V-2158-0201-A-8002 - 3 - 0020 VFD ACS1000i

User’s manual
Medium voltage AC drive

ACS 1000i, air cooled
300-1800 kW, 400-2414 hp
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ABB
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ABB
Table of contents
List of figures
List of tables
Terms, abbreviations, trademarks
General information on manual and equipment
Copyright notice 1
Document identification 1
Contact information 1
Equipment covered by the manual 1
Structure of the user documentation 2
Target groups and required qualifications 2
Relevant chapters of the manual 3
User’s responsibilities 4
Intended equipment use 4
Quality certificates and applicable standards 4
Writing conventions 5
Meaning of icons 5
Text conventions 5
Related documentation 6
Items covered by delivery 6
Identifying the delivery 7
Chapter 1 - Safety 1-1
1.1 Meaning of safety instructions 1-1

1.2 General safety information 1-1
1.3 Possible residual risks 1-2
1.4 Safety labels and signs 1-3
1.4.1 Safety labels 1-3
1.5 Important note on main circuit breaker design 1-4
1.5.1 Safety and protection requirements 1-6
1.5.2 Minimum requirements for MCB and MCB control 1-6
1.5.3 Maintenance recommendation 1-7
ACS 1000i User’s manual 3BHS206977 ZAB E01 Rev. A 1 (6)
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Table of contents ABB
Chapter 2 - Power electronics and cabinet features 2-1
2.1 Overview 2-1

2.1.1 Drive topology 2-2
2.2 Power supply configurations 2-3
2.2.1 Main power supply configurations 2-3
2.2.2 Auxiliary power supply 2-4
2.3 Technology 2-4
2.3.1 Fuseless design 2-4
2.3.2 Input stages 2-5
2.3.3 Voltage Source Inverter (VSI) technology 2-5
2.3.4 Drive output 2-5
2.4 Drive hardware 2-6
2.4.1 Overview 2-6
2.4.2 Power terminal compartment 2-8
2.4.3 Input disconnector and grounding switch 2-9
2.4.4 Control compartment 2-9
2.4.5 Rectifier compartment 2-11
2.4.6 Inverter compartment 2-12
2.4.7 Air cooling system 2-12
2.4.8 Redundant fan unit 2-13
2.5 Cabinet design 2-15
2.6 Door locks and door interlocking 2-16
Chapter 3 - Control system 3-1
3.1 Control compartment 3-1

3.1.1 Main components of the control compartment 3-1
3.1.2 Terminal and control compartment 3-2
3.2 Local control panel 3-2
3.2.1 Features and functions of the CDP control panel 3-3
3.2.2 Transformer protection 3-3
3.3 Control system configuration and main components 3-3
3.3.1 AMC controller 3-4
3.4 Control and operation modes 3-7
3.4.1 Control modes 3-7
3.4.2 Operation modes 3-8
3.5 I/O interfaces 3-9
3.5.1 Programmable digital and analog outputs 3-10
3.5.2 Scalable analog inputs 3-10
3.5.3 Customer control signals 3-11
3.5.4 Optional NTAC pulse encoder interface 3-11
3.5.5 Optional serial communication interfaces 3-11
2 (6) 3BHS206977 ZAB E01 Rev. A ACS 1000i User’s manual
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ABB Table of contents
Chapter 4 - Transportation, storage and disposal 4-1
4.1 Safety 4-1

4.2 Transport conditions 4-1
4.3 Unpacking and inspection 4-1
4.4 Lifting and transportation 4-1
4.4.1 General notes on transportation 4-1
4.4.2 Using a crane 4-2
4.4.3 Moving the drive to its final position 4-3
4.5 Storage 4-4
4.5.1 Storage conditions 4-4
4.5.2 Storage 4-4
4.6 Storage and handling instructions for spare parts 4-5
4.7 Disposal of packaging materials and components 4-6
Chapter 5 - Mechanical installation 5-1
5.1 Safety 5-1

5.2 Overview on installation work 5-1
5.3 General notes on installation 5-1
5.3.1 Dimensions, clearances 5-1
5.3.2 Ambient operation conditions 5-1
5.3.3 Foundation requirements 5-2
5.3.4 Cable ducts 5-2
5.3.5 Fire protection 5-2
5.3.6 Cabinet roof 5-2
5.3.7 Floor fixings 5-2
5.4 Installing the drive 5-3
5.4.1 Mechanical door interlock 5-3
5.4.2 Installation procedure 5-3
Chapter 6 - Electrical installation 6-1
6.1 Safety 6-1

6.2 Overview of installation work 6-1
6.3 Cable and wire requirements 6-1
6.3.1 General 6-1
6.3.2 Power cable dimensions 6-2
6.3.3 Feeder cables 6-2
6.3.4 Motor cables 6-2
6.3.5 Equipotential bonding conductor 6-3
6.3.6 Cable routing and termination 6-3
6.3.7 Auxiliary power cables 6-3
6.3.8 Control cables 6-3
6.4 Recommended grounding scheme 6-4
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6.5 Feeder and motor cables 6-5
6.5.1 Further information 6-5
6.5.2 Cable entry 6-5
6.5.3 Additional cabinet compartments 6-8
6.5.4 Final checks 6-8
6.6 Auxiliary power, control and serial communication cables 6-8
6.6.1 Further information 6-8
6.6.2 Cable preparation 6-8
6.6.3 Connecting auxiliary power cables 6-9
6.6.4 Connecting control cables 6-10
Chapter 7 - Commissioning 7-1
7.1 Required qualification 7-1

7.2 Commissioning procedure 7-1
7.3 Commissioning check list 7-1
7.4 Customer assistance 7-1
7.5 Customer acceptance 7-1
Commissioning check list
Mechanical installation 1
Electrical installation 1
Main circuit breaker (MCB) 2
Motor 2
Insulation tests 2
Power supply 3
Miscellaneous 3
Chapter 8 - Operation 8-1
8.1 Overview 8-1

8.2 Safety 8-1
8.3 Local operation 8-1
8.3.1 Overview of local operator panel 8-1
8.4 Status messages 8-3
8.4.1 Overview on status messages 8-3
8.4.2 Start sequence of the drive 8-5
8.4.3 Stop sequence 8-6
8.4.4 Emergency-off sequence 8-7
8.5 Starting the drive system 8-7
8.5.1 Prerequisites 8-7
8.5.2 Checks before starting the drive system 8-8
8.5.3 Starting the drive system from remote 8-8
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ABB Table of contents
8.5.4 Starting the drive system locally 8-8

8.6 Stopping 8-11
8.7 Emergency-off 8-12
8.7.1 Function 8-12
8.7.2 Initiating an emergency shutdown 8-12
8.7.3 Starting the drive system after an emergency shutdown 8-12
Chapter 9 - CDP control panel 9-1
9.1 Overview 9-1

9.1.1 Display and keypad 9-1
9.2 Overview on CDP control panel functions 9-1
9.3 Overview on CDP control panel modes 9-2
9.4 Identification mode 9-2
9.5 Actual signal display mode 9-3
9.5.1 Overview 9-3
9.5.2 Displaying three actual signals 9-6
9.5.3 Selecting actual signals 9-6
9.5.4 Displaying a fault and resetting the fault history 9-8
9.5.5 Displaying and resetting an active fault 9-10
9.6 Parameter mode 9-11
9.6.1 Overview 9-11
9.6.2 Procedure 9-13
9.6.3 Parameter lock 9-15
9.7 Function mode 9-16
9.7.1 Overview 9-16
9.7.2 Procedure 9-16
9.8 Operational commands 9-18
9.8.1 Local and remote control location 9-18
9.8.2 Setting the direction of rotation 9-20
9.8.3 Entering a setpoint 9-21
9.8.4 Run status indication 9-22
Chapter 10 - Troubleshooting and maintenance 10-1
10.1 General information 10-1

10.1.1 Required qualification 10-1
10.1.2 Warranty period 10-1
10.1.3 Training courses 10-1
10.1.4 Maintenance schedule 10-1
10.1.5 Logbook 10-1
10.1.6 Spare parts 10-1
10.2 Identifying electrical equipment 10-2
10.2.1 Device designation 10-2
10.2.2 Cables and wires 10-2
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10.2.3 Understanding wiring diagrams 10-2
10.3 Troubleshooting 10-3
10.3.1 Alarm and fault indications 10-3
10.3.2 Error message levels 10-3
10.3.3 Troubleshooting procedure 10-5
10.4 Malfunctioning grounding switch 10-6
10.5 Panel removal 10-6
10.6 LEDs and switches on PCBs and I/O devices 10-7
10.6.1 AMC circuit board 10-8
10.6.2 IOEC I/O modules 10-9
10.6.3 Serial communication interfaces 10-10
10.7 Maintenance 10-10
10.7.1 Overview on maintenance and service tasks 10-10
10.7.2 Safety 10-11
10.7.3 De-energizing the drive 10-12
10.7.4 Visual checks on the drive 10-13
10.7.5 Cleaning 10-14
10.7.6 Checking wire and cable connections 10-14
10.7.7 Checking and replacing the filter mats 10-15
10.7.8 Inspecting and replacing the battery 10-17
10.7.9 Replacing a fan unit 10-19
Maintenance schedule
Appendix A - Additional manuals
Appendix B - Technical data
Appendix C - Mechanical drawings
Appendix D - Wiring diagrams
Appendix E - Parts list
Appendix F - Test reports and certificates
Appendix G - Signal and parameter table
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ABB
List of figures
Figure 1 ACS 1000i delivered items 6
Figure 2 Location of rating label and CD-ROM 7
Figure 1-1 Safety labels 1-4
Figure 1-2 Drive system overview 1-5
Figure 1-3 MCB opening timing diagram 1-6
Figure 2-1 ACS 1000i with optional redundant fans 2-1
Figure 2-2 Elementary diagram 2-2
Figure 2-3 Drive overview with power supplies 2-3
Figure 2-4 Three-level voltage source inverter principle 2-5
Figure 2-5 Voltage and current waveforms at the drive output 2-6
Figure 2-6 The ACS 1000i (24-pulse, typical layout) 2-7
Figure 2-7 Terminal compartment 2-8
Figure 2-8 Input disconnector and grounding switch operation 2-9
Figure 2-9 Control compartment with open front door (typical layout) 2-10
Figure 2-10 Rectifier, filter and optional input contactor 2-11
Figure 2-11 Inverter compartment 2-12
Figure 2-12 Air flow through the drive 2-13
Figure 2-13 Air flow through the drive with redundant fan units 2-14
Figure 2-14 Operating principle with redundant fans 2-15
Figure 2-15 Door locks 2-17
Figure 3-1 Control compartment with open front door (typical layout) 3-1
Figure 3-2 Local operator panel (standard version) 3-2
Figure 3-3 Simplified illustration of control system 3-4
Figure 3-4 AMC mounted on INT circuit board (typical view) 3-5
Figure 3-5 DTC principle 3-6
Figure 4-1 Lifting the ACS 1000i 4-3
Figure 4-2 Moving the ACS 1000i sideways 4-3
Figure 4-3 Moving the ACS 1000i backwards or forwards 4-4
Figure 5-1 Typical anchor bolt 5-3
Figure 5-2 Position of mounting holes 5-3
Figure 5-3 Levelling the drive 5-4
Figure 5-4 Fan units 5-5
Figure 5-5 Positioning a fan unit 5-5
Figure 5-6 Mounting a fan unit 5-6
Figure 6-1 Grounding the drive equipment (recommended scheme) 6-4
Figure 6-2 Terminal compartment 6-5
Figure 6-3 Connection with spring and flat washers 6-7
Figure 6-4 Control cable entry 6-8
Figure 6-5 Fastening rail and terminals 6-9
Figure 6-6 Cable entry from top (A) and from bottom (B) 6-9
Figure 6-7 Shield grounding clamp 6-10
Figure 8-1 Local operator panel 8-2
Figure 9-1 CDP control panel 9-1
Figure 10-1 Example for device identification 10-2
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List of figures ABB
Figure 10-2 AMC circuit board 10-8
Figure 10-3 IOEC circuit board 10-9
Figure 10-4 Location of filter mat 10-15
Figure 10-5 Removing the grille of the inverter compartment 10-17
Figure 10-6 Grille of inverter compartment removed. 10-17
Figure 10-7 Hole grate behind filter mat (seen from rear side) 10-17
Figure 10-8 Battery (A) and UPS (B) 10-18
Figure 10-9 Fan unit 10-19
Figure 10-10 Fan insert with fixing screws 10-20
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ABB
List of tables
Table 3-1 I/O module configuration with number and type of I/O 3-9
Table 3-2 Fieldbus adapters 3-12
Table 6-1 Control cable requirements 6-4
Table 6-2 Creepage distance 6-6
Table 9-1 Actual signal parameter groups 9-4
Table 9-2 Commonly used parameter groups 9-11
Table 10-1 Filter material specification with type code 10-16
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List of tables ABB
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ABB
Terms, abbreviations, trademarks
Terms and abbreviations

The following table lists terms and abbreviations you should be familiar with when using the manual.
Some of the terms and abbreviations used in the manual are unique to ABB and might differ from the
normal usage.
Terms and Abbreviations Meaning
AMC circuit board Application and Motor Controller

The digital signal processor is the heart of the control system of the drive.
Cluster A cluster is a synonym for a group of hardware modules of the drive control system.
DDCS Distributed drive control system

DDCS is an acronym for a serial communication protocol designed for data transfer via
optical fibers.
Drive Short form for ACS1000 frequency converter
Drive system The drive system includes all equipment used to convert electrical into mechanical
power to give motion to the machine.
DriveBus Communication link dedicated for ABB drives
DriveDebug DriveDebug is part of ABB’s DriveWare® software tools for drives using the DDCS
communications protocol. DriveDebug runs on computers with Windows® operating
systems. DriveDebug is a specialist’s tool used to diagnose, tune and troubleshoot ABB
drives.
DriveWindow DriveWindow is a DriveWare® product. DriveWindow is a 32 bit Windows® application

for commissioning and maintaining ABB drives equipped with optical communication
links.
DriveMonitorTM DriveMonitor is a monitoring and diagnostics system that allows secure access to the
drive via the internet from a remote location. DriveMonitor provides long-term monitoring
functions that allow to infer equipment status and improve equipment performance.
Equipment Frequency converter and related equipment
EMC Electromagnetic compatibility

All measures to suppress electromagnetic disturbances caused by different electrical
equipment in the same electromagnetic environment, and to strengthen the immunity of
the equipment to such disturbances.
Ground Earth
To ground The conducting path (e.g. conductor) between the electric equipment (e.g. frequency
converter) and the earth. The electric equipment is connected to the earth, e.g. by a
grounding set or a grounding switch.
INU Inverter unit of the drive. The INU converts the DC voltage to the required AC motor
voltage and frequency.
IOEC module The IOEC module is an active input and output device for digital and analog signals.
Line voltage RMS voltage of the main power supply of the drive
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Terms, abbreviations, trademarks ABB
Terms and Abbreviations Meaning
MCB Main circuit breaker

The MCB is a major protection device of the drive system and connects and/or
disconnects the main power supply to the drive. The MCB is controlled entirely by the
drive.
PCB Printed circuit board
PCC Point of common coupling. The PCC is the point in the electrical power supply system
where the responsibility of the utility changes to the industrial customer. The utility is
responsible to provide clean voltage and current with respect to harmonic distortion up to
the PCC. The industrial customer is responsible not to distort voltage and current by its
electrical systems.
PE Protective earth
PPCS Power plate communication system

PPCS is an acronym for a serial communication protocol designed for data transfer via
optical fibers between AMC circuit board and INTerface circuit boards.
RTD Resistance temperature detector or device

The RTD is a temperature sensor where the change in electrical resistance is used to
measure the temperature.
Safeline ABB synonym for uninterruptable power supply
Supervisory signal Indicates the operating condition of a circuit or device.
TC Short form for terminal compartment of the drive
UPS Uninterruptable power supply
Zero speed threshold Used in the manual to indicate that the drive has reached the value “zero speed” that is
set in a parameter. The value can be set in the range of 0 and maximum speed (the unit
for the speed is rpm).
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ABB Terms, abbreviations, trademarks
Trademarks
Names that are believed to be trademarks of other companies and organizations are designated as
such. The absence or presence of such a designation should however not be regarded as an offence
of the legal status of any trademark. The following registrations and trademarks are used in this
manual:
Trademarks Meaning
Windows® Registered trademark of Microsoft Corporation
Industrial ITTM Trademark of ABB
DriveWare® Registered trademark of ABB
DriveMonitorTM Trademark of ABB
Advant® Registered trademark of ABB
Advant FieldbusTM Trademark of ABB
Ethernet® Registered trademark of Xerox Corporation
Profibus® Registered trademark of Profibus International (P.I.)
Modbus® Registered trademark of the Modbus IDA organization
DeviceNet® Registered trademark of the Open DeviceNet Vendor Association
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Terms, abbreviations, trademarks ABB
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ABB
General information on manual and equipment
Copyright notice
The information in this manual is subject to change without notice.
This manual and parts thereof must not be reproduced or copied, or
disclosed to third parties, nor used for any unauthorized purpose without
written permission from ABB Switzerland Ltd, Medium Voltage Drives.
The hardware and software described in this manual is provided under a
license and may be used, copied, or disclosed only in accordance with the
terms of such license.
Document identification
Ownership ABB Switzerland Ltd
Medium Voltage Drives
Document number 3BHS206977 ZAB E01
Revision index A
Issue date 13.01.2012
Contact information
Address ABB Switzerland Ltd
CH-5300 Turgi, Switzerland
Phone +41 844 845 845
Fax +41 58 589 2984
E-mail mvdrives@ch.abb.com
Equipment covered by the manual

This manual covers standard equipment and provides generic information
on the equipment. The manual does not claim to cover all variations and
details of the equipment, nor to consider all eventualities that may arise
during installation, commissioning, operation and maintenance of the
equipment.
If the equipment is adapted to specific customer needs or applications,
and handling, installation, and operation of the equipment are affected by
these modifications, information on these modifications is provided in the
appropriate documentation (e.g. layout drawings, wiring diagrams,
technical data, engineering notes).
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General information on manual and equipment ABB
If information is required beyond the instructions in this manual refer the
matter to ABB.
Structure of the user documentation

The complete set of user documentation of a standard drive consists of
this manual and supplementary documentation that is provided in the
following appendices:
• Appendix A - Additional manuals
The appendix provides manuals about additional equipment deliv-
ered with the drive (e.g. project specific options such as pulse
encoder or fieldbus interfaces), or information on modifications of the
standard equipment.
• Appendix B - Technical data
The appendix contains the technical data sheets of the drive.
• Appendix C - Mechanical drawings
The appendix provides the outline drawing(s) of the equipment. The
drawings are generated according to the customer specific project.
• Appendix D - Wiring diagrams
The appendix contains the circuit diagrams with information on
device designation, cross-reference and device-identification
conventions. The diagrams are generated according to the customer
specific project.
• Appendix E - Parts list
The parts list is produced for each project and contains all information
to identify a component.
• Appendix F - Test reports and certificates
The appendix provides the test reports of the equipment. Quality
certificates, and codes and standards the drive complies with are
added if required for the project.
• Appendix G - Signal and parameter table
The Signal and parameter table includes descriptions of actual
signals, control and status words, and control parameters and their
default settings.
Target groups and required qualifications

The equipment presented in this manual is part of an industrial environ-
ment where voltages are present that contain a potential hazard of electric
shock and/or burn. For this reason, only personnel who have a thorough
knowledge of the equipment and the industrial environment and have
obtained the required qualification must handle, install, operate, or
maintain the equipment.
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ABB General information on manual and equipment
The manual addresses personnel who are responsible for unpacking,

transportation, installation, operation and maintenance of the equipment.
The personnel must carry out the below listed tasks in a manner that does
not cause physical harm or danger, and to ensure the safe and reliable
functioning of the equipment.
Note: Commissioning of drive equipment must only be performed by
qualified and certified ABB personnel.
Handling The personnel must be skilled and experienced in unpacking and

transporting heavy equipment.
Mechanical installation The personnel must be qualified to prepare the installation site according
to the site and equipment requirements and to perform the installation
accordingly.
Electrical installation The personnel must have a sound knowledge of the relevant electrical
codes and specifications covering low and medium voltage equipment,
be experienced with electrical wiring principles, and know the electrical
symbols typically used in wiring diagrams.
Operation The personnel include all persons who operate the equipment from the
local operating panel of the drive. The personnel must know the functions
of the operating panel, be adequately trained for the equipment, and know
the driven process. Special knowledge of frequency converter technology
is not required.
Maintenance The personnel include all persons who

• are qualified to carry out preventive and corrective maintenance on
equipment as described in this manual,
• are thoroughly familiar with the equipment,
• have a sound knowledge of the relevant electrical codes and
specifications covering low and medium voltage equipment,
• are able to assess the hazards associated with the energy sources of
the equipment and act correspondingly,
• know the safe shutdown and grounding procedures for the
equipment.
Relevant chapters of the manual
Chapter Handling Installation Operation Maintenance
General information x x x x
Safety x x x x
Power electronics and x x
cabinet features
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Chapter Handling Installation Operation Maintenance
Control system x x
Transportation, x
storage and disposal
Mechanical installation x x
Electrical installation x
Operation x x
CDP control panel x x
Troubleshooting and x
maintenance
User’s responsibilities
It is the responsibility of those in charge of the equipment to ensure that
each person involved in the installation, operation or maintenance of the
equipment has received the appropriate training and has thoroughly read
and clearly understood the instructions in this manual and the relevant
safety instructions.
Intended equipment use

Those in charge of the equipment must ensure that the equipment is only
used as specified in the contractual documents, operated under the
conditions stipulated in the technical specifications and on the rating plate
of the equipment, and serviced in the intervals as specified by ABB.
Use of the equipment outside the scope of the specifications is not
permitted.
Intended equipment use also implies that only spare parts recommended
and approved by ABB must be used.
Unauthorized modifications and constructional changes of the equipment
are not permitted.
Quality certificates and applicable standards

The following certificates and conformity declarations are available with
ABB:
• ISO 9001 and ISO 14001 certificates stating that ABB Switzerland Ltd
has implemented and maintains a management system that fulfills
the requirements of the normative standards
• EC Conformity Declaration
• List of the standards the drive complies with
原図 3N4-S4293202 21
Writing conventions
The following icons and text conventions are used in the manual.
Meaning of icons
Illustrates an illuminated lamp or pushbutton.
Illustrates a button or key to be pressed.
Arrows indicate an alternating display message.
Refers to further information in a separate document.
Text conventions
• Bulleted list
Used to list items or steps in a procedure, where the sequence does
not matter.
• Bulleted list of a subsection following a main paragraph
Used to list items or for procedures, where the sequence does
not matter.
1 Steps of a procedure, to be followed in the specified order (e.g. 1, 2,
3 etc.)
1 Figure legend, numbers identify the items referred to in the illustration
above (e.g. 1, 2, 3 etc.)
Arial Bold is used to highlight switches to be operated, status messages
shown in a display and special terms.
UPPERCASE letters refer to a parameter.
Italic is used for references to illustrations, chapters and supplementary
documentation.
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Related documentation
The following documents are available for supplementary information:
Title Document number
Technical Specification for Power Cables 3BHS189994
Engineering Guidelines, Input Circuit Breaker Control 3BHS104785
Asynchronous Motor Specification 3BHS103892
Items covered by delivery
1
2
Figure 1 ACS 1000i delivered items
Delivery comprises typically the following items:

• Drive (1)
The drive is either shipped in sea freight or air freight packaging.
• 1 CD-ROM with user’s manual (see Figure 2)
• 1 set of door keys attached to the grounding switch socket (2)
• 2nd set of door keys inside the control compartment (3)
原図 3N4-S4293202 23
• Lever for input disconnector and grounding switch inside the control
compartment (4)
• Additional components depending on options
Identifying the delivery

The drive and accessories are identified by the type code printed on the
rating label (see 1 in Figure 1).
The rating label is located on the back of the control compartment door.
Besides information on equipment identification, the label provides
important information on rated voltage, frequency and current of the main
and the auxiliary power supply.
Figure 2 Location of rating label and CD-ROM
Legend
1 Rating label
2 CD-ROM with user’s manual
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原図 3N4-S4293202 25
ABB
Chapter 1 - Safety
1.1 Meaning of safety instructions

Safety instructions are used to highlight a potential hazard when working
on the equipment. Safety instructions must be strictly followed! Non-
compliance can jeopardise the safety of personnel, the equipment and the
environment.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTICE
NOTICE is used to address practices not related to personal injury.
The safety instructions are derived from the following standards:
• ISO 3864-2:2004 (E)
Graphical symbols – Safety colors and safety signs – Part 2: Design
principles for product safety labels
• ANSI Z535.6
American National Standard for Product Safety Information in
Product Manuals, Instructions, and Other Collateral Materials
1.2 General safety information

To maintain safety and minimize hazards observe the following:
• Before the drive is energized, make sure that:
• all foreign objects are removed from the drive,
• all internal and external covers are securely fastened and all
doors are closed, locked and/or bolted.
ACS 1000i User’s manual 3BHS206977 ZAB E01 Rev. A 1-1 (8)
原図 3N4-S4293202 26
Chapter 1 - Safety ABB
• Before starting to work on the drive, make sure that:
• the main and auxiliary power supply to the drive is switched off,
locked out, and tagged out,
• the drive is dead,
• safety ground connections are in place,
• appropriate personal protective equipment is provided and used
when required,
• everyone involved is informed.
• When working near the running drive protective earmuffs should be
worn.
• Before work is carried out simultaneously on the drive and on other
drive system equipment, make sure that:
• the relevant safety codes and standards are observed,
• all energy sources of the equipment are turned off,
• lockout and tagout devices are in place,
• barriers and appropriate covers are used on equipment which is
still live,
• In case of fire in the drive room:
• Observe the established rules and regulations for fire protection.
• Only firemen with appropriate protective equipment are allowed
to enter the drive room.
1.3 Possible residual risks

The following risks can arise from a drive system and pose a hazard to
people. These risks must therefore be taken into account by the system
integrator and/or the plant owner when assessing the risks of the
machinery.
• Electric power equipment generates electro-magnetic fields which
can cause a hazard to people with metal implants and/or a
pacemaker.
• Drive system components can move unintentionally when being
commissioned, operated, or serviced due to, for example:
• Operation of the equipment outside the scope of the specifica-
tions
• Incorrectly assembled or installed equipment
• Wrongly connected cables
• External influence on, or damage of the equipment
• Wrong parameter settings
1-2 (8) 3BHS206977 ZAB E01 Rev. A ACS 1000i User’s manual
原図 3N4-S4293202 27
ABB Chapter 1 - Safety
• Software errors
• Faulty hardware
• Hazardous touch voltages can be present on drive system
components caused by, for example:
tions
• Induced voltages by external equipment
• Condensation on equipment components, or pollution
• Faulty hardware
• High temperatures, noise, particles, or gases can be emitted from
drive system components caused by, for example:
tions
• Wrong parameter settings
• Software errors
• Faulty hardware
• Hazardous substances can be emitted from drive system
components due to, for example:
• Incorrect disposal of components
1.4 Safety labels and signs
1.4.1 Safety labels

Safety labels are attached to the cabinet where necessary to alert
personnel of potential hazards when working on the equipment. The
instructions on the safety labels must always be followed, and the labels
must be kept in a perfectly legible condition.
原図 3N4-S4293202 28
Figure 1-1 Safety labels
1.5 Important note on main circuit breaker design

The main circuit breaker (MCB) is a major protection device of the drive.
If a serious fault occurs in the drive, the MCB must disconnect the main
power supply to the drive immediately. The main power supply must be
disconnected without delay on an open or trip command from the drive to
prevent hazard to the personnel and further damage to the equipment.
The MCB is located on the primary side of the converter transformer.
原図 3N4-S4293202 29
Main power supply
MCB
Protection
relay CT
MCB control interface
Converter
transformer
Higher-level
Drive control system
Local MCB control
Motor M
Figure 1-2 Drive system overview
Figure 1-2 shows the conceptual single-line diagram of a typical drive

system, including main power supply, MCB, converter transformer, drive
and electrical motor.
The MCB is defined as a switching device to disconnect the power supply
whenever required by the process or when a fault occurs. Typical devices
used as MCBs are:
• Vacuum circuit breakers
• SF6 circuit breakers
• Fused contactors or motor control centers
The MCB is not included in the drive supply.
A dedicated protection relay is provided for:
• Transformer protection
• Backing up the drive protection
原図 3N4-S4293202 30
1.5.1 Safety and protection requirements
For safety and protection reasons, the MCB must meet the stipulated
minimum requirements of the specifications of ABB MV Drives. It is the
system integrator's responsibility to ensure that the minimum require-
ments are met. The minimum requirements for the MCB are stated in this
note and in the respective MCB specifications, which are available for
each medium voltage drive from ABB.
The safety requirements for the drive are based on the following
standards:
• ISO 13849-1 Safety of machinery - Safety-related parts of control
systems - Part 1: General principles for design, section 6.2.6
Category 3
• IEC 60204-1 Safety of machinery - Electrical equipment of machines
- Part 1: General requirements
1.5.2 Minimum requirements for MCB and MCB control

• The MCB open and/or trip command has to be wired directly from the
drive to the MCB. It is not permitted to wire the trip command through
any PLC or DCS system if it is not certified to meet SIL three-level
requirements and to fulfill the timing requirements outlined below.
• The maximum opening time of the MCB must never exceed the
product or project-specific maximum time defined in the MCB
specifications. Typical maximum values for the drive are defined as
follows:
• Maximum protection trip time: 120 ms
The maximum protection trip time is the maximum allowed
breaking time (open and arcing) of the breaking device after the
open command has been initiated to prevent further damage to
the drive, e.g. diode failures.
• Maximum safety trip time: 250 ms
The maximum safety trip time is the maximum allowed time to
ensure safe disconnection of the main power supply to prevent
any hazard to personnel.
Short-circuit occurs
Open and or trip command is set at the

drive control output
No further damage to drive No hazard to personnel
Max. protection trip time

Max. safety trip time
Figure 1-3 MCB opening timing diagram
原図 3N4-S4293202 31
In order to meet the stipulated safety requirements, it is recommended

that:
• the MCB is equipped with two independent opening coils, or
• the MCB is equipped with one opening coil and an undervoltage coil
for monitoring of the control voltage, or
• an upstream protection coordination scheme is provided which uses
the "breaker failure" (ANSI 50BF) signal to automatically trip the
upstream breaker, in case the MCB does not open. The upstream
breaker must open within the maximum safety trip time after a failure
has occurred.
1.5.3 Maintenance recommendation

The MCB trip circuits should be checked once yearly.
原図 3N4-S4293202 32
原図 3N4-S4293202 33
ABB
Chapter 2 - Power electronics and cabinet features
2.1 Overview
The air-cooled ACS 1000i is a general purpose frequency converter with
integrated converter transformer for the control of standard induction
motors.
See the technical specifications and/or the rating plate of your drive for
information on the power and voltage range of your drive.
Figure 2-1 ACS 1000i with optional redundant fans
The following sections provide an overview of:

• Drive topology and main features
• The available main and auxiliary power configurations,
• The power electronic components of the drive,
• The cooling system,
• Cabinet features such as the grounding switch and the
electromechanical door interlock.
原図 3N4-S4293202 34
Chapter 2 - Power electronics and cabinet features ABB
2.1.1 Drive topology
Figure 2-2 shows the elementary circuit diagram of the ACS 1000i.
3
NP M
1 2 3 4 5 6 7 8 9
Figure 2-2 Elementary diagram
Legend
1 Medium voltage switchgear

2 Input contactor (optional)
3 Converter transformer
4 Diode rectifier
5 Protection IGCTs
6 Intermediate DC link
7 Three-level inverter
8 Output sine filter
9 Squirrel cage induction motor
The drive system consists of the following main components:
• Input contactor or Main Circuit Breaker (MCB)
External Main Circuit Breaker (MCB) or integrated fused input
contactor (optional) and transformer protection.
• Integrated converter transformer
The three-phase AC line voltage is supplied to the rectifier bridges
through the multi-winding converter transformer. In order to obtain 24-
pulse rectification, appropriate phase shift is necessary between the
secondary windings of the transformer.
原図 3N4-S4293202 35
ABB Chapter 2 - Power electronics and cabinet features
• ACS 1000 frequency converter

with fuseless 24-pulse rectifier bridges, voltage DC link, three-phase
inverter and output sine filter. See Figure 2-2.
• Asynchronous motor
Optional additional cabinet compartments for various purposes (e.g.
motor operated input and output disconnectors) can be added to the left
or right side of the drive. Additional cabinet compartments are supplied as
separate units along with specific mounting instructions and must be
joined to the drive on site.
2.2 Power supply configurations

The drive requires two independent power supplies:
• Main power supply for the power electronic components
• Auxiliary power supply for the control and cooling equipment
ACS 1000
Control and cooling equipment
Cooling equipment
Auxiliary
power
Auxiliary distribution
power supply Control system
Power electronic components
Converter
Main transformer M
power supply
MCB
Diode rectifier DC link Inverter
Figure 2-3 Drive overview with power supplies
2.2.1 Main power supply configurations

In the standard configuration, the drive is equipped with an integrated five-
winding dry-type input transformer and a 24-pulse diode rectifier input
bridge.
原図 3N4-S4293202 36
2.2.2 Auxiliary power supply
The total auxiliary power demand of the drive includes:
• Auxiliary power for the cooling system and a short-time power
demand for the charging unit of the drive,
• Auxiliary power for the control hardware and the gate units which are
used to trigger the power semiconductors.
The total auxiliary power can be fed to the drive in the following two ways:
• Through a common power supply
The total auxiliary power is supplied to the drive by a three-phase AC
power supply.
If the power supply is interrupted, drive internal batteries provide a
backup for the control system, thus enabling the drive to ride-through
and/or to perform a controlled shutdown.
• Through separate power supplies
The auxiliary power is supplied to the drive by a three-phase AC
power supply and by a UPS to a separate single-phase AC or DC
input.
Feeding the control power separately by a UPS has the advantage
that the main control hardware will remain energized, the full ride-
through capabilities of the drive can be used, and the communication
to a higher-level control system will not be lost in the event of an auxil-
iary power outage.
Note: If the auxiliary voltage of the three-phase AC power supply is
applied the fuses on the customer side must be rated for the
corresponding inrush currents (see rating label for current rating).
See Appendix D - Wiring diagrams for information on the configuration of

the auxiliary power interface present in the drive.
See Rating label of the drive for information on the rated voltage(s) and
current(s).
2.3 Technology
2.3.1 Fuseless design

The drive features a fuseless protection concept.
The IGCT, which is placed between the DC link and the rectifier, can,
unlike conventional fuses, directly isolate the inverter of the drive system
from the power supply side. This is achieved within 25 microseconds,
which is faster than the operational performance of fuses.
原図 3N4-S4293202 37
2.3.2 Input stages

The drive features a 24-pulse diode rectifier input stage.
2.3.3 Voltage Source Inverter (VSI) technology

Each leg of the three-phase inverter bridge consists of a combination of
two IGCTs for three-level switching operation: with the IGCTs, the output
is switched between positive DC voltage, neutral point (NP) and negative
DC voltage. Hence, both the output voltage and the frequency can be
controlled continuously from zero to maximum using Direct Torque
Control.
Figure 2-4 Three-level voltage source inverter principle
2.3.4 Drive output

At the drive 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 2-5). Therefore, standard motors
can be used at their nominal ratings. The filter also eliminates all high dv/
dt effects and thus voltage reflections in the motor cables and stresses to
the motor insulation are totally eliminated.
• Harmonic heating is virtually eliminated. The drive may be used to
supply standard medium voltage motors (existing or new) without
applying thermal derating factors.
• Voltage reflection and the associated occurrence of voltage doubling
at the motor input terminals is no longer an issue (the causal high
frequency content does not exist). Therefore, any standard medium
voltage winding insulation system (existing or new) is compatible with
the drive.
• The maximum length of the motor cables is limited to 1000 m. Longer
motor cables are available on request.
• Motor bearing failures attributable to capacitively coupled high
frequency current are no longer a problem (the causal high frequency
common mode voltage is eliminated).
• Motor insulation is not subject to the common mode voltage typical for
other drive topologies.
原図 3N4-S4293202 38
Output voltage: 4.16 kV

Output frequency: 60 Hz
Figure 2-5 Voltage and current waveforms at the drive output
2.4 Drive hardware

This compartment describes the main design features and introduces the
major power electronics components of a typical drive.
2.4.1 Overview
The drive is equipped with an input transformer and a forced air cooling
system (see 2.4.7 Air cooling system).
原図 3N4-S4293202 39
1 2 3 4 3 5 6
Figure 2-6 The ACS 1000i (24-pulse, typical layout)
Legend
1 Power cable connections and input disconnector

2 Input contactor (optional, not shown), 24-pulse input transformer,
24-pulse input bridge, grounding switch, protection IGCTs and air
intake
3 Cooling fans
4 Control electronics mounted on swing frame (local control terminal
and pushbuttons on front door)
5 Three-level voltage source inverter, air intake, output filter and
DC link capacitors
6 Air intake in front door
原図 3N4-S4293202 40
2.4.2 Power terminal compartment
The left most compartment of the drive contains the power terminals
(Figure 2-7). The power terminals are located behind a bolted cover plate.
1
Figure 2-7 Terminal compartment
Legend
1 Terminal compartment
2 Feeder terminals and input isolator
3 Feeder terminals (detail)
4 Ground bus and terminal
5 Motor terminals (detail)
The terminal compartment provides the terminals for the feeder and motor
cables, the input isolator and the ground bus for the termination of the
ground cable and the cable screens.
The cables are either entered through the roof or through the floor of the
cabinet. The terminal compartment is prepared in the factory for top cable
原図 3N4-S4293202 41
entry and can be changed to bottom entry during installation. See Chapter
6 - Electrical installation for further details on cable entry and connection.
2.4.3 Input disconnector and grounding switch

The input disconnector and the grounding switch are mechanically
coupled:
• In position I (not grounded), the input disconnector is closed and the
grounding switch is open (A in Figure 2-8).
• In position O (grounded), the input disconnector is open and the
grounding switch is closed (B in Figure 2-8).
A B
Figure 2-8 Input disconnector and grounding switch operation
2.4.4 Control compartment

The control compartment of the drive is mounted on a swing frame which
is located in front of the transformer and rectifier compartment (Figure 2-
9).
原図 3N4-S4293202 42
Figure 2-9 Control compartment with open front door (typical layout)
Legend
1 Internal view of control compartment

2 Local operator control panel (back side)
3 Control and auxiliary cable entry area
The swing frame can be opened more than 120° to provide optimum
access to the equipment behind.
The control and auxiliary cables are either entered through the roof or
through the floor of the cabinet. See Chapter 6 - Electrical installation for
further details on cable entry and connection.
The control system is described in Chapter 3 - Control system.
原図 3N4-S4293202 43
2.4.5 Rectifier compartment
Figure 2-10 Rectifier, filter and optional input contactor
Legend
1 Surge arrestors
2 Grounding switch
3 24-pulse rectifier bridge
4 24-pulse input transformer
5 Optional input contactor
原図 3N4-S4293202 44
2.4.6 Inverter compartment
The inverter compartment contains the inverter stacks, the sine filter and
DC link capacitors.
Phase U Phase V Phase W
Sine filter and

DC link capacitors
Figure 2-11 Inverter compartment
2.4.7 Air cooling system

The air-cooled drive is designed with inverter stacks, output filter and
DC link capacitor in one compartment. This compartment is equipped with
an air intake covering the full area of the front door which is advantageous
for the temperature sensitive capacitors.
原図 3N4-S4293202 45
Air intakes
Figure 2-12 Air flow through the drive
The air intakes are provided with air filters to prevent dust and particles
from entering into the drive. The air filters can be replaced from outside
while the drive is in operation.
2.4.7.1 Space heaters (optional)

The self-regulating space heaters are switched on automatically when the
drive is not in operation (i.e. the cooling fans are switched off) in order to
prevent condensation inside the cabinets.
The heater consists of several heating elements with a rated power of
100 W each rated for 110 to 240 VAC supply voltage (50 or 60Hz).
2.4.8 Redundant fan unit

The redundant cooling option is intended for applications where enhanced
reliability of the installation is required.
With this option, continuous operation of the drive is guaranteed even if a
fan failure occurs. Switch-over from the faulty to the stand-by device will
take place automatically.
The redundant fan option is supplied as separate fan units to be mounted
on top of the drive.
原図 3N4-S4293202 46
Air intakes
Figure 2-13 Air flow through the drive with redundant fan units
Normal operation Under normal conditions, i. e. with both fans operable, the main cooling
fan (fan one) is switched on as soon as the main circuit breaker (MCB) is
closed (see Figure 2-14).
When opening the MCB, the cooling circuit will be switched off after some
delay. This delay corresponds to the discharging time of the drive which
can be up to 5 minutes.
The redundant fans are operated alternatively with different running
periods. The total cycle time is 10 hours by default and a fan switch-over
takes place twice within 10 hours.
If the drive is running continuously, fan one (main fan) will be running by
default up to a total of six hours (which is 60% of 10 hours). Consequently,
fan two (redundant fan) will be running the remaining 40% (4 hours).
Switching over between running and stand-by status will take place
automatically.
If the drive is running intermittently, the same fan will be selected
repeatedly until its duty cycle has elapsed.
If one fan is not available, the remaining unit will operate on a 100% cycle.
原図 3N4-S4293202 47
With the 60-to-40% default ratio, the resulting long-time operating times of
the two fans are not equal and the risk of a simultaneous failure of both
fans is minimized.
The total cycle time and the running times of the fans are adjusted by
setting the corresponding parameter during commissioning.
1
ACS 1000 MCB
0
10 h 10 h
Cycle time
Fan 1 1
0
60% 60%
1
Fan 2
0
40%
Figure 2-14 Operating principle with redundant fans
Non scheduled switch- A non scheduled switch-over to the stand-by unit occurs in the following
over situations:
• If the running fan has tripped (indicated with alarm Fan Grp 1 or
Fan Grp 2)
• If alarm FanDiffPress (differential pressure supervision across
inverter) is activated.
• Upon an alarm reset following one of the above mentioned situations.
By resetting the alarm, the fan which initially caused the alarm will be
taken back to operation.
For alarm definition see Chapter 10 - Troubleshooting and maintenance,
10.3.2 Error message levels.
A failure of one fan is indicated with an alarm. In opposition to all other
drive alarms, the above mentioned alarms are not reset automatically after
the disturbance has disappeared. They must be reset manually by setting
parameter 41.04 FAN ALARM RESET to RESET.
A drive shutdown will be initiated if the stand-by unit has already tripped
when a non-scheduled switch-over is requested, i. e. both fans are not
available (indicated with fault Fan Grp 1 or Fan Grp 2 or fault
FanDiffPress).
2.5 Cabinet design

The cabinet construction of the drive with riveted and folded metal sheets
ensures a strong, flexible and self-supporting framework. The construction
avoids the need for additional skeletal support and provides effective
protection against electromagnetic emissions.
原図 3N4-S4293202 48
EMC has been achieved by applying a cabinet design consisting of folded,
galvanized sheet metal plates (thickness of approximately 2 mm) and
minimizing the space between the rivets. The inside walls of the cabinet
are not painted, because paint tends to reduce the effectiveness of
metallic bonding which is paramount to successful EMC.
Accordingly, only the front of the drive 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 ducts.
2.6 Door locks and door interlocking

All doors are hinged and locked using carriage key locks.
Doors of power The doors of the power compartments of the drive are mechanically
compartments interlocked with the safety grounding switch and with the main circuit
breaker upstream of the drive transformer.
• The interlocking system ensures that the main power cannot be
connected to the drive unless the doors are securely closed and the
grounding switch is in position I (not grounded).
• The interlocking system also ensures that the doors cannot be
opened until the main power is disconnected, the DC link capacitors
are discharged and the grounding switch is in position 0 (grounded).
The door locks of the power compartments use triangular keys (Figure 2-
15).
Door of control The door of the control compartment is not linked to the interlocking
compartment system and can be opened at any time. The high voltage busbar
compartment is located behind the control swing frame and separated
from the control compartment by a bolted protective shield.
Additionally, the doors of the medium voltage compartments have locks
with different inserts than the control compartment door. The different lock
inserts ensure that these doors can only be opened by personnel
authorized to do so.
The door lock of the control compartment uses double-bit keys (Figure 2-
15).
Doors of additional The power compartment doors of all additional cabinets (e.g. braking
cabinets chopper cabinet) are electromechanically interlocked by separate door
switches since they are not included in the mechanical interlock system.
These door monitoring switches are wired to the safety grounding switch.
The doors can only be opened if the grounding switch unlocked lamp is
on. If any of the doors are opened during operation, the MCB will be
tripped immediately.
原図 3N4-S4293202 49
1 2 3 4
8 mm
Figure 2-15 Door locks
Legend
1 Cover plate of input compartment: bolted

2 Door of input, transformer and rectifier: electromechanically locked
Door cannot be opened when the main power is connected.
3 Door of control compartment: lockable
High voltage equipment behind control swing frame: bolted
4 Door of inverter compartment: electromechanically locked
Door cannot be opened when the main power is connected.
原図 3N4-S4293202 50
原図 3N4-S4293202 51
ABB
Chapter 3 - Control system
3.1 Control compartment
3.1.1 Main components of the control compartment

Legend
1 IOEC4 module
(optional)
2 IOEC3 module 1
(optional)
3 IOEC2 module
2
4 IOEC1 module
5 Delta p-transmitter
6 Control power supply
7 Delta p-transmitter
3
8 Fused terminal block for
internal aux. power
9 Motor starters and 4
circuit breakers
5
10 Option: batteries
11 Terminal blocks 6
(internal, cooling, fans,
external) 7
12 AC aux. supply 8
13 AMC and interface
board 9
14 Control panel
15 Control pushbuttons
and indication lights
16 Emergency-off
pushbutton 10
17 Transformer protection 11
12
13 14 15 16 17
Figure 3-1 Control compartment with open front door (typical layout)
The control compartment incorporates the hardware for the control,

monitoring and protection functions of the drive, and the communication
interfaces to the local control panel and to the remote control devices.
Depending on the control concept of the drive system, the remote control
devices include a higher-level control system and/or remote operator
stations.
原図 3N4-S4293202 52
Chapter 3 - Control system ABB
3.1.2 Terminal and control compartment
The control hardware (processor and communication circuit board) is
mounted on the swing frame. Details can be seen in Figure 3-1. The
customer I/Os for customer control and protection signals as well as I/Os
for auxiliary power supply are also located on the swing frame.
3.2 Local control panel

The local control panel on the door of the control compartment serves as
the basic user interface for monitoring, control and operation of the drive
and setting of parameters.
Figure 3-2 Local operator panel (standard version)
Legend
1 CDP control panel

2 Transformer protection
3 Main supply on-off pushbuttons
4 Grounding-switch-unlocked lamp
5 Emergency-off pushbutton
原図 3N4-S4293202 53
ABB Chapter 3 - Control system
3.2.1 Features and functions of the CDP control panel
Features The key features of the CDP control panel include:

• Four-line display
• User selectable display of actual values, e.g. motor speed, current,
voltage, torque, power
• Fault memory to support maintenance
Functions The CDP control panel allows the operator:

• to enter startup data into the drive,
• to control the drive by setting reference values and by giving start,
stop and direction commands,
• to display three actual values at a time,
• to display and set parameters,
• to display information on the last 64 fault events.
See Chapter 8 - Operation and Chapter 9 - CDP control panel for further
information.
3.2.2 Transformer protection
See Appendix A - Additional manuals for detailed information on the

transformer protection.
3.3 Control system configuration and main components

This compartment provides a brief functional overview of the main
hardware components of the control system and their interconnection.
The control system is configured, customized and tuned with a set of
application parameters. The application parameters are organized in
functional groups and have factory-set default values.
The default parameter values are adjusted during commissioning to the
specific application of the drive to activate the specific control, monitoring
and protection functions for the driven process, and to define the signals
and data to be transferred between drive and external equipment.
See Appendix G - Signal and parameter table for detailed information on

the effective software version as well as the parameters provided for
signal allocation, signal type selection, signal inversion, scaling and
filtering, etc.
原図 3N4-S4293202 54
Customer interface compartment

Higher-level
DriveMonitorTM control system
Fieldbus
Control compartment
PC tools
CDP control panel

DDCS
DDCS
RS485
DDCS
AMC controller
DDCS
IOEC1
Fiber optic
IOEC2
IOEC3*
INT circuit board
IOEC4**
Fiber optic
Converter compartment
* and ** Additional option for air-cooled ACS 1000
** Additional option for water-cooled ACS 1000
Figure 3-3 Simplified illustration of control system
3.3.1 AMC controller

The AMC controller is the major component of the control system which is
used for general drive, motor control, and closed loop functions. The main
internal control devices and the peripheral input and output interfaces to
the customer communicate with the AMC controller via optical fibers.
The circuit board is fitted with a Motorola DSP processor and features
two PPCS and eight DDCS communication channels. These
communication channels are used for high speed data transfer via the INT
circuit board to the drive (see Figure 3-3).
The AMC circuit board is mounted on the back side of the control
compartment door (see Figure 3-1).
原図 3N4-S4293202 55
Figure 3-4 AMC mounted on INT circuit board (typical view)
Control tasks General control, protection and monitoring tasks regarding the whole
drive as well as all rectifier and line related functions of the drive are
implemented in the AMC controller.
All relevant drive variables (e.g. speed, torque, current, voltage) are
continuously monitored by the control system. Pre-programmed
protection functions ensure that these variables remain within certain
limits in order to maintain safe operation of the drive. These internal
functions are not programmable by the user.
Other general control, protection and monitoring tasks regarding the
whole drive include control and monitoring of:
• Main circuit breaker (MCB)
• Grounding switch
• Door interlocking
• Cooling system
Optionally, the drive offers monitoring of signals from external
equipment.These can be activated and adjusted by parameter settings.
See Signal and parameter table for further information on control,

protection and monitoring functions.
Main circuit breaker The MCB is an important switching and protection device of the drive
control system. Therefore it must only be controlled and monitored by the drive.
原図 3N4-S4293202 56
The feedback signals from the MCB upon a close or an open command
from the drive are monitored. These signals must have the correct status
and must arrive within a preset time at the drive:
• If the drive applies a close command and the expected feedback
signal does not arrive after a preset time, the close command is reset
and the MCB is tripped.
• If the open command from the drive to the MCB is a maintained
signal, it is reset after receiving the open feedback signal from the
switchgear. If the feedback signal does not arrive after a preset time,
a trip command to the MCB is issued.
See Main circuit breaker engineering guideline for further information.
Speed and torque The speed and torque of the motor is controlled by DTC (Direct Torque
control Control). The DTC motor control platform is unique to ABB and has been
proven in all variable speed drives of the ACS product range. DTC
provides accurate speed and torque control, and high dynamic speed
response. DTC is implemented in the AMC controller.
Torque reference Torque

Torque- Switching
reference flux logic
controller comparator
Speed reference
Speed
controller
Actual speed Switch
positions
Motor Voltage
model
Current
M
Figure 3-5 DTC principle
Switching of the semiconductors in the inverter is directly controlled in

accordance with the motor core variables flux and torque.
The measured motor currents and DC link voltages are inputs to an
adaptive motor model. The model produces exact values of torque and
flux every 25 microseconds. Motor torque and flux comparators compare
the actual values to reference values which are produced by the torque
and flux reference controllers.
Depending on the outputs from the hysteresis controllers, the switching
logic directly determines the optimum switch positions every
50 microseconds and initiates switching whenever required.
原図 3N4-S4293202 57
Peripheral I/O devices The peripheral input and output devices connected to the AMC controller
include:
• Drive control interfaces
• IOEC modules for parallel signal transfer to external devices
• Optional advant or fieldbus adapters for serial data transfer to a
higher-level control system
• Local CDP control panel
• PC-based service tools comprising:
• DriveWare® software tools
DriveWare® includes software tools such as the commissioning
and maintenance tools DriveWindow and DriveDebug, and
DriveOPC for data transfer between ABB drives and Windows®-
based applications.
• DriveMonitorTM (Option)
DriveMonitorTM is a monitoring and diagnostics tool that allows
access to the drive from any location in the world via a secure in-
ternet connection.
3.4 Control and operation modes

The drive provides four different motor control modes and two additional
operation modes besides the standard single drive operation.
A control or operation mode is selected by setting parameters accordingly.
3.4.1 Control modes

The following control modes are available:
• Speed control mode
The speed control mode is the default control mode of the drive.
The control mode can be used for applications where constant speed
is required, such as pumps, fans and conveyors.
• Torque control mode
The torque control mode is used for processes requiring torque
control, such as mixers and slave drives. The torque reference comes
from a process automation system or a control panel.
• PID control mode
The PID control mode is intended for closed loop control systems
which control a process variable such as pressure, level or flow. For
example:
• Booster pumps of municipal water supply systems
• Automatic level control of water reservoirs
原図 3N4-S4293202 58
• Booster pumps of district heating systems
• Speed control of different types of material handling systems
where the material flow has to be regulated.
The PID control mode controls the process variable by adjusting the
speed of the motor accordingly.
Legend
1
1 Reference value
2 Level transducer 2
3 Actual value
4 Pump
• Sequential control mode

The sequential control mode is typically used in processes requiring
different constant speed settings and/or different acceleration and/or
deceleration settings in addition to an adjustable speed reference
value. Up to seven constant speed settings and two acceleration and/
or deceleration settings are possible. The selection of the different
settings can be automated by a process control system or can be
made manually by selector switches which are connected to the
corresponding digital inputs of the drive.
The preset values of a control mode can be left unchanged or they can be
set individually by the commissioning engineer as required for the
application.
See Appendix G - Signal and parameter table, Group 99, Start-up data for
an overview of control mode settings.
3.4.2 Operation modes

Besides the control modes, the following two operation modes are
provided:
• Master-follower operation mode
The master-follower operation mode is used for applications with
several drives where the motor shafts are coupled to each other by
gearing, chain, belt etc. Owing to the master-follower operation mode
the load can be evenly distributed between the drives or at some
adjustable other ratio which depends on the process.
原図 3N4-S4293202 59
• Hand-auto operation mode

The hand-auto operation mode is suitable for applications where the
speed has to be controlled automatically by a process automation
system and manually by an external control panel. The active control
station is selected via a digital input.
The operation mode is also recommended when two external control
stations exist from where the reference value can be set and the drive
can be started and stopped. The external control station is selected
via a digital input.
3.5 I/O interfaces

Overview Internal and external, analog and binary I/O signals are connected to the
control system by IOEC modules.
The standard I/O modules offer a number of preprogrammed analog and
digital I/Os which are sufficient for most applications. For a wider range of
signal interfaces optional I/O modules provide extended interfaces for
transformer and motor protection, 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 modules (IOEC1,
IOEC2) with the option of two additional I/O modules (IOEC3,
IOEC4).
The actual configuration and the exact number of available signals
depends on the selected options.
All I/O modules 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 3-1.
For the detailed I/O specifications see Appendix B - Technical data.

The actual I/O allocation is listed in the parameter list which is part of the
commissioning record.
Table 3-1 I/O module configuration with number and type of I/O
Number Signal type Ratings
4 Analog (AI) 0 to 20 mA or 4 to 20 mA or 0 to 10 V or 2 to 10 V
inputs scalable by parameter setting
2 Analog (AO) 0 to 20 mA or 4 to 20 mA
outputs scalable by parameter setting
14 Digital (DI) Opto-coupled, rated for 22 to 250 VAC or

inputs 22 to 150 VDC
6 Digital (DO) With switch-over contact (SPDT),

outputs rated for 250 VAC, 2 A
原図 3N4-S4293202 60
3.5.1 Programmable digital and analog outputs
Programmable digital Four digital outputs on the IOEC2 module can be programmed
outputs 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 or
trip, ACS 1000 temperature alarm or trip, reverse rotation selected,
external control selected, preset speed limits, DC voltage limits,
preset motor current limit, reference limits, loss of reference signal,
motor operating at reference speed, process PID controller actual
value limits (low, high) etc.
If optional modules IOEC3 and/or IOEC4 are installed, a maximum of
12 additional digital outputs (6 on each module) are available.
Programmable analog Two programmable analog outputs on each IOEC module are at the user’s
outputs disposal.
Depending on the setting of the corresponding parameters, the analog
output signals can represent for example:
• motor speed, process speed (scaled motor speed), output frequency,
output current, motor torque, motor power, DC link voltage, output
voltage, application block output (process PID controller output),
active reference, reference deviation (difference between the
reference and the actual value of the process PID controller).
The selected analog output signals can be inverted and filtered. The
minimum signal level can be set to 0 mA, 4 mA or 10 mA.
3.5.2 Scalable analog inputs

Each analog input can be adapted individually to the type and range of the
connected input signal:
• Signal type: voltage or current (selectable by DIP switches)
• Signal inversion: if a signal is inverted, the maximum input level
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 to 10 s.
The offset of the analog inputs can be calibrated automatically or
manually.
原図 3N4-S4293202 61
3.5.3 Customer control signals
See the ACS 1000 Terminal lists for the complete list of standard and
optional customer control signals.
3.5.4 Optional NTAC pulse encoder interface
Overview The NTAC interface is part of the control system of the drive if pulse
encoder feedback is used to control the motor.
Terminals X1 Terminals X2
1 A+ Channel A 1 -V 0V
2 A- 2 -V 24 V
3 B+ Channel B 3 +V
4 B- 4 24 and 25
5 Z+ Channel Z 5 15
6 Z- 6 24
7 SH Shield 7 0V
8 SH 8 +24 V
Communication with The NTAC module communicates with the AMC controller via a fast optical
AMC controller link using the standard DDCS protocol. The optical fibers are connected
to channel 1 of the AMC controller.
AMC controller
DDCS
NTAC
Location The NTAC interface is mounted to the left of the IOEC1 module (see
Figure 3-1).
The indicated mounting position may vary depending on the number of
optional devices present in the control compartment.
3.5.5 Optional serial communication interfaces
Overview Serial communication interfaces (also referred to as fieldbus adapters in

the documentation) are used for the bidirectional communication between
the drive and a higher-level process control system. Typically, operational
原図 3N4-S4293202 62
commands, status messages of the drive, speed or torque reference
values, and actual values are transmitted.
Communication with the AMC controller is done with data sets, each
containing 3 x 16 bit integers. Each data set contains a standardized set
of process data. The content of the data sets is programmed accordingly
in the remote control system.
Detailed information on data transmission and on data and signal

allocation to the transmitted data sets can be obtained from
• Appendix G - Signal and parameter table
• Installation and start-up guide of the installed fieldbus adapter (see
General information on manual and equipment, Related
documentation)
• Engineering documents
Available fieldbuses The drive can be equipped with one of the following fieldbus adapters.
Table 3-2 Fieldbus adapters
Fieldbus Adapter type
AF 100 fieldbus communication interface CI810
DeviceNet NDNA-02
Ethernet NETA-01
Modbus NMBA-01
Profibus DP NPBA-12
DriveBus CI858 (external adapter)
See Appendix D - Wiring diagrams to identify the adapter type installed in

your drive.
Communication with The optional fieldbus adapter is connected to channel 0 of the AMC
AMC controller controller via optical fibers.
原図 3N4-S4293202 63
Higher-level control system
Fieldbus
adapter
DDCS
AMC controller
Location The fieldbus adapter is mounted to the left of the IOEC1 module (see
Figure 3-1).
The indicated mounting position may vary depending on the number of
optional devices present in the control compartment.
原図 3N4-S4293202 64
原図 3N4-S4293202 65
ABB
Chapter 4 - Transportation, storage and disposal
4.1 Safety
The drive must only be handled by personnel who are skilled and
experienced in unpacking and transporting heavy equipment.
4.2 Transport conditions

The transport conditions for the drive are based on IEC 60721-3-2
'Classification of environmental conditions: Classification of groups of
environmental parameters and their severities; Transportation'.
Classification: 2K4 / 2B1 / 2M1
See Appendix B - Technical data for detailed information.
4.3 Unpacking and inspection

Proceed as follows:
1 Remove all packaging material carefully.
2 Check the drive and accompanying equipment for damages.
3 Compare the complete delivery with the purchase order and the
packing list.
4 If parts are missing or damaged, immediately inform the shipping
company and the ABB service organization.
It is recommended to photograph the damages and send the photo-
graphs to ABB.
4.4 Lifting and transportation

See Appendix C - Mechanical drawings for details on dimensions, weight,
and center of gravity of the cabinet.
It is recommended to have this information at hand before transporting the
cabinet.
4.4.1 General notes on transportation

Observe the following points when transporting the cabinet:
原図 3N4-S4293202 66
Chapter 4 - Transportation, storage and disposal ABB
NOTICE
Do not lift and move the drive or a transport unit using a forklift. The frame
of the cabinets could be damaged. If a crane is not available, contact ABB
for instructions on other means of transport.
NOTICE
When working on the drive, ensure that foreign matter cannot enter the
cabinet. Close the doors and cover openings completely when work is
discontinued.
Any foreign matter which accidentally dropped into the cabinet must be
retrieved. Metallic dust in particular could cause malfunction and damage
when the drive is energized.
• If the drive is delivered in several transport units, the drive must not
be lifted and moved by crane after the transport units have been
joined. Appropriate transport means such as heavy load hydraulic
rollers or air cushions must be used instead. If in doubt, contact ABB
for instructions.
• Drive components can be damaged during transportation. Therefore,
the cabinet must be transported in upright position.
4.4.2 Using a crane

Observe the following points when using a crane:
• Material and diameter of the lifting cables must correspond to the
weight of the drive.
• When lifting a drive always use the lifting lugs which are attached to
the base frame. The lugs can be removed after the drive has been
installed at its final location.
• Do not pass a lifting cable through the fastening hole of a lug. Use a
safety hook to attach a cable to a lug.
• Verify that the slope angle β corresponds to the weight of the
cabinet.The lifting cables should be approximately at an angle as
indicated in Figure 4-1.
原図 3N4-S4293202 67
ABB Chapter 4 - Transportation, storage and disposal
β
Protect
β
edges!
Figure 4-1 Lifting the ACS 1000i
Note: The lugs can be removed after the cabinet has been installed
at its final location.
• Observe the center of gravity.
• Lift the cabinet slowly and steadily to the required clearance height
maintaining the cabinet in upright position.
• Check the horizontal position of the cabinet. Reposition the slings if
necessary.
4.4.3 Moving the drive to its final position

When moving the drive sideways (Figure 4-2) use rollers with a minimum
length of 1.2 m and, beneath the transformer, at least 5 rollers, evenly
spaced.
Min. 5 rollers Min. 1.2 m
Figure 4-2 Moving the ACS 1000i sideways
To move the drive backwards or forwards (see Figure 4-3) rollers with a
length of 1m should be used, with at least 4 pieces each placed in the
原図 3N4-S4293202 68
areas directly beneath the control cubicle and between the left side and
the left lifting ring.
NOTICE
The rollers must be able to take the full weight of the drive cubicle.
Take appropriate measures when moving the drive cubicle with the rollers.
Min. 1.0 m Min. 4 rollers
Figure 4-3 Moving the ACS 1000i backwards or forwards
4.5 Storage
4.5.1 Storage conditions

The minimum requirements for storage are based on IEC 60721-3-1
'Classification of environmental conditions: Classification of groups of
environmental parameters and their severities; Storage'.
Classification: 1K4 / 1Z5 / 1B1 / 1M1
See Appendix B - Technical data for detailed information.
The drive can be stored for up to one year in the original packaging as long
as it is not damaged or opened. For information on longer storage periods
contact the ABB service organization.
4.5.2 Storage
If the drive is taken out of service for a longer time proceed as follows:
1 Remove the batteries (if applicable).
2 Cover all cable inlets and ventilation slots with an impermeable plastic
or aluminum foil and a wooden panel.
3 Add a desiccant of the appropriate quality:
• 1 unit desiccant (30 g) absorbs 6 g water vapor.
原図 3N4-S4293202 69
ABB Chapter 4 - Transportation, storage and disposal
The following quantity is needed when using a polyethylene foil:

• 10 units/m2 foil
4 Close and lock the doors of the cabinet.
5 Use polyethylene or equivalent for packaging:
• 0,3 g/m2/24h water vapor diffusion
6 Attach humidity indicators to the packaging.
The storage conditions and the packaging should be checked regularly.
Any damages that occur during the storage period should be repaired
immediately.
4.6 Storage and handling instructions for spare parts
NOTICE
Static electricity can damage printed circuit boards.
Apply static-sensitive precautions when handling these components.
Check the spare parts immediately after receipt for damages. Report any
damage to the shipping company and the ABB service organization.
Observe the following to maintain spare parts in good condition and to
keep the warranty valid during the warranty period:
• Keep spare parts in their original packaging.
• Store printed circuit boards in antistatic bags or boxes.
• Storage temperature range: -5 °C to + 55 °C (23 °F to 131 °F)
• Storage place requirements:
• Free of vibration and shock.
• Protected against dust, sand, vermin and insects.
• Free of corrosive gases, salt or other impurities that could
damage electronic equipment.
• Dry; no condensation
Relative air humidity: 5 to 85%
If in doubt whether the maximum allowed humidity is exceeded,
protect the spare parts by an external heater.
• Do not touch a component without wearing a wrist grounding
strap.
• Put the component on a grounded working surface protected
against electrostatic discharges.
• Hold the component only at the edge.
原図 3N4-S4293202 70
4.7 Disposal of packaging materials and components
Dispose of the packaging materials and the components at the end of the
life time of the drive according to local regulations.
原図 3N4-S4293202 71
ABB
Chapter 5 - Mechanical installation
5.1 Safety
All installation work must be carried out by qualified personnel according
to the site and equipment requirements and in compliance with local
regulations.
5.2 Overview on installation work

The installation includes the following work:
• Preparing the foundation
See 5.3.3 Foundation requirements.
• Fixing the drive to the floor
See 5.3.7 Floor fixings.
5.3 General notes on installation
NOTICE
discontinued.
5.3.1 Dimensions, clearances
See Layout drawing in Appendix C - Mechanical drawings for information

on:
• Cabinet dimensions
• Clearances to be observed
• Mounting hole sizes
5.3.2 Ambient operation conditions

Ambient conditions for operation such as temperature, relative humidity,
air contamination, shock and vibration must be in compliance with the
maximum permissible levels.
原図 3N4-S4293202 72
Chapter 5 - Mechanical installation ABB
Contact the ABB service organization if the condition of the installation site
is not within the specifications or if the transportation or the installation
require special measures.
See
• Rating plate of the drive for the maximum ambient temperature
• Appendix B - Technical data for information on the climatic and
environmental conditions based on IEC 60721-3
Classification: 3K3 / 3B1 / 3C2 / 3S2 / 3M3
5.3.3 Foundation requirements

The floor must be of non-flammable material, with smooth and non-
abrasive surface, protected against humidity diffusion, leveled and able to
support the weight of the cabinet.
The maximum recommended allowable overall unevenness is ≤ 5 mm per
5 m.
5.3.4 Cable ducts

Cable ducts should be of non-flammable material with non-abrasive
surface.
All cable entries and exits should be protected to prevent dust, humidity
and animals entering into the drive.
5.3.5 Fire protection

Suitable fire protection measures should be applied to prevent fire
spreading into the drive.
5.3.6 Cabinet roof

The cabinet roof is not designed as a mounting base for foreign devices,
cable ducts etc. Therefore, it is not permitted to install any foreign device
on the roof.
5.3.7 Floor fixings

The drive is equipped with holes in the base to fix it to the floor. The holes
can be accessed from inside the cabinet after removing the floor plates.
See Layout Drawing in Appendix C - Mechanical drawings for exact
dimensions. Holes and channels for cables have to be cut into the floor
and mounting holes have to be drilled before the drive is moved to the final
location.
Floor fixings are not supplied. Anchor bolts as illustrated, or screws and
nuts of size M16 are recommended.
原図 3N4-S4293202 73
ABB Chapter 5 - Mechanical installation
Figure 5-1 Typical anchor bolt
x x ACS 1000i
x x
Figure 5-2 Position of mounting holes
If the doors do not open and close properly place levelling plates under the
base (see 5.4.2 Installation procedure).
5.4 Installing the drive
5.4.1 Mechanical door interlock

The door keys are attached to the grounding switch socket.
The doors of the medium voltage units are interlocked with the grounding
switch. If the doors of medium voltage units cannot be opened, contact the
ABB service organization.
5.4.2 Installation procedure
NOTICE
discontinued.
原図 3N4-S4293202 74
Proceed as follows:
1 Drill the floor fixing holes before moving the drive to the final location.
2 Be careful when moving the drive.
See Chapter 4 - Transportation, storage and disposal, 4.2 Transport
conditions for information to be observed.
3 Check if the doors are misaligned.
If the doors do not open and close properly place levelling plates
(80 x 300 x 0.5 mm) under the base:
1 Lift the drive by crane at the corresponding side (see Figure 5-3).
2 Place the required number of plates under the base.
For the position of the levelling plates see the arrows in
Figure 5-3.
Figure 5-3 Levelling the drive
4 Fix the drive to the floor.
原図 3N4-S4293202 75
ABB Chapter 5 - Mechanical installation
See Appendix C - Mechanical drawings for illustrations of the cable duct

and the roof cutouts for the fan units.
Mounting the cable The cable duct must be mounted if the power cables are entered through
duct the roof of the cabinet.
The cable duct is fastened to the cabinet roof using the supplied screws.
Mounting the fan units Standard drives have two fan units. Redundant versions have four fan
units.
The fan units have different sizes. The mounting position can be identified
by the cutout in the drive roof. The mounting surface of a fan unit
corresponds to the cutout in the drive roof.
Figure 5-4 Fan units
Proceed as follows:
1 Remove the transportation covers on top of the cabinet.
2 Carefully lift the fan unit onto of the cabinet using the supplied lifting
eyes.
Figure 5-5 Positioning a fan unit
原図 3N4-S4293202 76
3 Align the four screw holes on the underside of the fan unit with the
screw holes on the cabinet roof and carefully lower the fan unit to the
roof.
4 Enter the supply cable of the fan motor through the cable entry.
Cable entry
Rear
Figure 5-6 Mounting a fan unit
5 Fix the fan unit to the roof, using the supplied bolts.
6 Mount the fan cover.
7 Plug the supply cable into its counterpart inside of the drive.
Additional cabinet If optional additional cabinet compartments are delivered as separate

compartments units, they must be joined to the drive on site according to the supplied
specific mounting instructions.
原図 3N4-S4293202 77
ABB
Chapter 6 - Electrical installation
6.1 Safety
WARNING
Hazardous voltage!
Improper work could lead to life-threatening injury or death.
The electrical installation must be carried out by qualified personnel
according to the site and equipment requirements, and the relevant
electrical codes.
When the electrical installation is completed, the main and auxiliary power
supply to the drive must not be switched on without the consent of the ABB
commissioning personnel.
Take appropriate measures to prevent main and auxiliary power supply
being switched on during installation.
6.2 Overview of installation work

The electrical installation includes the following wire and cable
connections:
• Feeder and motor cables, ground cable and equipotential bonding
conductor
See 6.5 Feeder and motor cables
• Auxiliary power and control cables
See 6.6 Auxiliary power, control and serial communication cables
6.3 Cable and wire requirements
6.3.1 General
The connection from the mains supply to the drive and from the drive to
the motor comprises the following power cables:
• Feeder cables (transformer primary cables)
• Motor cables
Recommendations for the installation of these components are given
below. All applicable manufacturer's instructions and local regulations
must be followed when installing this equipment.
原図 3N4-S4293202 78
Chapter 6 - Electrical installation ABB
6.3.2 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.
6.3.3 Feeder cables

The cables from the Main Circuit Breaker (MCB) to the main power input
terminals of the drive (transformer primary side) must fulfill the following:
• Voltage rating consistent with the voltage present in the primary
circuit.
• Ampacity rating consistent with the size of the transformer 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 The installation must be in compliance with standard industry practice for
medium voltage equipment.
6.3.4 Motor cables

The cables from the drive to the motor must fulfill the following:
• Voltage rating consistent with the voltage present at the motor.
• Ampacity rating consistent with the size of the motor 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.
• Cable screening is not required for the motor cables, since the drive
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 must
be in accordance with the code.
See Appendix B - Technical data for information on the maximum length

of the motor cables.
Installation The installation must be in compliance with standard industry practice for
medium voltage equipment.
原図 3N4-S4293202 79
ABB Chapter 6 - Electrical installation
6.3.5 Equipotential bonding conductor
Requirements It is important that the drive is properly grounded to maintain safety and to
ensure smooth functioning of the equipment.
The equipotential bonding conductor must be securely tied to the ground
system of the installation site and to the ground bus closest to the cable
entry of the drive. See 6.4 Recommended grounding scheme for further
information.
Cross-section The cross-section of the equipotential bonding conductor and the ground
connection must be in compliance with national and local electrical codes.
Recommended minimum cross-section of equipotential bonding
conductor: 50 mm2.
6.3.6 Cable routing and termination
Power cables Routing of mains and motor cables must be carried out in compliance with
the local regulations and according to the specifications and
recommendations of the cable manufacturer.
• For best EMC performance, screened 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.
If the cross-section of the cable screening 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 screenings.
See the local regulations for further details.
Cable termination Cables must be terminated with connectors according to the cable
manufacturer's requirements.
Grounding wire Routing of the grounding connection must comply with local regulations.
6.3.7 Auxiliary power cables

A three-core cable is required for the auxiliary power supply. A neutral
connector is not required. Type and rating is to be selected according to
local code.
6.3.8 Control cables

Control cables should be provided in accordance with Table 6-1. Either
single or multiple-twisted pair cables may be used.
原図 3N4-S4293202 80
Control cables should not be laid in parallel to the power cables. If this
cannot be avoided, a minimum distance of 30 cm must be maintained
between control and power cables. Control and power cables should be
crossed at an angle of 90°.
Table 6-1 Control cable requirements
Signal type General cable type Cross-section
Analog in Twisted pair(s) - Overall screen 0.5 to 2.5 mm2

AWG 20 to AWG 12
Analog out Twisted pair(s) - Overall screen 0.5 to 2.5 mm2

AWG 20 to AWG 12
Digital in Twisted pair(s) - Overall screen 0.5 to 2.5 mm2

AWG 20 to AWG 12
Digital out Twisted pair(s) - Overall screen 0.5 to 2.5 mm2

AWG 20 to AWG 12
Speed Twisted pair cable with separately 0.5 mm2

encoder screened pairs and overall screen 4 x (2+1)
6.4 Recommended grounding scheme

Legend
U1 V1 W1
1 Integrated input
transformer 1
2 Drive
3 Motor
4 Earth electrode ACS 1000i
5 Ground cable
2 4
6 Cable screen (optional)
7 Cable shield (optional)
8 Equipotential bonding
conductor (optional) U2 V2 W2 PE
5
1 2 3
6
7 Optional
8
1 2 3
U V W PE
5
3 M
4
Figure 6-1 Grounding the drive equipment (recommended scheme)
原図 3N4-S4293202 81
6.5 Feeder and motor cables
6.5.1 Further information
See Layout drawing in Appendix C - Mechanical drawings for:

• Project-specific cable entry
• Distance between point of cable entry and termination bars
• Busbar and fastening hole dimensions
See Appendix D - Wiring diagrams for information on:
• Designation, cross-reference and device-identification conventions
6.5.2 Cable entry
Cable entry and termi- Cable entry into the power terminal compartment is through the top or the
nation bottom of the cabinet. The power terminal compartment is located behind
the bolted cover on the left side of the drive. It is accessible after the cover
and the acrylic pane behind it have been removed. The terminal bars can
be identified by their phase designations.
Legend 1
1 Terminal compartment
2 Feeder terminals and
input isolator
3 Feeder terminals 2
(detail)
4 Ground bus and
terminal
5 Motor terminals (detail)
3
Figure 6-2 Terminal compartment
原図 3N4-S4293202 82
See Appendix C - Mechanical drawings for details on entry plates
(dimensions) and on busbars (dimensions, layout).
Minimum creepage When using spacers for cable connection to a busbar, the minimum
distance required creepage distance must be observed. Depending on the
Comparative Tracking Index (CTI) of the insulation material of the cable
the following Minimum Creepage Distances (MCD) apply:
Table 6-2 Creepage distance
MCD in mm CTI
63 600
71 400 to 600
80 175 to 400
If the CTI value of the insulation material is unknown, the values in row
three of the table apply.
Equipotential bonding The terminal compartment is equipped with a ground bus (marked PE,
conductor and cable Protective Earth). The ground bus (see Figure 6-2) is provided to ground
screen connections the armor and screens of the cables and to connect the equipotential
bonding conductor.
NOTICE
If possible, do not cut cables inside the terminal compartment. Make sure
that waste from cable cutting and stripping cannot enter the cabinet. Any
waste which accidentally dropped into the cabinet must be retrieved. The
waste could cause damage or malfunction.
Determining the cable Determine the required length of a cable between the point of entry and
length the connection point inside the cabinet. Cut the cable to the required
length before connection to avoid excess cable to be stored in the cable
ducts.
Cable entry and cable 1 Prepare the entry plate.

connection
Drill holes adequate to the diameter of the cables and cable glands.
2 Strip the conductor ends and mount the cable lugs. Cables must be
terminated with lugs according to the specification of the cable manu-
facturer.
3 Check the insulation of each cable before connection and verify that
the results are within the specifications of the cable manufacturer.
4 Connect the phase conductors to the corresponding busbars.
See the specification of the manufacturer of the cable lugs for tight-
ening torques.
原図 3N4-S4293202 83
If two conductors are used per phase, mount the second conductor
on the rear side of the busbar.
WARNING
High voltages will be present in the terminal compartment. High voltages
can cause flashover between the potential of a phase conductor and
ground.
The required minimum creepage and sparking distances as stated earlier
in this compartment must be observed.
5 Connect the shield ends of all conductors to the ground busbar.

6 Fasten entry and blanking plates with the supplied screws.
Material requirements Use stainless steel bolts and nuts with the appropriate steel grade and
for bolted connections property class for the connection (recommended: A2-70 [designation
according to ISO 3506]). Nuts with bonded coating can be used as an
alternative to uncoated stainless steel nuts.
Connection type The following connection type is recommended when connecting a cable
lug (3) to a busbar:
Spring washer (1) and flat washer (2) on each side of the busbar (4).
1 2 4 3 2 1
Figure 6-3 Connection with spring and flat washers
Other washers may be used, provided they can maintain the required
contact pressure.
Lubrication If stainless steel bolts and nuts are used, lubricate the thread and head
contact surface of the bolt using recommended pasts, e.g. Molykote D
paste.
Note: If a coated nut (e.g. with bonded molybdenum-disulfide [MoS2]
coating) is used, the connection does not have to be lubricated.
Tightening torque Tighten bolted connections with the nominal torque recommended by the
cable manufacturer (typical value for M12: 40 Nm)
原図 3N4-S4293202 84
6.5.3 Additional cabinet compartments
If optional additional cabinet compartments are delivered as separate
units, they must be connected to the drive on site according to the supplied
specific mounting instructions.
6.5.4 Final checks

Check that the entry plates are properly fastened.
6.6 Auxiliary power, control and serial communication cables
6.6.1 Further information
See Layout drawing in Appendix C - Mechanical drawings for information

on:
• Project-specific cable entry
• Dimensions between point of cable entry and terminals
See Appendix D - Wiring Diagrams for information on:
• Designation, cross-reference and device-identification conventions
• Terminals
6.6.2 Cable preparation

Cable entry is through the roof or through the bottom of the control
compartment.
Determining the cable Determine the required length of a cable between the point of entry and
length the connection point inside the cabinet. Cut the cable to the required
length before connection to avoid excess cable to be stored in the cable
ducts.
Cable entry and cable 1 Remove the cover of the cable entry. The cover can be used as an
connection entry plate.
Figure 6-4 illustrates the top cable entry (1) for control and auxiliary
power cables.
Figure 6-4 Control cable entry
原図 3N4-S4293202 85
2 Drill holes adequate for the diameter of the cables and cable glands.
3 Enter the cables through the roof or the bottom.
4 Connect the cables and fasten them to the fastening rail as shown in
Figure 6-5.
4
3
Figure 6-5 Fastening rail and terminals
1 Control terminals X300 and X301

2 Auxiliary power terminals
3 Fixing rail
4 Shield grounding clamp connections
6.6.3 Connecting auxiliary power cables

The standard three-phase auxiliary power supply cable is entered into the
control compartment either through the bottom or the top cable entry.
A B
Figure 6-6 Cable entry from top (A) and from bottom (B)
原図 3N4-S4293202 86
With bottom cable entry the cable is routed as shown in B in Figure 6-6
and connected to the terminals shown in Figure 6-5.
It is recommended to seal the bottom cable entry with polyurethan foam.
Terminal sizes The size of the terminals is suitable for wires with a maximum cross-
section of 0.2 to 2.5 mm2.
6.6.4 Connecting control cables

Control cables for analog and digital signals are connected to the
terminals X300, X301 and to the IOEC modules in the control
compartment (see Figure 6-5).
Terminal sizes The size of the terminals is suitable for wires with a maximum cross-
section of 0.2 to 2.5 mm2.
Shielded cables If shielded cables are used, connect the cable shield to PE using shield
grounding clamps (e.g. Phoenix) as shown in Figure 6-7. The shield
grounding clamps are fastened to the fastening rail inside the control
compartment as illustrated in 4 in Figure 6-5.
Figure 6-7 Shield grounding clamp
原図 3N4-S4293202 87
ABB
Chapter 7 - Commissioning
7.1 Required qualification

Commissioning, parameter adjustments and functional tests of the drive
must be carried out only by commissioning personnel certified by ABB.
7.2 Commissioning procedure

Information on the commissioning procedure and the start conditions for
commissioning can be obtained from ABB.
See General information on manual and equipment for address.
7.3 Commissioning check list

In order to ensure uncomplicated and speedy commissioning, it is
important that drive and associated equipment are ready for
commissioning. Reviewing and completing the items in the
Commissioning check list before the commissioning personnel arrive on
site will help to achieve this.
7.4 Customer assistance

During the commissioning period, the customer is requested to provide
qualified personnel for assistance, who are
• experienced with medium and low voltage equipment and with the
local safety regulations,
• familiar with the driven process,
• authorized to operate associated medium and low voltage equipment
(main circuit breaker, other low and medium voltage switchgear etc.),
• authorized to operate the driven process for functional tests.
7.5 Customer acceptance

When commissioning has been completed, the commissioning report is
signed by the responsible commissioning personnel and by the customer
as a sign of acceptance. A copy of the report and a copy of the actual
parameter settings are handed out to the customer.
原図 3N4-S4293202 88
Chapter 7 - Commissioning ABB
原図 3N4-S4293202 89
ABB
Commissioning check list
Mechanical installation
1 Drive installed according to the instructions in the User’s manual
2 Drive securely fastened to the floor (if applicable)
3 Fan units installed
4 Visual inspection:
- no badly affixed or damaged components
- no foreign objects inside cabinet
- no dirt, dust and humidity inside cabinet
Electrical installation
1 Types and cross-sections of control cables suitable for the signal type and signal level
2 Types and cross-sections of power cables selected according to the “ABB power cable
specification”
3 Pulse encoder connected according to the relevant manual (only applicable for drives
with pulse encoder interface)
4 Cable entry made according to the instructions in the User’s manual
5 All control cable screens and conductors are connected according to the instructions of
the User’s manual, appropriately labelled, and the customer-side connections are
completed
6 Equipotential bonding conductor of drive securely connected at both ends
7 Supply and motor cables not connected at both ends (cables and drive must be
meggered before connection)
原図 3N4-S4293202 90
Commissioning check list ABB
Main circuit breaker (MCB)
1 Type of MCB selected as per “ABB MCB specification”
2 High voltage connections completed
3 MCB ready to be tested with drive
4 MCB protection relay settings tested
5 Safety devices (door locks etc.) tested and in operation
Motor
1 Motor installed, aligned and alignment protocol available
2 Motor not coupled to driven load
3 Ground connection completed
4 Motor auxiliaries (bearing lubrication, heater cooling etc.) ready
5 Control and monitoring signals connected
Insulation tests
1 All power cables to converter transformer, between converter transformer and drive,
and from drive to motor are meggered, and measured values are within the required
limits.
2 Test report of the megger test available
Note: If the test is carried out by the commissioning engineer of the drive, an additional
day per drive motor combination needs to be reserved. After the test, the feeder cables
can be connected, except at the drive end. The test must comply with the specification.
原図 3N4-S4293202 91
ABB Commissioning check list
Power supply
1 Medium voltage available for start-up of drive
2 Low voltage auxiliary power available for start-up of drive
Miscellaneous
1 Sufficient number and correct type of spare parts available
2 Air conditioning of drive room ready for load run of drive
3 Optional equipment ready
原図 3N4-S4293202 92
Commissioning check list ABB
原図 3N4-S4293202 93
ABB
Chapter 8 - Operation
8.1 Overview
The chapter outlines the local operation using the CDP control panel and
the control switches on the control compartment door of the drive as
illustrated in 8.3.1 Overview of local operator panel.
Control of the drive via a PLC or higher-level control systems is not
described in this chapter. If the drive is controlled from remote, see the
appropriate manuals for information.
Note: The panel messages and parameter settings used in this chapter
are typical examples to illustrate the related instructions and display
functions and may therefore differ from the actual messages and
parameter settings in your drive.
8.2 Safety
The drive system must only be operated by qualified and authorized
personnel, i.e. personnel who are familiar with the operation of the drive
system and the hazards involved.
8.3 Local operation
8.3.1 Overview of local operator panel

The operator panel on the control compartment door enables the operator
to control the drive without restrictions provided that all requirements for
normal operation are met.
The functions of the operator panel include:
• Connecting and disconnecting the main power supply
• Setting the reference value
• Starting, stopping the drive system
• Displaying:
• Actual values
• Status messages
• Alarm and fault messages
• Viewing, setting parameters
• Resetting alarm and fault messages
• Activating the emergency-off circuit
原図 3N4-S4293202 94
Chapter 8 - Operation ABB
Legend
1 CDP control panel

Main functions:
• Starts and stops the
motor 1
• Displays status
messages 6
• Displays alarm and
fault messages of the
drive and monitored
foreign equipment
• Resets alarm and fault 3
messages
2 Main circuit offline
2
Illuminated pushbutton
opens the main circuit 4
breaker
3 Main circuit online
Illuminated pushbutton
charges the DC link and
closes the main circuit 5
breaker
4 Grounding switch
unlocked
Lights up to indicate that the
grounding switch of the drive
can be turned to the grounded
or ungrounded position
5 Emergency-off latching
pushbutton
Prevents starting when pressed
at standstill of the drive
Main circuit breaker opens
immediately and DC link
discharges when pressed
during operation of the drive
6 Transformer protection (see
Application note transformer
protection relay settings
3BHS217968 ZAB E01)
Figure 8-1 Local operator panel
See Chapter 9 - CDP control panel for further information on the CDP
control panel.
原図 3N4-S4293202 95
ABB Chapter 8 - Operation
8.4 Status messages
8.4.1 Overview on status messages

The following section lists the messages of the main operating states the
drive passes through, when it is put into operation (see 8.4.2 Start
sequence of the drive), when it is stopped (see 8.4.3 Stop sequence), or
when a fault condition has occurred. The messages are sent to the higher-
level control system and are displayed on the CDP control panel of the
drive.
See the status words in the Appendix G - Signal and parameter table of
the drive for information on other status messages, such as fault status
messages in particular.
The status message signals that the drive is healthy and ready for the ON
RdyForMCBOn command. The ON command initiates charging of the DC link capacitors
and closing of the main circuit breaker of the drive. Depending on the
control place, the command can either be sent from the higher-level
control system to the drive or be initiated by pressing the Main circuit
online pushbutton on the control compartment door.
The status message RdyForMCBOn changes to Charging when the

Charging DC link capacitors of the drive are being charged.
The message Rdy to Strt tells the operator that the drive is energized and
Rdy to Strt ready for operation. As soon as the start command is initiated, the motor
is magnetized and the drive starts to modulate.
The status message Rdy to Strt changes to Magnetizing when the firing
Magnetizing pulses of the inverter are released.
When the drive is in Running state, it is running and operating according

Running to the set speed or torque reference value. When in remote control mode,
the reference value is set at the higher-level control system. When in local
control mode, the value is entered into the CDP control panel.
Stopping indicates that the drive has received a stop command and that
Stopping a ramp or coast stop has been initiated. The stopping mode depends on
the parameter setting. The status indication changes to Rdy to Strt when
the zero speed threshold is reached.
When a start command is given while the drive is stopping, the drive
resumes operation and the status indication changes to Running again.
The status message Rdy to Strt changes to Discharging when the MCB
Discharging has opened and the DC link capacitors are discharging.
The status message indicates that a fault condition has occurred that
Tripped requires a shutdown of the drive. The status message always alternates
原図 3N4-S4293202 96
with the specific fault message. The type of shutdown depends on the fault
class the fault condition is assigned to in the drive software.
原図 3N4-S4293202 97
8.4.2 Start sequence of the drive
Not ready on
Ready on conditions:
Auxiliary supply on
Doors closed and locked
Drive not grounded
No emergency off
No fault
RdyForMCBOn
On command
Charging
DC link charges
Fan switches on
MCB closes
Rdy to Strt
Start command
Inverter starts to modulate
Magnetizing
Running
Operation
原図 3N4-S4293202 98
8.4.3 Stop sequence
Operation
Running
Stop command
Stopping
Speed ramps down

Inverter stops to modulate
Rdy to Strt
Off command
Discharging
MCB opens
DC link discharges
Fan switches off
after a delay
RdyForMCBOn Actions:
Drive is grounded
Doors are released for opening
Auxiliary supply is switched off
Not ready on
原図 3N4-S4293202 99
8.4.4 Emergency-off sequence
Operation
Running
Emergency-off command
MCB opens
Inverter stops to modulate
Speed coasts down
Not ready on
8.5 Starting the drive system

It is recommended to have the following documents at hand when starting
the drive system locally for the first time after commissioning:
• Appendix D - Wiring diagrams to identify the circuit breakers to be
switched on
• Chapter 9 - CDP control panel for information on functions and
features of the CDP control panel
8.5.1 Prerequisites
The drive has been properly installed and commissioned.
原図 3N4-S4293202 100
8.5.2 Checks before starting the drive system
DANGER
Hazardous voltages!
All doors must be closed and all covers must be screwed in place to
prevent unintentional contact with energized components.
When the drive system is put into service after it has been commissioned,
or after it has been taken out of service for a longer period, check the drive
according to the following list:
• Check that no tools and foreign objects are left inside the cabinet.
• Check that all auxiliary power supplies from external sources are
switched on.
• Check that all internal circuit breakers of the drive are closed.
• Check that all covers are mounted and the doors are closed, locked
or bolted.
• Check that the input disconnector and grounding switch lever is in
position I (not grounded.)
• If applicable: check that input and output isolators are closed.
• Check that the MCB is in operating position.
• Check that there is no run interlock active.
The drive is now ready to be started.
8.5.3 Starting the drive system from remote

When the drive system is operated from remote through a higher-level
control system or an operator control desk, follow the instructions in the
appropriate manuals.
8.5.4 Starting the drive system locally

1 Set the CDP control panel to LOCAL mode.
2 Check that no alarm or fault messages are displayed on the CDP

control panel.
If a fault message is displayed on the CDP control panel, reset the
fault.
原図 3N4-S4293202 101
If a fault cannot be reset, it must be rectified by the responsible

personnel.
See Chapter 10 - Troubleshooting and maintenance for further infor-
mation.
When no alarms and faults are present and the drive is ready, the
CDP control panel displays RdyForMCBOn:
1 L -> 0.0 rpm

Status RdyForMCBon
MotorSpeed 0.00 rpm
Power 0.0 %
3 Press the Main circuit online pushbutton on the control compart-

ment door to charge the DC link. The pushbutton flashes during
charging.
The status line of the CDP control panel changes to Charging.
1 L -> 0.0 rpm

Status Charging
MotorSpeed 0.00 rpm
Power 0.0 %
After charging has been finished, the following takes place:

• The MCB closes automatically.
• The Main circuit online pushbutton lights up permanently.
The status line of the CDP control panel changes to Rdy to Strt and
the motor can be started.
原図 3N4-S4293202 102
See also Flow diagram in 8.4.2 Start sequence of the drive.
1 L -> 0.0 rpm 0

Status Ready to Strt
MotorSpeed 0.00 rpm
Power 0.0 %
4 Enter the setpoint.
1 L -> [600.0 rpm] 0

MotorSpeed 0.00 rpm
Power 0.0 %
5 Start the motor.
1 L -> [600.0 rpm] 0

Status Magnetizing
MotorSpeed 0.00 rpm
Power 0.0 %
After the motor has been magnetized, the motor speed ramps up to
the setpoint.
While the motor is accelerating, the run status indication on the
display blinks. When the motor speed has reached the setpoint, the
run status indication lights up permanently.
原図 3N4-S4293202 103
The display shows Running to indicate that the drive system is oper-
ating:
1 L -> 600.0 rpm

Status Running
MotorSpeed 600.00 rpm
Power 30.0 %
8.6 Stopping
Press the stop key on the CDP control panel.
The motor stops according to the preset stop function and the drive stops
modulating. While the motor stops, the status line of the display shows
Stopping. The run status indication blinks during the stop sequence.
1 L -> 600.0 rpm

Status Stopping
Power 20.0 %
As long as the stop sequence is in progress, the drive can always be

restarted by pressing the start key on the CDP control panel.
When the drive has stopped modulating, the CDP control panel displays
Rdy to Strt:
1 L -> 600.0 rpm 0

Status Rdy to Strt
MotorSpeed 0.00 rpm
Power 0.0 %
As long as the MCB has not been opened, the motor can be started again.
原図 3N4-S4293202 104
8.7 Emergency-off
8.7.1 Function
The drive is equipped with a hard-wired emergency-off circuit. When an
emergency situation occurs during operation, this safety feature ensures
that the drive system can be disconnected without delay from the main
power supply. If the emergency-off pushbutton has been pressed while the
drive is at standstill, the main power supply cannot be connected to the
drive, hence the drive cannot be started up.
The emergency-off pushbutton of the drive is part of the operator control
panel (see Figure 8-1) and features a latching switch action.
Note: Pressing the emergency-off pushbutton does not disconnect the
auxiliary power supply from the drive.
8.7.2 Initiating an emergency shutdown

An emergency shutdown is initiated by pressing the emergency-off
pushbutton on the control compartment door or an external emergency-off
pushbutton (if present) linked to the emergency-off circuit.
When an emergency shutdown is initiated during drive operation, the
following takes place:
• The MCB opens.
• The drive system coasts down.
• The status line of the CDP control panel displays the message
Emerg Off.
1 L -> 600.0 rpm

ACS 1000
*** FAULT “**
Emerg Off
• The DC link of the drive discharges.
8.7.3 Starting the drive system after an emergency shutdown

To start up the drive system after an emergency shutdown, the
emergency-off pushbutton must be unlatched. The emergency-off
pushbutton returns to its initial position when turned into the direction
indicated by the arrows on the pushbutton. Then, the reset button on the
control keypad must be pressed in order to reset the emergency-off safety
relay of the drive.
原図 3N4-S4293202 105
After resetting, the status indication of the drive changes to

RdyForMCBOn.
1 L -> 0.0 rpm

Status RdyforMCBOn
MotorSpeed 0.00 rpm
Power 0.0 %
Now, the main power supply can be connected to the drive again and the
drive system can be started up.
原図 3N4-S4293202 106
原図 3N4-S4293202 107
ABB
Chapter 9 - CDP control panel
9.1 Overview
Note: The panel messages and parameter settings used in this chapter
are typical examples to illustrate the related instructions and display
functions and may therefore differ from the actual messages and
parameter settings in your drive.
9.1.1 Display and keypad

Legend
1 Mode selection keys

2 Fast navigation keys,
select and / or change a
value fast
3 Slow navigation keys,
select and / or change a 1 L -> 600.0 rpm
value slowly
Status Running
4 Enter key, terminates a Display
procedure MotorSpeed 600.00 rpm
5 Local and remote Power 30.0 %
selection key
6 Reset key
7 Reference key
8 Start key
1
9 Forward key
10 Reverse key
3
11 Stop key
2 4
Keypad
7
5 8
6
9 11
10
Figure 9-1 CDP control panel
9.2 Overview on CDP control panel functions

The CDP control panel serves as the basic user interface for operating
and monitoring the drive when the local operating mode has been
selected.
原図 3N4-S4293202 108
Chapter 9 - CDP control panel ABB
The CDP control panel can be attached to or detached from the drive
without having to switch off the auxiliary power supply first.
Using the CDP control panel it is possible to
• enter start-up data,
• control the drive with a reference value and 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,
• upload and download complete parameter sets from one drive to
another.
9.3 Overview on CDP control panel modes

The CDP control panel provides the following modes:
• Identification mode
See 9.4 Identification mode for further information.
• Actual signal display mode
See 9.5 Actual signal display mode for further information.
• Parameter mode, selected by the PAR key
See 9.6 Parameter mode for further information.
• Function mode, selected by the FUNC key
See 9.7 Function mode for further information.
• Drive selection mode, selected by the DRIVE key
See 9.8 Operational commands for further information.
9.4 Identification mode

When the power supply is switched on, or the CDP control panel is
connected to the drive and the auxiliary voltage has been switched on
already, the identification display appears showing the CDP control
panel version and then the ID-number of the drive. When the CDP control
panel is initialized, the display changes as follows:
CDP312 PANEL V5.30
........
原図 3N4-S4293202 109
ABB Chapter 9 - CDP control panel
After 2-3 seconds, information on the drive (1, 2) and the drive
identification (3) is displayed.
ACS 1000 xxxx 1

< Device Name > 2
ID-NUMBER 1 3
After another few seconds:
1 L -> 0.0 rpm

Status InitSeq....
MotorSpeed 0.00 rpm
Power 0.0 %
After another few seconds, the display changes to the actual signal
display mode.
1 L -> 0.0 rpm

Status ErthIsoClos
MotorSpeed 0.00 rpm
Power 0.0 %
9.5 Actual signal display mode
9.5.1 Overview
Two kinds of displays can be selected in the actual signal display mode:
• Actual signal display
• Fault history display
The actual signal display appears first when the actual signal display
mode has been selected. However, when the drive is in a fault condition,
the fault display will be shown instead.
The actual signal display is used to monitor the drive without interfering
its operation. Three selectable actual values are shown continuously on
the display.
原図 3N4-S4293202 110
The CDP control panel will automatically return to the actual signal
display mode from other modes within one minute when no keys are
pressed (exceptions: status display and common reference display
when in drive selection and fault display mode).
Actual values Table 9-1 Actual signal parameter groups
Group 01 Measured or calculated motor values
Group 02 Measured or calculated drive values
Group 03 Speed and torque reference values
Group 04 Basic I/O-Values (IOEC 1 & 2)
Group 05 Data values
Group 06 Information: Software version, drive and motor nominal values
Group 07 Control words
Group 08 Status words
Group 09 Fault and alarm words
See Appendix G - Signal and parameter table for the complete list of
selectable actual signals.
Control panel overview

Legend
1 Status line
2 Actual signal names and
values
3 Selects the function
mode 1 L -> 600.0 rpm 1
Status RdyForMCBOn
4 Selects actual signals
and faults
MotorSpeed 0.00 rpm 2
Power 0.0 %
5 Scrolls through signal
and fault messages
6 Enters the selection 3
mode
Acknowledges the 4
selection 5
6
原図 3N4-S4293202 111
Fault memory The fault memory includes information on the 64 most recent fault events
that occurred in the drive. The name of the fault and the actual time are
displayed. The procedure for selecting and clearing the fault history is
described in 9.5.5 Displaying and resetting an active fault.
When a fault or warning is generated in the drive, the message will be
displayed immediately, except when in drive selection mode.
Changing from the fault display mode to other display modes is possible
without resetting the fault first. When no keys are pressed, the fault or
warning text is displayed as long as the fault is pending.
Selecting the actual The actual signal display mode is selected by pressing the ACT key.
signal display
1 L -> 600.0 rpm 0

Status RdyForMCBon
MotorSpeed 0.00 rpm
Power 0.0 %
Toggle between actual When in actual signal display mode, the fast up or down keys allow to
signal display and fault toggle between actual signal display and fault history display.
history
1 L -> 600.0 rpm 0

1 LAST FAULT
Overspeed
070730 12:30:02.3256
原図 3N4-S4293202 112
9.5.2 Displaying three actual signals
1 To display the full name of three actual signals, press and hold the
ACT key:
1 L -> 600.0 rpm 0

DriveStatusWord
MotorSpeed
Power
2 To return to the actual signal display, release the ACT key.
9.5.3 Selecting actual signals

1 To select the actual signal display, press the ACT key:
1 L -> 600.0 rpm

Status Running
Power 75.0 %
2 To select a row where the actual signal is to be displayed, press the

corresponding slow navigation key.
A blinking cursor indicates the selected row.
1 L -> 600.0 rpm

Status Running
Power 75.0 %
原図 3N4-S4293202 113
3 To enter the actual signal selection function, press the ENTER key:
1 L -> 600.0 rpm

1 Actual Signals
10 ShaftPower
0.0 %
4 To select a parameter group, press the corresponding fast navigation

key:
1 L -> 600.0 rpm 0

2 Actual Signals
01 ControlMode
SPEED-CTRL
5 To select an actual signal, press the corresponding slow navigation

key:
1 L -> 600.0 rpm 0

2 Actual Signals
02 DC Voltage Udc1
1000.0 V
6 To accept the selection and to return to the actual signal display

mode, press the ENTER key:
原図 3N4-S4293202 114
1 L -> 600.0 rpm 0

MotorSpeed 0.00 rpm
DC Voltage Udc1 1000.0 V
7 To cancel the selection and keep the original selection, press any of
the mode keys:
1 L -> 600.0 rpm 0

MotorSpeed 0.00 rpm
Power 0.0 %
The selected CDP control panel mode is entered.
9.5.4 Displaying a fault and resetting the fault history

1 To enter the actual signal display mode, press the ACT key:
1 L -> 600.0 rpm 0

MotorSpeed 0.00 rpm
Power 0.0 %
原図 3N4-S4293202 115
2 To enter the fault history display, press any of the fast navigation
keys:
1 L -> 600.0 rpm 0

1 LAST FAULT
+ Panel Lost
0707730 12:30:02.3256
3 To select the previous or next fault, press the corresponding slow

navigation key. The up key selects the previous, the down key the
next fault.
1 L -> 600.0 rpm 0

2 LAST FAULT
+ AMC: Fault Class 1
0707730 12:21:02.2452
4 To clear the fault history, press the RESET key:
1 L -> 600.0 rpm 0

1 LAST FAULT
H MIN S
原図 3N4-S4293202 116
5 To return to the actual signal display mode, press any of the fast
navigation keys:
1 L -> 600.0 rpm 0

MotorSpeed 0.00 rpm
Power 0.0 %
9.5.5 Displaying and resetting an active fault

1 To display an active fault, press the ACT key:
1 L -> 600.0 rpm 0

ACS 1000
*** FAULT ***
MCB CloseControl
2 To reset the fault, press the RESET key:
1 L -> 600.0 rpm 0

MotorSpeed 0.00 rpm
Power 0.0 %
原図 3N4-S4293202 117
9.6 Parameter mode
NOTICE
Running the drive system with incorrect data can result in improper oper-
ation, reduction of control accuracy and damage of equipment. Do not
change any parameter, if the meaning of the parameter and the effects of
the change are not fully understood.
9.6.1 Overview
Parameters allow the drive to be configured and set-up specifically for an
application. Parameters are organized in functional groups. All control
functions are represented by a parameter group and can be activated and
set-up individually by the parameter mode.
Table 9-2 Commonly used parameter groups
Group 07 Control words
Group 08 Status words
Group 09 Fault & alarm words
Group 11 Start, stop, direction and MCB control
Group 12 Reference selection
Group 13 Basic analog inputs
Group 14 Basic digital outputs
Group 15 Basic analog outputs
Group 16 System control inputs
Group 17 Utilities
Group 18 Process speed
Group 19 Data storage
Group 20 Limits
Group 21 Start, stop and process stop
Group 22 Ramp functions
Group 23 Speed reference
See Appendix G - Signal and parameter table for further information on the
parameters, their settings and functions.
When the parameter mode is entered for the first time after the auxiliary
voltage of the drive has been switched on, the display will show the first
parameter of parameter group 99 (Language: ENGLISH). The next time
the parameter mode is entered, the previously selected parameter is
shown.
原図 3N4-S4293202 118
Some parameter values cannot be changed while the drive is running. If
tried, the following warning will be displayed:
** Warning **
Write Access Denied
Parameter Setting
Not Possible
Legend
1 Status line
2 Group number and name
3 Parameter number and
name 1 L -> 600.0 rpm 0 1
4 Parameter value 75 OPTION MODULES 2
5 Selects the parameter 01 IOEC3 OptionBoard 3
mode YES 4
6 Selects the parameter
number and name
5
7 Selects the parameter
value
8 Enters change mode 6
7
Acknowledges the
selection 8
原図 3N4-S4293202 119
9.6.2 Procedure
1 To enter the parameter mode, press the PAR key:
1 L -> 600.0 rpm 0

12 REFERENCE SELECT
01 KeypadRefSelect
1
2 To select a different group, press the corresponding fast navigation

key:
1 L -> 600.0 rpm 0

75 OPTION MODULES
01 IOEC3 OptionBoard
YES
3 To select a parameter, press the corresponding slow navigation key:
1 L -> 600.0 rpm 0

75 OPTION MODULES
NO
原図 3N4-S4293202 120
4 To enter the parameter setting function, press the ENTER key:
1 L -> 600.0 rpm 0

75 OPTION MODULES
[NO]
5 To change the parameter value, press:

• the corresponding slow navigation key for numbers and text,
• the corresponding fast navigation key for numbers only.
1 L -> 600.0 rpm 0

75 OPTION MODULES
[YES]

1 L -> 600.0 rpm 0

75 OPTION MODULES
YES
7 To cancel the setting and keep the original selection, press any of the
mode keys.
The selected CDP control panel mode is entered.
原図 3N4-S4293202 121
1 L -> 600.0 rpm 0

75 OPTION MODULES
[NO]
9.6.3 Parameter lock

Unwanted parameter entry can be prevented by activating the
ParameterLock function in parameter group 16 SYSTEM CTRL INPUTS.
The ParameterLock is activated by setting parameters 16.02 and 16.03
accordingly.
The user pass code can be changed by setting parameters 16.04 and
16.05.
Activating the 1 Select parameter 16.02 PARAMETER LOCK.

ParameterLock
2 Set parameter 16.02 to LOCKED.
3 Save the setting and exit the Parameter mode.
Opening the 1 Select parameter 16.03 PASSCODE.

ParameterLock
2 Set the correct pass code.
3 Save the setting and exit the Parameter mode.
See Appendix G - Signal and parameter table for further information.
原図 3N4-S4293202 122
9.7 Function mode
9.7.1 Overview
The function mode is used to set the display contrast.
Legend
1 Status line
2 Selectable functions
3 Selects the function
mode
1 L -> 0.0 rpm 0 1
4 Selects the line UPLOAD <= <=
5 Acknowledges the DOWNLOAD => => 2
selection CONTRAST 4
4
5
9.7.2 Procedure
1 To enter the function mode, press the FUNC key:
1 L -> 0.0 rpm 0

UPLOAD <= <=
DOWNLOAD => =>
CONTRAST 4
原図 3N4-S4293202 123
2 To select a function (a blinking cursor indicates the selected function),

press the corresponding slow navigation key:
1 L -> 0.0 rpm 0

UPLOAD <= <=
DOWNLOAD => =>
CONTRAST 4
3 To enter the contrast setting function, press the ENTER key:
1 L -> 0.0 rpm 0

CONTRAST [4]
4 To change the contrast value, press the corresponding slow naviga-

tion key:
1 L -> 0.0 rpm 0

CONTRAST [6]
原図 3N4-S4293202 124
1 L -> 0.0 rpm 0

UPLOAD <= <=
DOWNLOAD => =>
CONTRAST 6
6 To cancel the setting and keep the original selection, press any of the
mode keys.
The selected CDP control panel mode is entered:
1 L -> 0.0 rpm 0

UPLOAD <= <=
DOWNLOAD => =>
CONTRAST 6
9.8 Operational commands
9.8.1 Local and remote control location

The local and remote feature of the CDP
control panel allows the operator to select
the control location of the drive:
• Local control
• Remote control
The control location is selected by
pressing the LOC-REM key on the CDP
control panel.
Local control When the CDP control panel is switched to local, operation via the
pushbuttons on the control compartment door and the CDP control panel
is possible. Control commands from remote have no effect.
原図 3N4-S4293202 125
Remote control When the CDP control panel is switched to remote, the pushbuttons on
the control compartment door and the operational keys of the CDP control
panel are disabled. Operational commands and reference value from a
remote control station are transmitted via fieldbus or remote I/O to the
drive. Switching from remote to local while the drive is running is not
possible.
Selecting local To select local control, press the LOC- REM key. The local control location
is indicated by the letter L.
1 L 600.0 rpm 0
MotorSpeed 0.00 rpm
Power 0.0 %
Selecting remote To select remote control, press the LOC - REM key. The remote control
location is normally indicated by a blank (see arrow).
1 600.0 rpm 0
MotorSpeed 0.00 rpm
Power 0.0 %
If desired, the START or STOP command can then be given and the
reference value can be set from the CDP control panel (for example
START or STOP from remote while the reference value is set from the
CDP control panel). To achieve this, the relevant parameters 11.01, 11.02,
12.03 or 12.06 must be set to KEYPAD.
原図 3N4-S4293202 126
If any of these parameters is set to KEYPAD and remote control is
selected, this is indicated by the letter R (see arrow).
1 R 600.0 rpm 0
MotorSpeed 0.00 rpm
Power 0.0 %
9.8.2 Setting the direction of rotation

The direction of rotation is selected using the forward (I) or reverse (0)
key of the CDP control panel. Both keys can be used if the CDP control
panel is in local mode. The function is released with parameter 11.03
Direction (REQUEST).
1 L -> 600.0 rpm

Status Running
Power 75.0 %
1 L <- 600.0 rpm

Status Running
Power 75.0 %
The arrow on the display indicates the direction:

• When the motor is running, the arrow indicates the actual sense of
rotation.
• When the motor is not running, the arrow indicates the preselected
sense of rotation.
原図 3N4-S4293202 127
When the direction of rotation is changed while the motor is running, the
speed will automatically ramp to zero and the motor will accelerate in
opposite direction to the preset speed. The direction of the arrow on the
display changes to the new direction when the motor has reached zero
speed.
9.8.3 Entering a setpoint

The setpoint can be changed at any time if the CDP control panel has
been set to local.
1 To enter a control panel mode displaying the status row, press a
mode key:
:
1 L -> 600.0 rpm

Status Running
Power 75.0 %
2 To enter the setpoint setting function, press the REF key:
1 L -> [600.0 rpm]

Status Running
Power 75.0 %
3 To change the setpoint, press either the corresponding fast or slow

navigation key:
1 L -> [550.0 rpm]

Status Running
Power 75.0 %
原図 3N4-S4293202 128
4 To exit the setpoint setting mode, press any of the mode keys:
1 L -> 550.0 rpm

Status Running
Power 75.0 %
9.8.4 Run status indication

The run status indication on the display (see arrows) changes depending
on the state the drive is in:
1 L -> 600.0 rpm

Status RdyForMCBon
Power 0.0 %
1 L -> 600.0 rpm 0

Power 75.0 %
1 L -> 600.0 rpm

Status Running
Power 75.0 %
原図 3N4-S4293202 129
ABB
Chapter 10 - Troubleshooting and maintenance
10.1 General information
10.1.1 Required qualification

Maintenance and parts replacement on the drive must only be carried out
by qualified personnel, and in compliance with local regulations.
10.1.2 Warranty period

During the warranty period of the drive, any repair work must be carried
out exclusively by ABB service personnel. After the warranty period, repair
work may only be carried out by qualified personnel.
10.1.3 Training courses

ABB offers maintenance and service training courses. Customer staff
having successfully attended such courses, will be certified to do
maintenance and repair work on the drive. To maintain safe and reliable
operation of the drive, ABB recommends taking out a service contract with
the ABB service organization.
For more information contact the ABB service organization. See chapter
General information on manual and equipment for address.
10.1.4 Maintenance schedule

It is strongly recommended to carry out all maintenance tasks according
to the maintenance schedule and the applicable service instructions, on
time and at the stated intervals.
10.1.5 Logbook
It is recommended to record all troubleshooting and maintenance work in
a logbook including:
• Date and time
• Detailed description
10.1.6 Spare parts

To ensure safe and reliable operation, it is important to use only spare
parts recommended and approved by ABB.
See Appendix E - Parts list for information on types and identification

codes.
原図 3N4-S4293202 130
Chapter 10 - Troubleshooting and maintenance ABB
10.2 Identifying electrical equipment
10.2.1 Device designation

All devices are labelled as per DIN for easy identification of the
components in wiring diagrams and parts lists. The labels are located
either on or alongside the device (Figure 10-1). See also page Item
Designation & Cross Reference Identification in the wiring diagrams for
further information.
Figure 10-1 Example for device identification
10.2.2 Cables and wires

Cables and wires in the drive are equipped with marker sleeves which
carry the same identification number as in the wiring diagrams.
Cables with connectors are equipped with markers on the connector.
10.2.3 Understanding wiring diagrams
Item designation and cross-reference conventions are defined in

Appendix D - Wiring diagrams.
原図 3N4-S4293202 131
ABB Chapter 10 - Troubleshooting and maintenance
10.3 Troubleshooting
10.3.1 Alarm and fault indications

When a malfunction occurs in the drive or in the equipment monitored by
the drive (e.g. MCB, transformer, cooling system), the CDP control panel
displays a corresponding alarm or fault message.
1 L -> 600.0 rpm 0

ACS 1000
*** FAULT ***
MCB CloseControl
The display message can be saved and viewed in the fault logger of the
drive when a PC with the DriveWindow, DriveDebug or DriveMonitorTM
tool is connected to the drive. The fault logger can also be called up on the
CDP control panel.
10.3.2 Error message levels

Two error message levels are used in the drive:
Alarm or warning An alarm does not shut down the drive. However, a persisting alarm
condition can often lead to a fault if the condition causing the alarm is not
corrected. An alarm cannot be reset manually (Exception: Pump alarm, if
Parameter 41.1 is set). The alarm message will be deleted from the
display as soon as the alarm condition has been corrected.
Fault A fault always shuts down the drive. The type of shutdown depends on the
origin of the fault.
Depending on the type of fault, the MCB is opened by the drive or stays
closed.
In general, a fault condition must be corrected and the fault be manually
reset before the drive can be started again.
Trip reactions The following reactions to a trip are possible:

• Soft Stop
This is the normal stopping procedure:
• The rotation frequency of the drive will be reduced according to
the deceleration time to a programmable level. If possible,
braking energy will be provided to speed up this procedure.
• The flux will be reduced with a ramp in order to avoid overcur-
rents.
原図 3N4-S4293202 132
• Then the zero voltage vector will be switched to short circuit the
machine. After a programmable period (5 times the rotor time
constant, at least 1second) the inverter will be switched off.
• Trip 1 (with de-magnetization)
Trip 1 will be used for slower protective actions and includes the
following actions:
• The flux will be reduced with a ramp in order to avoid overcur-
rents.
• Then the zero voltage vector will be switched to short-circuit the
machine. After a programmable period (5 times rotor time
constant, at least 1second) the inverter will be switched off.
• Depending on the failure, the MCB will stay closed (trip 1a) or be
opened (trip 1b).
• Trip 2 (without de-magnetization)
Trip 2 will be used for fast protective actions and includes the
following actions:
• All inverter IGCTs will be switched off immediately.
• In case of a GUSP failure the protection IGCTs will be opened
immediately. In case of another fault the protection IGCTs will
stay closed until the DC link voltage reaches the undervoltage
alarm level.
• Depending on the failure, the MCB will stay closed (trip 2a) or be
opened (trip 2b).
• Trip 3 (with zero vector)
Trip 3 is an enhanced version of trip 2 and normally only is initiated if
a serious damage to the inverter has occurred:
• The zero voltage vector will be switched immediately to short
circuit the machine.
• In case of short circuit faults the protection IGCTs will be opened
immediately. In case of another fault the protection IGCTs will
stay closed until the DC link voltage reaches the undervoltage
alarm level.
• the MCB will be opened.
Alarm and fault In the event of an alarm or a fault, a specific message is saved in the fault
handling logger of the drive. Information on the 64 most recent fault and alarm
events are saved.
The faults are entered into the fault buffer as they occur and are
numbered; the last fault entered always has number 1 assigned to it and
the first fault always has the highest number in the fault buffer.
Date and time stamps facilitate fault tracing, especially when a fault leads
to several subsequent faults.
原図 3N4-S4293202 133
Example:
1. -Fault RESET FAULT 2011-04-26 14:57:56.5370
2. +Fault Undervoltage 2011-04-26 14:47:41.1110
3. +Warn Undervoltage 2011-04-26 14:47:41.1000
4. +Fault MCB Disturb 2011-04-26 14:47:38.0230
In the above example:
• 4. +Fault MCB Disturb is the reason for the failure of the drive, as it
occurred first.
• The message 3. +Warn Undervoltage occurred approx. 3 sec after
the first fault.
• The message 2. +Fault Undervoltage immediately followed the
warning.
• The message 1. -Fault RESET FAULT informs that the fault has been
reset.
See Appendix G - Signal and parameter table for further information on

alarms and faults.
10.3.3 Troubleshooting procedure

Follow the procedure when a malfunction shuts down the drive:
1 Do not switch off the auxiliary power supply or try to reset a fault
message before all essential information at the time of the occurrence
of the fault condition has been saved.
2 Call up the Fault History Display on the CDP control panel.
See Chapter 9 - CDP control panel if further information is required.
Do not clear the fault buffer of the drive now!
3 Identify the fault and make a logbook entry.
Note the fault message displayed on the CDP control panel and look
up the fault message in the Alarms and Faults Troubleshooting Guide
for further information.
4 Save the content of the data logger when a PC is available that has
the DriveWindow tool installed.
The data logger provides useful information (e.g. waveforms of
voltage, current, torque etc.) for efficient troubleshooting.
5 Contact ABB service if a fault cannot be rectified.
When calling ABB service, it is recommended to have the following
data available at the time when the fault occurred:
• Operating, ambient and load conditions
• Unusual events
原図 3N4-S4293202 134
After the fault has been rectified, start the drive as described in Chapter 8
- Operation.
10.4 Malfunctioning grounding switch
CAUTION
If the control circuit of the grounding switch malfunctions, it is possible that
the grounding switch can be closed while the DC link is still charged.
As a consequence, the DC capacitors are short-circuited and the short-
circuit will cause a loud bang.
To avoid a temporary minor hearing impairment, follow the instructions
below.
After the DC link of the drive has been de-energized, the lamp
GROUNDING SWITCH UNLOCKED lights up to indicate that the
grounding switch is released and can be turned to the grounded position.
If for some reason the lamp does not light up or if a malfunctioning of the
grounding circuit is presumed, proceed as follows:
1 Do not try with force to turn the grounding switch in any direction.
The handle or the switch could be damaged if tried.
2 Verify that the DC link has been discharged.
The discharging level can be viewed in parameter 2.01 DC
VOLTAGE. The value should be below 50 V.
3 Verify that the MCB is in the open position and racked out.
4 Check if there are any alarm and fault messages on the display.
5 Try to rectify the reason for the alarms and faults, and then press the
reset key on the CDP control panel.
6 Call ABB service if the cause for the malfunctioning grounding switch
cannot be rectified.
See General information on manual and equipment for address.
10.5 Panel removal

Procedure If the CDP control panel must be removed from its mounting cradle, follow
the instructions below.
1 When the panel is removed while the drive is in operation, check the
setting of parameter 31.06 PANEL LOSS SUPERVISION first.
If the parameter is set to NOT USED, the panel can be removed
without interrupting drive operation.
原図 3N4-S4293202 135
See Appendix G - Signal and parameter table if information on setting

parameters is required.
Note: If the CDP control panel has been removed during operation,
the drive can only be stopped by pressing the emergency-off button.
2 Proceed as illustrated below.
1 2 3
Meaning of the LEDs The green LED (see arrow in 3) is illuminated when the control voltage has
been switched on.
The red LED is not used.
Panel dimensions and Dimensions (H x W x D): 170 mm x 80 mm x 2 mm

weight
Weight: 0.2 kg
10.6 LEDs and switches on PCBs and I/O devices

The following section provides an overview on the meaning of LEDs and
switches of the main circuit boards and I/O devices. The LEDs presented
in the following section can be checked easily with the auxiliary voltage
switched on and without the need to remove covers first. The LEDs
provide information on the status of the devices and can be used for
diagnostic purposes when calling ABB service.
原図 3N4-S4293202 136
10.6.1 AMC circuit board
F R
M P
T1 T2
S3 S1
S4 S0
Cover removed for illustration purposes
Figure 10-2 AMC circuit board
LED Color Function
F red Fault, not used (ON when booting)
R green Run, always OFF
M green Not used (ON when booting)
P green Supply OK
T1 yellow ON = receiving data on DDCS channel 0
T2 yellow ON = receiving data on DDCS channel 3
S3 yellow Always OFF
原図 3N4-S4293202 137
10.6.2 IOEC I/O modules
LEDs
1 2 3 4 5
Figure 10-3 IOEC circuit board
LED Meaning
1 in Figure 10-3 Status LEDs of digital On if energized

inputs
2 in Figure 10-3 Link error light LED is either on or off. It is on only

when there is a problem with the
optical fibers.
4 in Figure 10-3 Status LEDs of digital On if energized

outputs
5 in Figure 10-3 Status LED of the 24 V On if energized

internal voltage supply
Cluster address Each IOEC module has a unique cluster address that identifies the module
in the software and links it to a parameter.
The address is set with the rotary switch on the module (see 3 in Figure
10-3). The factory set value must not be changed.
See Appendix D - Wiring diagrams for information on IOEC switch

settings.
原図 3N4-S4293202 138
10.6.3 Serial communication interfaces
See Appendix D - Wiring diagrams or the Parts list to identify the serial
communication interface in your drive and select the appropriate manual
from the list below for further information:
• AF 100 fieldbus - NAFA-01 installation and start-up guide
• DeviceNet - NDNA-02 installation and start-up guide
• Ethernet - user’s manual ethernet adapter module NETA-01
• Modbus - NMBA-01 installation and start-up guide
• Profibus - NPBA-12 installation and start-up guide
• CI858 DriveBus - user’s manual
10.7 Maintenance
10.7.1 Overview on maintenance and service tasks

The maintenance and service tasks as well as the de-energizing
procedure are described in the following chapters:
10.7.4 Visual checks on the drive
10.7.5 Cleaning
10.7.6 Checking wire and cable connections
10.7.7 Checking and replacing the filter mats
10.7.8 Inspecting and replacing the battery
10.7.9 Replacing a fan unit
原図 3N4-S4293202 139
10.7.2 Safety
DANGER
Hazardous voltages!
Before starting to work on the drive, make sure that:
• the main and auxiliary power supply to the drive is switched off,
locked out, and tagged out,
• the drive is dead,
• safety ground connections are in place,
• personal protective equipment is provided and used when required,
Before energizing the drive again, make sure that:
• all foreign objects are removed from the drive,
• all internal and external covers are securely fastened and all doors
are closed, locked and/or bolted.
DANGER
Hazardous voltages!
If a phase module has to be removed from the drive, the connection of
grounding equipment at the appropriate locations is a must. The
grounding equipment ensures that hazardous voltages cannot be fed into
the drive neither from the main power supply nor the motor.
NOTICE
discontinued.
原図 3N4-S4293202 140
10.7.3 De-energizing the drive
The following section describes how to de-energize the drive using the
local operator panel of the drive. If the drive is controlled from remote,
follow the established shutdown procedures.
Procedure 1 Set the CDP control panel to LOCAL mode.
See Chapter 9 - CDP control panel if further information is required.

2 Stop the motor.
When the motor has reached zero speed, the display shows Rdy to
Strt:
1 L -> 600.0 rpm 0

Status Rdy to Strt
MotorSpeed 0.00 rpm
Power 0.0 %
3 Press the Main Circuit Offline pushbutton to disconnect the drive

from the main power supply. The following takes place:
• The MCB opens.
• The DC link discharges.
While the DC link discharges, the display shows Discharging:
1 L -> 600.0 rpm 0 Discharging

Status Discharging CoolOFFDelay
MotorSpeed 0.00 rpm RdyForMCBon
Power 0.0 %
• The SUPPLY OFF pushbutton flashes and changes to a perma-

nent light when the DC link has discharged completely.
原図 3N4-S4293202 141
When the DC link has discharged, the display shows RdyforMCBOn:
1 L -> 0.0 rpm

Status RdyForMCBon
MotorSpeed 0.00 rpm
Power 0.0 %
4 Lockout, ground and tagout the main power feeder.

5 Turn the grounding switch to the grounded position when the lamp
GROUNDING SWITCH UNLOCKED is on.
The lamp is only turned on after the fan has stopped. The fan contin-
uous running for a preset time after the main power supply has been
switched off to dissipate the heat from the resistor assembly in the
back of the cabinet.
If the lamp does not light up and there is reason to believe that the
grounding circuit is malfunctioning, Discharging Fault is displayed.
10.7.4 Visual checks on the drive

Check the drive and its immediate vicinity visually at the intervals stated in
the maintenance schedule and pay attention to the following items:
• Humidity inside the drive
• Permitted range of ambient air temperature and humidity of the drive
See Rating label of the drive for information on the permitted air
temperature range.
• Dust built-up inside the drive room and inside the drive
• Signs for overheated components, wires, cables or busbars
• Corrosion on circuit boards, connectors or busbars
• Appropriate fastening of cables and wires and connections of cable
screens
See Chapter 6 - Electrical installation if further information is required.
• Integrity of cable insulation
The outer cable sheath must not be damaged.
• Correct type of signal and power cables
See applicable cable specifications for reference.
原図 3N4-S4293202 142
10.7.5 Cleaning
Dust on electrical components and wiring can cause malfunction and
damage the components. Dust and moisture can build up in loose
connections and cause loss of low-level signals.
For these reasons, the cabinet should be checked regularly and cleaned
if necessary.
When cleaning the drive cabinet, mind the following:
• Cover equipment or assemblies to prevent dirt falling into them.
• The drive contains components which are sensitive to electrostatic
discharge. Therefore, take electrostatic-sensitive precautions and
use suitable tools when cleaning circuit boards and assemblies that
are sensitive to electrostatic discharge.
Circuit boards should be cleaned with special care using antistatic
brushes and a vacuum cleaner with a soft nozzle to prevent compo-
nent damage.
• Dust inside the cabinet (assemblies, busbars etc.) can be removed
with a vacuum cleaner and lint-free cleaning cloths.
• Water, oily or greasy deposits on assemblies, components, busbars
etc. should be removed with water- and oil-absorbing microfibers
such as "3M Scotch Brite".
• Use a nylon brush or a vacuum cleaner to remove dust or deposits
from holes.
• The outside of the drive enclosure can be cleaned using a vacuum
cleaner and cleaning cloths.
Do not use alcohol or solvents.
10.7.6 Checking wire and cable connections

Vibration can loosen electrical connections and cause occasional
malfunction or equipment failure.
Check all power and control cable connections and tighten them if
necessary. Check that all plugs and connectors are tight.
Note: Capacitor bushings will be damaged when excessive force is
applied. Do not exceed the maximum tightening torque when tightening
the capacitor terminals. The tightening torque value is printed on a label
which is attached to the capacitor. If not otherwise specified, the maximum
torque must not exceed 20 Nm.
Tighten bolted busbar and cable connections with the nominal torque
recommended by the cable manufacturer (typical value for M12: 40 Nm)
原図 3N4-S4293202 143
10.7.7 Checking and replacing the filter mats
Location The drive is equipped with an open air cooling. The filter mats are located
behind the air intake grilles of the inverter compartment door (1 in Figure
10-4) and in the lower area of the rectifier and filter compartment (2 in
Figure 10-4).
Figure 10-4 Location of filter mat
Note: Filter mats can be checked, cleaned and replace while the drive is
in operation.
DANGER
High voltage can cause injury or death.
When removing the filter mats of the air intakes, especially while the drive
is in operation, be careful that no items (such as wires, screw drivers etc.)
can enter the hole grate by accident (see Figure 10-7).
These items can cause short circuits which can result in injury, death and
severe damage of the drive.
Checking Check the filter mats regularly. The intervals at which the mats are
checked depend on the cleanliness of the cooling air.
Cleaning The filter mats can be cleaned using compressed air or a vacuum cleaner.
Cleaning should always be carried out away from the drive so that dust
cannot enter the cabinet.
Replacement When removing a filter mat, proceed as quickly as possible and do not
discontinue work for a longer period to prevent foreign matter entering the
drive.
If the filter mats are replaced, filter material for the minimum particle size
as specified in the type code of the drive must be used. Position 29 of the
原図 3N4-S4293202 144
type code (see highlighted positions in Table 10-1) specifies the required
minimum particle size the mat must be able to filter.
Table 10-1 Filter material specification with type code
Filter material for

Type code example
particle sizes
ACS1x4x-Ax-xx-xx-xxxx-xxxx-xxxx-xxxC-xxxxx-xx ≥ 18 μm
ACS1x4x-Ax-xx-xx-xxxx-xxxx-xxxx-xxxD-xxxxx-xx or ≥ 12 μm
ACS1x4x-Ax-xx-xx-xxxx-xxxx-xxxx-xxxE-xxxxx-xx or
ACS1x4x-Ax-xx-xx-xxxx-xxxx-xxxx-xxxF-xxxxx-xx or
ACS1x4x-Ax-xx-xx-xxxx-xxxx-xxxx-xxxG-xxxxx-xx
ACS1x4x-Ax-xx-xx-xxxx-xxxx-xxxx-xxxH-xxxxx-xx or ≥ 10 μm
ACS1x4x-Ax-xx-xx-xxxx-xxxx-xxxx-xxxJ-xxxxx-xx or
ACS1x4x-Ax-xx-xx-xxxx-xxxx-xxxx-xxxK-xxxxx-xx or
ACS1x4x-Ax-xx-xx-xxxx-xxxx-xxxx-xxxL-xxxxx-xx
Filter mat dimensions • Dimension of inverter door mat: 1774 x 800 mm (H x B)

(1 in Figure 10-4)
• Dimension of rectifier and filter compartment mat: 320 x 2235 mm
(H x B) (2 in Figure 10-4)
Replacement proce- Proceed as follows:

dure
1 Loosen the Phillips head screws from the panel to be worked on to
remove the grille of an air intake.
2 When removing a filter mat, roll down the filter mat beginning at the
top.
Filter mats are secured to the panel with steel hooks. The mats can
be lifted up and off from the hooks.
The rear side of the filter panel has a fixed touch guard to prevent
access to parts inside the drive and to support the filter mat.
3 Clean or replace the filter mat.
4 Reassemble the filter mat and grille in reverse order.
原図 3N4-S4293202 145
Figure 10-5 Removing the grille of the inverter compartment
Figure 10-6 Grille of inverter compartment removed.
Figure 10-7 Hole grate behind filter mat (seen from rear side)
10.7.8 Inspecting and replacing the battery

The battery (marked -G5053) is located at the bottom of the swing frame
in the control compartment (see A in Figure 10-8).
Checking the battery The end of the battery life is indicated in two ways:
• The CDP control panel displays an alarm message.
• The alarm LED on the power supply unit for the battery lights up (see
B in Figure 10-8).
原図 3N4-S4293202 146
Figure 10-8 Battery (A) and UPS (B)
Replacement proce- Note: Batteries can be changed while the drive is in operation.
dure
WARNING
Hazardous voltage.
When the drive is in operation, voltages are present in the control
compartment.
Do not touch any live circuitry!
1 When changing the batteries during operation, disable the battery

monitoring function. Set parameter 31.05 DISABLE BATTERY TEST
to ON.
Note: Parameter 31.05 will automatically be set to OFF after 1 hour.
2 Disconnect the wires from the UPS (-G5054, see 2 in Figure 10-8).
3 Unscrew batteries (two front bolts and two rear bolts, right side bolts
(1) are shown in Figure 10-8), and withdraw the battery unit.
4 Place and fasten the new batteries and re-plug the cables.
5 Lock the door and record the date of replacement in the logbook.
原図 3N4-S4293202 147
10.7.9 Replacing a fan unit

The replacement of a fan takes about 1 hour.
Note: The supply voltage for the fan must be disconnected and secured.
The protection relays -Q5021, -Q5022 (in case of redundant fans -Q5021,
-Q5022, -Q5023, -Q5024) must be opened.
Replace a fan after 40 000 hours (about 4½ years) time of use.
Note: In case redundant fans are installed:
Replace the main fan after 70 000 hours (about 8 years) time of use (of
the drive) and the redundant fan after 100 000 hours (about 12 years) time
of use (of the drive).
Replacement proce- 1 Disconnect all power supplies to the drive and ground the drive.
dure
See 10.7.3 De-energizing the drive if further information is required.
Switch off the motor starter of the fan unit to isolate the fan unit from
the auxiliary power supply.
2 Unplug the supply cable of the fan inside of the drive.
3 Remove the fan cover by loosening and removing the 12 bolts (Figure
10-9).
Figure 10-9 Fan unit
4 Loosen and remove the five screws located to the left and right side
of the fan insert (1 in Figure 10-10).
原図 3N4-S4293202 148
1 1
1
2
1 1
Figure 10-10Fan insert with fixing screws
WARNING
The total weight of the fan is approximately 50 kg. It could fall down.
Take appropriate measures when transporting the fan.
5 Withdraw the fan insert by lifting it carefully out of the case.

6 Remove the 8 screws in the center (2 in Figure 10-10) and withdraw
the cover plate.
7 Mount the cover plate to the replacement fan.
8 Reassemble the fan unit in reverse order. Be sure that the blower
wheel and the cone are properly aligned.
9 Manually check that the cooling fans rotate smoothly (bearings) and
visually check the general condition of the cooling fans.
10 Reconnect the supply cable of the fan.
11 Check that the fan works properly when re-energizing the system.
Later, during the drive test run, the cooling fan operation must be
observed once again audibly (healthy sound, no large vibration
expected).
原図 3N4-S4293202 149
ABB
Maintenance schedule
The maintenance schedule applies to all air-cooled and water-cooled medium voltage drives. Note
the maintenance items in the schedule which only apply to particular drives.
The recommended intervals for maintenance and component replacement are based on the normal
operational conditions of the drive. The drive should be checked at least every two years by qualified
personnel whose recommendations should be followed. Depending on the actual condition of the
drive, the maintenance work can be carried out before or after the recommended interval.
Years from start-up

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Air cooling
- Air filters 1 I R R R R R R R R R R R R R R R R R R R
- Cooling fan (continuous operation) 2, A I I P I R I P I R I P I R I P I R I P I
- Cooling fan (redundant) 2, B I I P I P I P I R I P I P I P I R I P I
Water cooling C
- Deionizer, microfilter and strainer 3 I I R I R I R I R I R I R I R I R I R I
- Cooling pump gasket - - - - R - - - R - - - R - - - R - - -
- Cooling pump (continuous operation) 2 I I P I R I P I R I P I R I P I R I P I
- Cooling pump (redundant) 2 I I P I P I P I R I P I P I P I R I P I
- Hoses I I I I I I I I R I I I I I I I R I I I
- Plastic tubes and connectors I I I I I I I I I I I I I I I I I I I I
Aging
- Capacitors 4 I I I I I I I I P I P I P I P I P I P I
- Printed circuit boards, power supplies - - - - - - - - - - R - - - - - - - - -
- Batteries D I I R I R I R I R I R I R I R I R I R I
Connections and operational conditions
- Optical fibers 5 - - - - - - P - P - P - P - P - P - P -
- Cable connections I I I I I I I I I I I I I I I I I I I I
- Dustiness, corrosion, temperature I I I I I I I I I I I I I I I I I I I I
Improvements and spare parts
- Software, hardware upgrades 6 I - I - I - I - I - P - I - I - I - I -
- Spare parts I - I - P - I - P - I - P - I - P - I -
Measurements and tests
- Measurements with auxiliary voltage I I P I P I P I P I P I P I P I P I P I
- Insulation - - - - P - - - P - - - P - - - P - - -
- Safety circuits P P P P P P P P P P P P P P P P P P P P
R Replacement of the component

I Inspection (visual inspection; corrective measures, repair and/or replacement of component if needed)
P Performance of on-site work (commissioning, tests, measurements, etc.)
- No action
A Applies to ACS 1000i, ACS 1000A, ACS 1000W, ACS 2000, ACS 5000A, ACS 5000W, ACS 6000, MEGADRIVE-LCI
B Applies to ACS 1000i, ACS 1000A, ACS 1000W, ACS 2000, ACS 5000A, ACS 5000W
C Applies to all water-cooled drives
D Applies only to ACS 1000i, ACS 1000A, ACS 1000W
1 Air filters can be replaced or cleaned. The decision to replace or clean a filter depends on the condition of the filter.
User’s manual 3BHS351169 ZAB E01 Rev. - 1 (2)
原図 3N4-S4293202 150
Maintenance schedule ABB
2 The device can be serviced or be replaced by authorized service personnel. It is recommended to replace the device
after four years of operation.
3 The average lifetime of the deionizer is 2-4 years, depending mainly on the water quality. At the same time the
deionizer is changed, the micro filter should also be replaced and the strainer should be cleaned.
4 The expected lifetime of the capacitors depends mainly on the ambient conditions. The recommended intervals are
based on operation with rated current and maximum permitted temperature. A capacitor should be replaced when
regularly taken measurements show significant deviation from the rated capacitance.
5 The expected lifetime of the optical fibers depends mainly on the ambient conditions. The recommended intervals are
based on operation with rated current and maximum permitted temperature. An optical fiber should be replaced when
regularly taken measurements show significant deterioration of the fiber.
6 Improvements based on further development, software modifications, etc. When printed circuit boards must be
replaced, an upgrade of the control system should be considered as well.
2 (2) 3BHS351169 ZAB E01 Rev. - User’s manual
原図 3N4-S4293202 151
原図 3N4-S4293202 152
Contact us
Last page
© Copyright 2009 ABB. All rights reserved. Specifications subject to change without notice. 3BHS206977 ZAB E01 Rev. A.
ABB Switzerland Ltd
CH-5300 Turgi
Phone: +41 58 589 27 95
Fax: +41 58 589 29 84
E-Mail: mvdrives@ch.abb.com
www.abb.com/drives
原図 3N4-S4293202 153

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User’s manual

Medium voltage AC drive

Terms, abbreviations, trademarks

General information on manual and equipment

Chapter 1 - Safety 1-1

1.1 Meaning of safety instructions 1-1

ACS 1000i User’s manual 3BHS206977 ZAB E01 Rev. A 1 (6)

2.1 Overview 2-1

Chapter 3 - Control system 3-1

3.1 Control compartment 3-1

2 (6) 3BHS206977 ZAB E01 Rev. A ACS 1000i User’s manual

Chapter 4 - Transportation, storage and disposal 4-1

4.1 Safety 4-1

Chapter 5 - Mechanical installation 5-1

5.1 Safety 5-1

Chapter 6 - Electrical installation 6-1

6.1 Safety 6-1

ACS 1000i User’s manual 3BHS206977 ZAB E01 Rev. A 3 (6)

Chapter 7 - Commissioning 7-1

7.1 Required qualification 7-1

Commissioning check list

Chapter 8 - Operation 8-1

8.1 Overview 8-1

4 (6) 3BHS206977 ZAB E01 Rev. A ACS 1000i User’s manual

8.5.4 Starting the drive system locally 8-8

Chapter 9 - CDP control panel 9-1

9.1 Overview 9-1

Chapter 10 - Troubleshooting and maintenance 10-1

10.1 General information 10-1

ACS 1000i User’s manual 3BHS206977 ZAB E01 Rev. A 5 (6)

Appendix A - Additional manuals

Appendix B - Technical data

Appendix C - Mechanical drawings

Appendix D - Wiring diagrams

Appendix E - Parts list

Appendix F - Test reports and certificates

Appendix G - Signal and parameter table

6 (6) 3BHS206977 ZAB E01 Rev. A ACS 1000i User’s manual

ACS 1000i User’s manual 3BHS206977 ZAB E01 Rev. A 1 (2)

2 (2) 3BHS206977 ZAB E01 Rev. A ACS 1000i User’s manual

ACS 1000i User’s manual 3BHS206977 ZAB E01 Rev. A 1 (2)

2 (2) 3BHS206977 ZAB E01 Rev. A ACS 1000i User’s manual

Terms, abbreviations, trademarks

Terms and abbreviations

Terms and Abbreviations Meaning

AMC circuit board Application and Motor Controller

DDCS Distributed drive control system

Drive Short form for ACS1000 frequency converter

DriveBus Communication link dedicated for ABB drives

DriveWindow DriveWindow is a DriveWare® product. DriveWindow is a 32 bit Windows® application

Equipment Frequency converter and related equipment

EMC Electromagnetic compatibility

ACS 1000i User’s manual 3BHS206977 ZAB E01 Rev. A 1 (4)

Terms and Abbreviations Meaning

MCB Main circuit breaker

PCB Printed circuit board

PPCS Power plate communication system

RTD Resistance temperature detector or device

Safeline ABB synonym for uninterruptable power supply