.5 to 2.5 mm2 / AWG 20 to AWG 12

Cable Routing Power Cables

Cable Termination Grounding Wire Control 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.

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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Appendix A - Installation Guidelines

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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Appendix A - Installation Guidelines

Transformer Connection Diagram for 12-pulse ACS 1000 PE

Transformer

Factory Ground

a1

b1

b2

a2

c1

c2

Armouring

Shielding

1V1

1U1

1W1

2U1

2V1

2W1

Factory Ground

ACS 1000

PE

Figure A-6 Typical 3-line transformer connection diagram.

Transformer Connection Diagram for 24-pulse ACS 1000 PE

Transformer

Factory Ground

a1

b1

c1

a2

b2

c2

a3

b3

c3

a4

b4

c4

Armouring

Shielding

1U1 1V1 1W1

2U1 2V1 2W1

3U1 3V1 3W1

4U1 4V1 4W1

Factory Ground PE

ACS 1000

Figure A-7 Typical 3-line transformer connection diagram

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Appendix A - Installation Guidelines

Motor Connection Diagram for 12 / 24-pulse ACS 1000

ACS 1000

V2

Factory Ground

U2

W2

PE

V W

U Factory Ground

PE

M

Figure A-8 Typical 3-line motor connection diagram

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ACS 1000 Technical Catalog

Appendix B - Technical Data Transformer Connection / Converter Input Primary Side Voltage

Any medium voltage level can be applied to the primary side of the converter input transformer.

Secondary Side Voltage

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

Frequency Range Voltage Unbalance

Phase shift between transformer secondary windings: •

30° for 12-pulse ACS 1000

•

15° for 24-pulse ACS 1000

50 / 60 Hz max. ± 2% (Umax - Umin ) / Uavg

Fundamental Power Factor

cos ϕ1 > 0.97

Total Power Factor

cos ϕT > 0.95

Transformer Secondary Cables

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

ACS 1000 Technical Catalog

Rectifier Type

Max. cable length

Air-cooled

12-pulse

30 m (98 ft)

Water-cooled

12-pulse

30 m (98 ft)

Air-cooled

24-pulse

20 m (66 ft)

Water-cooled

24-pulse

20 m (66 ft)

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Appendix B - Technical Data

Table B-2 ACS 1000 with CMC ACS 1000 Types

Rectifier Type

Max. cable length

Air-cooled

12-pulse

200 m (656 ft)

Water-cooled

12-pulse

200 m (656 ft)

Air-cooled

24-pulse

Not available with CMC

Water-cooled

24-pulse

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

UNom: 2.3 kVAC, 3.3 kVAC, 4.0 kVAC UOut: 0…UNom, 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 45…66 Hz 1 kHz (3-level inverter, operating at 2 x 500 Hz) 1000 m (3281 ft)

Acceleration Time

0…1800 s

Deceleration Time

0…1800 s

Efficiency

Approximately 98% (with nominal input voltage and DC-link under full load)

Auxiliary Supply Auxiliary Voltage Level

88

•

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%

ACS 1000 Technical Catalog

Appendix B - Technical Data

Auxiliary Power Consumption

Table B-3 Auxiliary power consumption Air-cooled Types

Water-cooled Types

Power consumption

all types

7.3 kW * ACS1012-W1 ACS1013-W1

4.3 kW *

ACS1012-W2 ACS1013-W2 ACS1013-W3 ACS1014-W2 ACS1014-W3

4.6 kW *

ACS1014-W1

4.9 kW *

*) without optional heaters / coolers

Environmental Aspects Ambient Temperature

The permitted temperature range for the ACS 1000 is: •

+1…+40 °C (34…104 °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

Installation Site Altitude

+1…+50 °C (34…122 °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.

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.

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89

Appendix B - Technical Data

Relative Humidity

Vibration

Sound Pressure Level

The permitted ranges for relative humidity are: •

5…95%, no condensation is allowed

•

5…60%, if corrosive gases are present.

The ACS 1000 can be exposed to the following maximum values for vibration: •

0.3 mm (2…9 Hz)

•

1 m/s2 (2…200 Hz), sinusoidal (according to IEC 721-3-3).

•

< 75 dB (A) for air-cooled types

•

< 70 dB (A) for water-cooled types.

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

Remark

Derating in %

18 µm

Standard

0

12 µm

Option

5

10 µm

Option

10

Derating for Redundant Cooling Fan

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

Installation Site Altitude

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

90

ACS 1000 Technical Catalog

Appendix B - Technical Data

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 Rated motor Power (kW)

Cooling Water Inlet Temp. Range

Derating in % / K

ACS1012-W1

1800…2250

27°C to max. 38°C

0

ACS1012-W2

2500…2800

27°C to max. 38°C

0

ACS1013-W1

2000…2500

27°C to max. 38°C

0

ACS1013-W2

2800…4000

27°C to max. 38°C

0

ACS1013-W3

4500…5000

27°C to max. 38°C

0.4

ACS1014-W1

1800…2250

27°C to max. 38°C

0.6

ACS1014-W2

2500…3550

27°C to max. 38°C

0

ACS1014-W3

4000…5000

27°C to max. 38°C

1.35

Converter Type

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

Glycol Concentration

Derating in %

- 10°C

20 %

4.5

- 20°C

34 %

7

- 30°C

44 %

9

- 40°C

52 %

11.5

Transportation and Storage Temperature Relative Humidity

-40…+70 °C (-40…+158 °F) Less than 95%, no condensation allowed

Vibration (Storage)

Max. 0.3 mm (2..9 Hz), max.1 m/s2 (2..200 Hz), sinusoidal (IEC 721-3-1)

Vibration (Seismic)

Max. 9 mm (5…35 Hz), max. 18 m/s2, sinusoidal (IEEE 344)

Shock (Storage and Transportation)

Max. 100 m/s2, 11 ms, (IEC 721-3-2 / 2M2), Spectrum I

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Appendix B - Technical Data

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

Water-cooled closed loop system with superimposed closed circuit air cooling. approx. 1 kW +4…+27 °C (+40…+80 °F)

Raw Water Pressure

1…10 bar (14.22…144.2 lb/sq in)

Extended Raw Water Temperature

+27…+38 °C

Raw Water Flow

Water Quality

•

≥

•

≥ 150

80 l/min (21.1 gal/min for ACS 1000 - W1) or l/min (39.6 gal/min for ACS 1000 - W2/W3)

Table B-7 Make-up water (drinking water) quality requirements Parameter pH conductivity

6 – 8.5 < 300 µS / cm

hardness

3 – 10 dH

chloride (Cl)

< 100 mg/l

copper (Cu)

< 0.1 mg/l

total dissolved solids (TDS)

< 300 mg/l

suspended solids

92

Value

< 5 mg/l

ACS 1000 Technical Catalog

Appendix B - Technical Data

Table B-8 Raw water (industrial water) quality requirements Parameter

Value

pH

6–9

conductivity

< 500 µS / cm

hardness

3 – 15 dH

chloride (Cl)

< 300 mg/l above 300 mg/l titanium stabilized exchanger plates are required

total dissolved solids (TDS)

recommended: < 300 mg/l up to 1000 mg/l are possible, provided above limits for hardness and chloride are not exceeded

suspended solids

< 10 mg/l

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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Appendix B - Technical Data

Analog Inputs Analog Input (AI)

Common Mode Voltage Isolation Voltage Common Mode Rejection Ratio Resolution Accuracy Protection

Floating, galvanically isolated inputs •

Signal Level: 0…20 mA / 4…20 mA or 0…10 V / 2…10 V, individually scalable by parameter setting

•

Input Resistance:

Rin = 100 Ω for current input Rin = 210 kΩ for voltage input

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)

Input Updating Time

100 ms (with standard application software)

Terminal Block Size

Cables 0.5…2.5 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

94

Floating, galvanically isolated outputs 0…20 mA / 4…20 mA individually scalable by parameter setting 350 VAC 0.03% (12 bit)

± 0.25% (Full Scale Range) at 25 °C (± 50 µA offset) 250 Ω No internal damage up to 250 VAC/DC input voltage, short circuit proof 250 ms (with standard application software) Cables 0.5…2.5 mm2 (up to AWG12)

ACS 1000 Technical Catalog

Appendix B - Technical Data

Digital Inputs Digital Input (DI) Signal Level Logical Thresholds Input Current Filtering Time Constant Isolation Isolation Test Voltage

Floating, galvanically isolated inputs (opto-coupled) 22…250 VAC / 22…150 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

250 ms (with standard application software)

Terminal Block Size

Cables 0.5…2.5 mm2 (up to AWG12)

Digital Outputs Digital Output (DO)

With switch-over contact (SPDT)

Switching Capacity

•

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

Contacts Isolation Voltage Output Updating Time Terminal Block Size

Encapsulated Contacts 4 kVAC, 1 minute 250 ms (with standard application software) Cables 0.5…2.5 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 0.5…2.5 mm2 (up to AWG12)

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95

Appendix B - Technical Data

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 0.5…2.5 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, Ø 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

96

IP21 (for air-cooled types) IP31 (for water-cooled types)

ACS 1000 Technical Catalog

Appendix C - Dimensions and Weights 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

Dimensions and Weights

Length

2.3

ACS1012-A1-A0-00

Air

2.3

ACS1012-A1-B0-00

Air

2.3

ACS1012-A1-C0-00

Air

2.3

ACS1012-A1-D0-00

Air

2.3

ACS1012-A1-E0-00

Air

2.3

ACS1012-A1-F0-00

Air

2.3

ACS1012-A1-G0-00

Air

2.3

ACS1012-A1-H0-00

Air

2.3

ACS1012-A2-J0-00

Air

2.3

ACS1012-A2-K0-00

Air

2.3

ACS1012-A3-L0-00

Air

2.3

ACS1012-A3-M0-00

Air

2.3

ACS1012-A3-N0-00

Air

2.3

ACS1012-W1-P0-00

Water

2.3

ACS1012-W1-Q0-00

Water

2.3

ACS1012-W2-R0-00

Water

2.3

ACS1012-W2-S0-00

Water

Depth

Height

Weight**

(mm)

(ft/in)

(mm)

(ft/in)

(mm)

(ft/in)

(kg)

(lbs)

3000

9’10’’

900

3’0’’

2005

6’7’’ *

1600

3530

3000

9’10’’

900

3’0’’

2005

6’7’’ *

1750

3860

3000

9’10’’

900

3’0’’

2005

6’7’’ *

2000

4410

4200

13’10

902

3’0’’

2002

6’7’’

3300

7260

4700

15’5’’

902

3’0’’

2002

6’7’’

3680

8100

*) without air-exhaust fan cover (see Table C-4) **) approximate values

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Appendix C - Dimensions and Weights

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

Dimensions and Weights

Length (mm)

Depth (ft/in)

(mm)

Height (ft/in)

(mm)

Weight** (ft/in)

(kg)

(lbs)

3.3

ACS1013-A1-A0-00

Air

3000

900

2005

1600

3.3

ACS1013-A1-B0-00

Air

3000

900

2005

1600

3.3

ACS1013-A1-C0-00

Air

3000

900

2005

1600

3.3

ACS1013-A1-D0-00

Air

3000

900

2005

1600

3.3

ACS1013-A1-E0-00

Air

3000

900

2005

1600

3.3

ACS1013-A1-F0-00

Air

3000

900

2005

1600

3.3

ACS1013-A1-G0-00

Air

3000

900

2005

1600

3.3

ACS1013-A1-H0-00

Air

3000

3.3

ACS1013-A2-J0-00

Air

3000

900

2005

1750

3.3

ACS1013-A2-K0-00

Air

3000

900

2005

1750

3.3

ACS1013-A2-L0-00

Air

3000

900

2005

1750

3.3

ACS1013-A2-M0-00

Air

3000

900

2005

1750

3.3

ACS1013-A2-N0-00

Air

3000

’

900

2005

1750

3.3

ACS1013-A2-P0-00

Air

3000

9’10’

900

3’0’’

2005

6’7’’ *

1750

3860

3.3

ACS1013-A3-Q0-00

Air

3.3

ACS1013-A3-R0-00

Air

3000

9’10’

900

3’0’’

2005

6’7’’ *

2000

4410

3.3

ACS1013-W1-S0-00

Water

3.3

ACS1013-W1-T0-00

Water

3.3

ACS1013-W1-U0-00

Water

4200

13’10

902

3’0’’

2002

6’7’

3300

7260

3.3

ACS1013-W2-V0-00

Water

3.3

ACS1013-W2-W0-00

Water

3.3

ACS1013-W2-X0-00

Water

3.3

ACS1013-W3-Y0-00

Water

3.3

ACS1013-W3-Z0-00

Water

3.3

ACS1013-W3-10-00

Water

4700

15’5’’

902

3’0’’

2002

6’7

3680

8100

9’10’

900

3’0’’

2005

6’7’’ *

1600

3530

*) without air-exhaust fan cover (see Table C-4) **) approximate values

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ACS 1000 Technical Catalog

Appendix C - Dimensions and Weights

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

Dimensions and Weights

Length

4.16

ACS1014-A1-A0-00

Air

4.16

ACS1014-A1-B0-00

Air

4.16

ACS1014-A1-C0-00

Air

4.16

ACS1014-A1-D0-00

Air

4.16

ACS1014-A1-E0-00

Air

4.16

ACS1014-A1-F0-00

Air

4.16

ACS1014-A1-G0-00

Air

4.16

ACS1014-A1-H0-00

Air

4.16

ACS1014-A2-J0-00

Air

4.16

ACS1014-A2-K0-00

Air

4.16

ACS1014-A3-L0-00

Air

4.16

ACS1014-A3-M0-00

Air

4.16

ACS1014-A3-N0-00

Air

4.16

ACS1014-W1-P0-00

Water

4.16

ACS1014-W1-Q0-00

Water

4.16

ACS1014-W2-R0-00

Water

4.16

ACS1014-W2-S0-00

Water

4.16

ACS1014-W2-T0-00

Water

4.16

ACS1014-W2-U0-00

Water

4.16

ACS1014-W3-V0-00

Water

4.16

ACS1014-W3-W0-00

Water

4.16

ACS1014-W3-X0-00

Water

Depth

Height

Weight**

(mm)

(ft/in)

(mm)

(ft/in)

(mm)

(ft/in)

(kg)

(lbs)

3000

9’10’’

900

3’0’’

2005

6’7’’ *

1600

3530

3000

9’10’’

900

3’0’’

2005

6’7’’ *

1750

3860

3000

9’10’’

900

3’0’’

2005

6’7’’ *

2000

4410

4200

13’10

902

3’0’’

2002

6’7’’

3300

7260

4700

15’5’’

902

3’0’’

2002

6’7’’

3680

8100

*) without air-exhaust fan cover (see Table C-4) **) approximate values

ACS 1000 Technical Catalog

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Appendix C - Dimensions and Weights

Table C-4 Dimensions and weights of the ACS 1000 and optional equipment Description

Dimensions and Weights ACS 1000 Type

Length

Depth

Height

Weight**

(mm)

(ft/in)

(mm)

(ft/in)

(mm)

Air-exhaust fan cover

Air-cooled

654

2’ 2"**

733

2’ 5"

278

-

-

Redundant cooling fan unit

Air-cooled

2000

6’ 7""*

870

2’10""

800

300

660

Braking chopper (placed on the right side)

644

2’ 1"

902

3’

2005/ 2070*

6’ 7"/ 6’ 10"*

460

1012

Synchronous bypass (placed on the left side)

644

2’ 1"

902

3’

2005/ 2070*

6’ 7"/ 6’ 10"*

460

1012

(ft/in)

(kg)

(lbs)

24-pulse extension (placed on the left side)

Watercooled

844

2’ 9""*

902

3’

2005/ 2070*

6’ 7"/ 6’ 10"*

350

770

Redundant fan unit

Watercooled

650

2’ 2"

865

2’10""

312

1’ **

100

220

*) including lifting lugs **) approx. values

100

ACS 1000 Technical Catalog

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.

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Appendix D - Applicable Codes and Standards

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 User’s Manual.

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Appendix D - Applicable Codes and Standards

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

• IEC 146-1-1

Semiconductor convertors

• IEC 529

Degrees for protection provided by enclosures (IP-Code)

• IEC 664-1

Insulation coordination for equipment within low-voltage systems

• IEC 721-3-1 A1

Classification of environmental conditions Part 3: Storage

• IEC 721-3-2 A2

Classification of environmental conditions Part 3: Transportation

• IEC 721-3-3 A1

Classification of environmental conditions Part 3: Stationary use at weatherprotected locations

• IEC 1000-4-2

Electrostatic immunity test - contact discharge 4 kV - air discharge 8 kV

• IEC 1000-4-4

Fast Transient immunity test - Aux-Supply Power-Ports: 2 kV, 5 kHz - Signal-Ports: 2 kV, 5 kHz

• IEC 1000-4-5

Surge immunity test - Aux-Supply Power Ports - Line to Line 2 kV - Line to Earth 4 kV - Signal-Ports 1 kV

• EN 50081-2

Electromagnetic compatibility (EMC)

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103

Appendix D - Applicable Codes and Standards

generic emission standard part 2: Industrial environment

104

• EN 50082-2

Electromagnetic compatibility (EMC) generic immunity standard part 2: Industrial environment

• EN 50178

Electronic equipment for use in power installations

• EN55011; A2

Suppression of Radio disturbances caused by electrical appliances and systems - Aux-Supply Power-Ports conducted emission 0.15 - 30 MHz Class A

• ENV 50141

Radio frequency common mode - Aux-Supply Power-Ports - Signal-Ports AM 0.15 - 80 MHz 10 V (rms)

• UL 347

High Voltage Industrial Control Equipment

• UL 347A

Medium Voltage Power Conversion Equipment Proposed first edition of the standard

• UL 508C

Power Conversion Equipment

• IEEE 519

Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems

ACS 1000 Technical Catalog

Appendix E - ACS 1000 Type Code 1

A

Product Category A = AC Drive

2/3

C S

Product Type CS = Standard

4

1

xx = OEM

ACS Product Family 1 = ACS 1000

5

Variation 0 = Standard

6

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

7

-

Voltage Rating 2 = 2.3 kV

-

8/9

2 = 24 Pulse Rectifier 4 = 24-Pulse Rect. with Integrated Transformer

3 = 3.3 kV

4 = 4.0 kV

6 = 6.6 kV

Frame Size A1, A2 and A3 for Air Cooled Converters

10

W1, W2 and W3 for Water Cooled Converters

Sub-Frame Size

See Option Sheet

See ACS 1000 rating tables

11

-

Extended Ambient Air / Raw Water Temperature 0 = None

12

Maximum Output Frequency 0 = 66 Hz (Standard)

13

See Option Sheet

x = extended ambient air / raw water temperature

-

2 = 82.5 Hz

x = Other options will follow later

Field Weakening 0 = 1 : 1.1 (Standard) 4 = max. FW 1 : 1.5

14

1 = max. FW 1 : 1.2

2 = max. FW 1 : 1.3

3 = max. FW 1 : 1.4

Filter Equipment F = Sine Filter and Common Mode Choke

15

S = Sine Filter (without Common Mode Choke)

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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Appendix E - ACS 1000 Type Code

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ACS 1000 Technical Catalog