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ACS 1000

Medium Voltage AC Drives


for speed and torque control of
315 to 5000 kW / 400 to 6700 hp
squirrel cage induction motors

Technical Catalog

3BHS125029, Rev. B

Effective: May 24, 2002

 ABB Schweiz AG. All Rights Reserved.


We reserve all rights to this document, also in the event of patent issue or
registration of any other industrial property protection right. Misuse and in
particular duplication and forwarding to third parties are not permitted.
This document has been checked with care. However, should the user find
any errors, they should please be reported to ABB Schweiz AG.
The data stated in this manual is for product description purposes and
does not represent assured characteristics. As we aim to keep our prod-
ucts up to the most modern standard, differences may occur between
entries in this technical catalog and the actual product.

ACS 1000 Technical Catalog


Table of Contents

Chapter 1 - Overview 5

1.1 Introduction 5
1.2 The Standard Solution 5
1.3 Key Technology 5
1.4 Technical Benefits 6
1.5 ACS 1000 Types 7

Chapter 2 - Main Features 9

2.1 IGCT Power Semiconductors 9


2.2 Fuseless Design 9
2.3 Direct Torque Control 10
2.4 Input Stage 11
2.5 Output Stage 11
2.6 Elementary Diagram 12

Chapter 3 - Hardware Description 15

3.1 Electromagnetic Compatibility 15


3.2 ACS 1000 Cabinet Layout 15
3.2.1 Air-Cooled Type 15
3.2.2 Water-Cooled Type 17
3.2.3 Power Terminals 18
3.3 Control Equipment 19
3.4 Door Locks 20
3.5 IP Ratings 21
3.6 Lifting Arrangements 21
3.7 Standard Color 21
3.8 Additional Cabinets 21

Chapter 4 - User Interfaces 23

4.1 Overview 23
4.2 CDP 312 Control Panel 23
4.3 Standard I/Os 24
4.4 Fieldbus Adapter Modules 29
4.5 PC Tools 29

ACS 1000 Technical Catalog 1 / 104


Chapter 5 - Parameters and Application Macros 31

5.1 Overview 31
5.2 Suitable Applications for Different Macros 31
5.3 Macro I/O interfaces 33

Chapter 6 - Standard Functions 37

6.1 General 37
6.2 Standard Control Functions 37
6.2.1 General Functions 37
6.2.2 Main Circuit Breaker Control 40
6.2.3 Local and Remote Control 40
6.2.4 Diagnostics 41
6.2.5 Programmable Digital and Analog Outputs 41
6.2.6 Scalable Analog Inputs 42
6.2.7 Input Signal Source Selections and
Signal Processing 42
6.3 Standard Protection Functions 43
6.3.1 Programmable Fault Functions 43
6.3.2 Pre-programmed Protection Functions 45
6.3.3 Other Protection Functions 47
6.4 Other Functions 47
6.4.1 Customer Specific Options 48

Chapter 7 - Options 49

7.1 Environmental Conditions 49


7.2 Converter Enclosure 49
7.3 Input Section 50
7.4 Motor Side 52
7.5 Converter Cooling 54
7.6 Converter Isolators and Bypass 57
7.7 Auxiliary & Control Interfaces 59
7.8 PC Tools 59

Chapter 8 - Selecting the Drive System 61

8.1 Overview 61
8.2 Main Circuit Breaker 61
8.2.1 Main Circuit Breaker Control 61
8.2.2 Tripping Loop 62
8.2.3 Main Circuit Breaker Features 63
8.3 Converter Input Transformer Selection 66

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8.4 Selection of the ACS 1000 Converter 67
8.4.1 ACS 1000 Output Filter 67
8.4.2 Non Quadratic Load Applications 67
8.4.3 ACS 1000 Selection Tables 68
8.5 Motor Selection 71
8.5.1 Load Capacity Curves 71
8.5.2 Selection Criteria 72
8.5.3 Retrofit 72
8.5.4 Torsional Excitation 73

Appendix A - Installation Guidelines 75

Ambient Conditions 75
Mounting 75
Power Equipment Installation 78
General 78
Transformer Primary Cables 79
Transformer Secondary Cables 79
Motor Cables 80
Power Cable Dimensions 80
Equipment Grounding 80
Auxiliary Power Cables 80
Control Cables 81
Cable Routing 81
ACS 1000 Cable Entry and Termination 82
Transformer Connection Diagram for
12-Pulse ACS 1000 83
Transformer Connection Diagram for
24-Pulse ACS 1000 84
Motor Connection Diagram for
12 / 24-Pulse ACS 1000 84

Appendix B - Technical Data 85

Transformer Connection / Converter Input 85


Converter Output / Motor Connection 86
Auxiliary Supply 86
Environmental Aspects 87
Derating of Drive Power 88
Air-Cooled Converters 88
Water-Cooled Converters 89
Transportation and Storage 89

ACS 1000 Technical Catalog 3 / 104


Cooling 90
Air-Cooled Converters 90
Water-Cooled Converters 90
Protection Functions 91
Analog Inputs 92
Analog Outputs 92
Digital Inputs 93
Digital Outputs 93
Auxiliary Power Output 93
Reference Voltage Output 94
DDCS Fiber Optical Link 94
Enclosures 94

Appendix C - Dimensions and Weights 95

Appendix D - Applicable Codes and Standards 99

CE Marking 99
Low Voltage Directive 99
Machinery Directive 99
EMC Directive 100
Emissions 100
Immunity 100
UL Marking 101
Applicable Codes and Standards 101

Appendix E - ACS 1000 Type Code 103

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Chapter 1 - Overview

1.1 Introduction

This Technical Catalog describes the main electrical, mechanical and


environmental features of the ACS 1000 – ABB’s contribution to new solu-
tions of medium-voltage AC drives. In addition, the Catalog looks at the
various options available for the drive and offers advice on selecting a
motor and drive combination. It also provides useful installation tips.

1.2 The Standard Solution

The ACS 1000 is a standard, medium-voltage AC drive, rated from 315 to


5000 kW (400 to 6700 hp) for motor voltages of 2.3, 3.3 and 4.0 kV.
The drive has been designed as a standard product rather than an engi-
neered drive. It is, therefore, a core product of ABB, forming part of the
company’s ACS family. As such, the drive uses standard components,
software tools and design principles as employed in the low voltage ACS
range. This vastly increases the reliability of the drive and offers users a
consistent addition to the extensive ACS product range.
As a standard solution the ACS 1000 has many of the benefits associated
with engineered drives already included. This meets the most common
system specifications with minimal engineering. In addition, because the
drive is pre-engineered, shorter delivery times to end-users are possible.
About 85% of all medium-voltage drives are applied in standard applica-
tions such as fans, pumps, conveyors and compressors, where the
customized engineering content is minimal. The ACS 1000 is ideally suit-
able for retrofit applications, where only a small portion of the world’s
motors are fitted with drives.
Industries, which can benefit from this approach, include oil and gas,
mining, water, pulp & paper, cement and power generation.

1.3 Key Technology

Two main technology features distinguish the ACS 1000 from other types
on the market:
• The motor control platform is based on Direct Torque Control (DTC)
which achieves the ultimate torque and speed performance.
DTC allows the speed of any standard squirrel cage induction motor
to be controlled without the need for expensive and fragile encoders
or tachogenerator feedback devices.

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Chapter 1 - Overview

• For the first time in any AC drive, a new power semiconductor switch-
ing device is utilized. Known as IGCT (Integrated Gate Commutated
Thyristor), the device provides an intrinsically less complex, more ef-
ficient and reliable drive. This is achieved by fast switching and inher-
ently low losses which mean less cooling equipment is needed.
IGCTs do not require snubber circuits and allow power bridge imple-
mentation with fewer power devices than conventional medium-
voltage drives. While reliability is improved, the physical size of the
ACS 1000 is compact.

1.4 Technical Benefits

The technology described above brings many more practical benefits to


the ACS 1000, as described within this Catalog.
For instance, the use of IGCTs together with active feedback control by
means of an LC filter results in a sinusoidal output voltage. This proves
useful in retrofit applications, as the drive is compatible with existing
squirrel cage motors without the need to derate it. There are no undue
voltage rises stressing the motor insulation and voltage reflections are
eliminated on long cable runs.
Furthermore, DTC avoids any torque pulsations, which can be damaging
to loads and their associated mechanical connections.
The ACS 1000 is available for use with a separately mounted input isola-
tion transformer (standard) or alternatively with an integrated dry-type
transformer. This provides installation flexibility and allows for the use of
oil filled transformers which are typically mounted outdoors.
The ACS 1000 meets all common standards including IEC and EN. In
order to meet the requirements of the North American market, the
ACS 1000 is also UL and Canadian UL listed. In addition, ABB has under-
taken much development work to ensure that the converter adequately
meets the requirements of the world’s harmonics standards, such as
IEEE 519-1992.
For details please refer to Appendix D - Applicable Codes and Standards.
The ACS 1000 features a selection of pre-programmed and standardized
application macros for the configuration of inputs, outputs, signal
processing and other parameters.

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Chapter 1 - Overview

1.5 ACS 1000 Types

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

Motor Rated Motor Max. cont.


Voltage Type of Power Range** Power of
Frame Size
Cooling ACS 1000
(kV) HP (kVA)

2.3 Air 400 - 1500 400 - 1350 A1 - A2

3.3 Air 400 - 2250 400 - 2150 A1 - A3

3.3 Water 2500 - 6700 2400 - 5950 W1 - W3

4.0 Air 400 - 2250 400 - 2000 A1 - A3

4.0 Water 2500 - 6700 2300 - 5800 W1 - W3

** The power ratings apply to typical 4 pole motors. For those motors the
frequency converter has a built-in overloadability of 10%. When selecting
the frequency converter it should be observed that the rated current of the
ACS 1000 must be higher than or equal to the rated motor current in order
to achieve the rated motor power given in the table.
Note: For air-cooled units (with enclosure class IP21) the load capacity
(current and power) depends on the altitude and the ambient temperature
at the installation site. In case of water-cooled units the load capacity
depends on the cooling water temperature at the installation site. For
details on the derating factors, see Appendix B - Technical Data.

ACS 1000 Technical Catalog 7 / 104


Chapter 1 - Overview

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Chapter 2 - Main Features

2.1 IGCT Power Semiconductors

ABB researched and designed the Integrated Gate Commutated Thyristor


(IGCT) specifically for the medium voltage market. IGCTs provide high
speed switching like IGBTs (Insulated Gate Bipolar Transistors) and at the
same time provide high voltage blocking and low loss conduction like
GTOs (Gate Turn-Off Thyristors). The result is a fast, low loss device that
can be used at medium voltage levels without resorting to series topolo-
gies. It transcends both of the older technologies from which it evolved.
IGCTs also provide other benefits:
• Freewheeling diode is integrated into the same package
• Snubber circuits are not required
• Gating circuitry is packaged with the power device
• High reliability (low total parts count)
• High power density (combination of low total parts count and low
power losses)
• Self-protecting against destructive failures.
All these features combined provide a medium voltage power switching
device with the best combination of performance, reliability, efficiency, and
space effectiveness available in the market today.

2.2 Fuseless Design

The ACS 1000 features a fuseless protected medium voltage drive.


The patented design uses the new power semiconductor switching
device, IGCT, for circuit protection.
The IGCT, which is placed between the DC link and the rectifier, can,
unlike conventional fuses, directly isolate the inverter of the drive system
from the power supply side. This is achieved within 25 microseconds,
which is 1000 times faster than the operational performance of fuses.
Using the IGCT as an integrated protection device leads to a lower parts
count within the drive system making the ACS 1000 a drive with
outstanding reliability.
The reason why IGCTs are capable of performing a protection function,
unlike other power semiconductor devices, lies in their low onstate losses
and their ability to turn off at high speed at medium voltage levels.

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Chapter 2 - Main Features

2.3 Direct Torque Control

Direct Torque Control (DTC) is a unique motor control method for AC


drives. The inverter switching is directly controlled according to the motor
core variables flux and torque.
The measured motor current and DC link voltage are inputs to an adaptive
motor model which produces exact actual values of torque and flux every
25 microseconds. Motor torque and flux comparators compare actual
values to the reference values produced by the torque and flux reference
controllers. Depending on the outputs from the hysteresis controllers, the
pulse selector directly determines the optimum inverter switch positions.
Mains

Rectifier
Speed controller
+ acceleration compensator
Internal torque Torque Control Switch position
reference status signals commands
Torque Torque DC bus
Torque
reference comparator Optimum
reference controller pulse
selector
Speed
Flux
comparator
=
PID
reference Flux ~
Inverter
status
Actual torque ASIC
Flux Actual flux Switch
reference positions
controller Adaptive
U
motor
U
f
model
f
T
Internal flux Output
f
reference filter
Actual speed

DC bus voltage
Inverter current (4 measurements)

Filter current
(3 measurements) M
3~

Figure 2-1 DTC Block Diagram

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Chapter 2 - Main Features

How does DTC differ In DTC, each switching instance is determined separately based on the
from PWM Flux Vector values of flux and torque, rather than switching in a predetermined pattern
Drives? as in conventional PWM flux vector drives.
Table 2-1 DTC versus PWM Flux Vector Controlled Drives

DTC Flux Vector

Switching based on core motor Switching based on separate control of


variables Flux and Torque magnetising and torque producing
components of current

Shaft speed and position not required Mechanical speed is essential. Requires
shaft speed and position
(either measured or estimated)

Each inverter switching is determined Inverter switching based on average


separately (every 25 µs). references to a PWM modulator. This
results in delays in response and wasted
switchings.

Torque Step Rise Time (open loop) is Torque Step Rise Time
less than 10 msec. Closed Loop 10 to 20 msec.
Sensorless 100 to 200 msec.

For more information on DTC, please refer to the Technical Guide


No. 1 Direct Torque Control (3AFY 58056685 R0025).

2.4 Input Stage

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

2.5 Output Stage

As a standard the ACS 1000 is equipped with a low pass LC sine filter in
its output stage. Current feedback is used to actively control filter opera-
tion. The low pass frequency is designed to be well below the lowest
switching frequency used by the inverter output stage. This greatly
enhances the purity of both the voltage and current waveforms applied to
the motor. This in turn provides many important benefits:
• Harmonic heating is virtually eliminated. The drive may be used to
supply standard medium voltage motors (existing or new) without ap-
plying thermal derating factors.

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Chapter 2 - Main Features

• Voltage reflection and the associated occurrence of voltage doubling


at the motor input terminals is no longer an issue (the causal high fre-
quency content does not exist). Therefore, any standard medium volt-
age winding insulation system (existing or new) is compatible with the
ACS 1000.
• The maximum length of the motor cables is not limited by the
ACS 1000 (normal voltage drop restrictions as found in any electrical
installation still apply).
• Motor bearing failures attributable to capacitively coupled high fre-
quency current are no longer a problem (the causal high frequency
common mode voltage is eliminated).
• Motor insulation is not subject to the common mode voltage typical for
other drive topologies.

2.6 Elementary Diagram

Figure 2-2 and Figure 2-3 show the elementary circuit diagram of the 12-
pulse and the 24-pulse versions of the ACS 1000.
The 3-phase AC line voltage is supplied to the rectifier bridges through the
3-winding converter transformer. In order to obtain 12 or 24-pulse rectifi-
cation, appropriate phase shift is necessary between the secondary wind-
ings of the transformer.
The two fuseless rectifier bridges in the 12-pulse scheme (Figure 2-2) are
connected in series, such that the DC voltages are added up. Therefore,
the full DC bus current flows through both bridges. In the 24-pulse
scheme, 2 such bridge arrangements are connected in parallel as shown
in Figure 2-3.

3 Converter
Transformer
NP
NP M
M
Main Circuit
Breaker

Medium Diode Protection Intermediate Three Level Output Squirrel Cage


Voltage Rectifier IGCTs DC Link Inverter Sine Filter Induction Motor
Switchgear

Figure 2-2 Elementary Diagram - ACS 1000, 12-Pulse Version

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Chapter 2 - Main Features

Converter
Transformer

Main Circuit
Breaker

Medium Diode Protection Intermediate Three Level Output Squirrel Cage


Voltage Rectifier IGCTs DC Link Inverter Sine Filter Induction Motor
Switchgear

Figure 2-3 Elementary Diagram - ACS 1000, 24-Pulse Version


Each leg of the 3-phase inverter bridge consists of a combination of 2
IGCTs for 3-level switching operation: with the IGCTs the output is
switched between positive DC voltage, neutral point (NP) and negative DC
voltage. Hence both the output voltage and the frequency can be
controlled continuously from zero to maximum, using Direct Torque
Control.
At the converter output a LC filter is used for reducing the harmonic
content of the output voltage. With this filter, the voltage waveform applied
to the motor is nearly sinusoidal (see Figure 2-4). Therefore, standard
motors can be used at their nominal ratings. The filter also eliminates all
high dv/dt effects and thus voltage reflections in the motor cables and
stresses to the motor insulation are totally eliminated.

Output voltage: 4.16kV


ACS 1000 Output frequency: 60Hz

Figure 2-4 Voltage and Current Waveforms at Converter Output

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Chapter 2 - Main Features

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Chapter 3 - Hardware Description

3.1 Electromagnetic Compatibility

The riveted and folded cabinet construction of the ACS 1000 ensures an
extremely strong yet flexible and self-supporting framework which avoids
the need for additional skeletal support. Compared with traditional bolted
frames the cabinet provides extremely effective protection against electro-
magnetic emissions.
The design fulfils the requirements of international standards like
UL 347A. For details please refer to Appendix D - Applicable Codes and
Standards.
Electromagnetic Compatibility (EMC) has been achieved by applying a
cabinet design consisting of folded, galvanized sheet metal plates and
minimizing the spacing between the rivets. The cabinet’s inside walls are
not painted, because paint tends to reduce the effectiveness of metallic
bonding which is paramount to successful EMC.
Accordingly, only the front of the ACS 1000 cabinet is painted while all
other walls are galvanized. However, the cabinet can be ordered
optionally with the whole of the outside painted.
EMC performance is further enhanced by the use of metal cable channels.

3.2 ACS 1000 Cabinet Layout

3.2.1 Air-Cooled Type


The air-cooled type of the ACS 1000 is designed with inverter stacks,
output filter and DC link capacitor in one section (see Figure 3-1). This
section experiences maximum air flow which is advantageous for the
temperature sensitive capacitors. The construction of the inverter stacks
allows easy exchange of IGCTs by means of a specially designed tool
which is part of the supply.
The middle section accommodates cooling fan, rectifier stack, protection
IGCTs and filter reactor. The construction is such that the fan can be
exchanged easily.
The air intake is provided with an air filter in order to prevent dust and
particles from entering into the converter. The air filter can be replaced
from outside while the drive system is in operation.

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Chapter 3 - Hardware Description

1 2 3 4

Figure 3-1 The ACS 1000 Air-Cooled Type (12 / 24-Pulse)


1 Control section with separate power cable connection section
2 Grounding switch and filter reactor section (24-pulse version with
additional rectifier stack)
3 Rectifier stack, protection IGCTs and cooling fan
4 Inverter stacks, air intake, output filter and DC link capacitors

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Chapter 3 - Hardware Description

3.2.2 Water-Cooled Type

12-Pulse Version The water-cooled type of the ACS 1000 (see Figure 3-2) is equipped with
a closed circuit water cooling system. Part of the cooling system is a fan
and an air-to-water heat exchanger to maintain cooling of all components
which cannot be cooled by water.
As with the air-cooled type, the construction of the inverter stacks allows
easy exchange of IGCTs by means of a specially designed tool which is
part of the supply.

1 2 3 4 5

Figure 3-2 The ACS 1000 Water-Cooled Type (12-Pulse)


1 Control section with separate power cable connection section
2 Filter and DC components section (grounding switch, filter reactor
and filter capacitors, DC link capacitors, common mode choke)
3 see item 2
4 Converter section (rectifier stack, protection IGCTs, inverter stacks)
5 Cooling unit

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Chapter 3 - Hardware Description

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

3.2.3 Power Terminals


The leftmost section (Figure 3-1 and Figure 3-2) contains the swing frame
with the control equipment (see Section Control Equipment, page 19).
Behind this swing frame and a protective separation door is the drive’s
power terminal section with busbars for mains and motor cables. To
provide optimum access to the power terminals, the swing frame can be
opened more than 120°.
Please refer to Appendix A - Installation Guidelines for further details on
cable entry and connection.

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Chapter 3 - Hardware Description

3.3 Control Equipment

The layout of the control cabinet is identical for all converter types.
The control hardware (processor and communication boards) are
mounted on the swing frame. Details can be seen in Figure 3-3.
The customer I/Os are located behind the swing frame on the right side
wall (see Figure 3-4). Terminals for customer control and protection
signals as well as for auxiliary power supply are also located there.

Swing frame

Electronic power
supply board (EPS)

AMC3 control board


Interface board

Pulse encoder
Fieldbus interface

IOEC1 board

∆p-transmitters
(air-cooled
converters only)

Motor starters and


circuit breakers

Aux. supply
transformer

Batteries

Figure 3-3 Control Section with Open Front Door

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Chapter 3 - Hardware Description

IOEC2 board
(standard)

Terminals for aux.


voltages, control sig-
nals and tripping loop

Access door to power


cable connection
section

IOEC3 board (stan-


dard for water-cooled
converters)

IOEC4 board
(optional)

Figure 3-4 Control Section with Swing Frame Removed

3.4 Door Locks

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

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Chapter 3 - Hardware Description

The doors of the control section and of the cooling section (water-cooled
type) are not linked to the interlocking system. They can be opened at any
time. The high voltage busbar section is located behind the control swing
frame and separated from the control section by a bolted protective shield.
The power section doors of all additional cabinets (e.g. additional rectifier
cabinet, braking chopper cabinet) are monitored by separate door
switches since they are not included in the electromechanical interlock
system. These door monitoring switches are wired to the drive’s tripping
loop. If any of the doors are opened during operation, the MCB will be
tripped immediately.

3.5 IP Ratings

The standard ACS 1000 cabinet is rated IP21 for air-cooled and IP 31 for
water-cooled types. Higher IP ratings are available as options. See
Chapter 7 - Options for further details.

3.6 Lifting Arrangements

The cabinets are fitted with lifting lugs as standard.

3.7 Standard Color

The standard color is RAL 7035 (light grey). Other colors are available on
request.

3.8 Additional Cabinets

The ACS 1000 cabinet system provides the flexibility to add further
sections to the converter at any time. Sections can be added in width of
600, 800 and 1000 mm (24, 32 and 39 inches).

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Chapter 3 - Hardware Description

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Chapter 4 - User Interfaces

4.1 Overview

The ACS 1000 can be controlled from several control locations:


• The detachable CDP 312 control panel mounted on the ACS 1000
front door of the control section
• External control devices, e.g. a supervisory control system,
connected to the analog and digital I/O terminals on the standard I/O
Boards (IOEC)
• Fieldbus adapter modules
• PC Tools (DriveWindow and DriveSupport) hooked up via a PC
adapter to the ACS 1000 control board.

4.2 CDP 312 Control Panel

The CDP 312 Control Panel is the basic user interface for monitoring,
adjusting parameters and controlling the ACS 1000 converter operation.
Enclosure class IP54 when attached to
the Control Panel Mounting Platform

Multilingual Alphanumeric Display


Control 1 L -> 1242rpm I (4 lines x 20 characters)
CURRENT 76.00 A
Panel SPEED 1242.0rpm Plain text messages available in
Display TORQUE 86.00 % several languages

ACT PAR FUNC DRIVE Control Panel Mode Selection keys

Double Up Arrow, Up Arrow


ENTER Enter
Control Double Down Arrow, Down Arrow
Panel
Keypad LOC RESET REF Local/Remote, Reset, Reference and
REM Start keys

Forward, Reverse and Stop keys

Figure 4-1 CDP 312 Control Panel

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Chapter 4 - User Interfaces

Using the CDP 312 panel it is possible to


• enter start-up data into the drive
• set a reference signal and give Start, Stop and Direction commands
• display actual values (three values can be read simultaneously)
• display and adjust parameters
• display information on the most recent forty fault events.

4.3 Standard I/Os

The standard I/O-boards offer a number of pre-programmed analog and


digital I/Os which are sufficient for most applications. For a wider range of
signal interfaces optional I/O-boards can be ordered for water and air-
cooled ACS 1000 to provide extended protection for transformer and
motor, external cooling equipment (e.g. fans, chillers), on-line
synchronization logic and other customer requirements.
The air-cooled ACS 1000 is equipped with two I/O-boards (IOEC1 and
IOEC2) as a standard with the option of two additional I/O-boards (IOEC3
and IOEC4). The water-cooled ACS 1000 is equipped with three I/O-
boards (IOEC1, IOEC2, IOEC3) with the option of one aditional I/O-board
(IOEC4).
All I/O-boards are identical in design with the same number of I/Os. The
analog and digital I/Os are floating and galvanically isolated with ratings
as indicated in Table 4-1.
While the function of digital and analog inputs are fixed and cannot be
altered, the signals allocated to digital and analog outputs can be changed
by setting the corresponding parameters accordingly.

Table 4-1 I/O Board Configuration with Number and Type of I/O

Number Signal Type Ratings

4 Analog (AI) 0...20 mA / 4...20 mA or 0...10 V / 2...10 V


Inputs scalable by parameter setting

2 Analog (AO) 0...20 mA / 4...20 mA


Outputs scalable by parameter setting

14 Digital (DI) Opto-coupled, rated for 22...250 VAC or


Inputs 22...150 VDC

6 Digital (DO) With switch-over contact (SPDT),


Outputs rated for 250 VAC, 2 A

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Chapter 4 - User Interfaces

Standard I/Os are marked in the following tables with a dot ( ). The letter
(W) indicates that these I/Os are standard for the water-cooled ACS 1000.
A signal name beginning with a slash (/) indicates a signal which is true
when its status is low.
i

Table 4-2 I/O Signals: Remote Control Interface

Type Signal Name Remarks Standard

DI STANDARD INPUT 1 Macro specific I/O *

DI STANDARD INPUT 2 Macro specific I/O *

DI STANDARD INPUT 3 Macro specific I/O *

DI STANDARD INPUT 4 Macro specific I/O *

DI STANDARD INPUT 5 Macro specific I/O *

DI STANDARD INPUT 6 Macro specific I/O *

DI DISABLE LOCAL Remote input to disable the


possibility for a local/remote
switch-over from the CDP 312
control panel

DI REM ORD MCB CLOSE Remote request for closing


the main circuit breaker

DI REM ORD MCB OPEN Remote request for opening


the main circuit breaker

DI REMOTE RESET Remote fault reset (some


converter related faults
cannot be reset remotely)

DO DRIVE READY Status output “Drive Ready”


(i.e. MCB closed, DC link
charged, no lockout active)

DO DRIVE RUNNING Status output “Drive Running”

DO DRIVE ALARM Status output “Drive Alarm”

DO DRIVE TRIP Status output “Drive Tripped”

DO LOCAL MODE Local mode operation status


indication

AI REF VALUE 1 Macro specific I/O

ACS 1000 Technical Catalog 25 / 104


Chapter 4 - User Interfaces

Table 4-2 I/O Signals: Remote Control Interface (continued)

Type Signal Name Remarks Standard

AI REF VALUE 2 Macro specific I/O

AO SHAFT SPEED ACT VAL Actual speed monitoring


output

AO MOT CURRENT ACT VAL / Actual current / torque


MOT TORQUE ACT VAL monitoring output
(programmable)

* see Chapter 6 - Standard Functions

Table 4-3 I/O Signals: Main Circuit Breaker

Type Signal Name Remarks Standard

DI MCB IS CLOSED Status feedback from the


main circuit breaker

DI MCB IS OPEN Status feedback from the


main circuit breaker

DI MCB IS AVAILABLE Status feedback from the


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

DO MCB ORD CLOSE Drive command to close the


main circuit breaker (pulse
signal or maintained)

DO /MCB ORD OPEN Drive command to open the


main circuit breaker (pulse
signal or maintained)

DO /MCB ORD TRIP Hardware tripping loop to the


main circuit breaker (signal
active when low)

Table 4-4 I/O Signals: Transformer

Type Signal Name Remarks Standard

DI /EXT TRAFO PROT TRIP Initiates a main circuit breaker


trip (included in hardwired
tripping loop)

DI OIL LEVEL ALARM Transformer oil level alarm W


indication

26 / 104 ACS 1000 Technical Catalog


Chapter 4 - User Interfaces

Table 4-4 I/O Signals: Transformer (continued)

Type Signal Name Remarks Standard

DI OIL TEMP ALARM, or Transformer oil temperature W


alarm indication

TRAFO WDG TEMP ALARM Transformer winding


temperature alarm indication

DI /OIL TEMP TRIP, or Transformer oil temperature W


trip indication
/TRAFO WDG TEMP TRIP Transformer winding
temperature trip indication

DI BUCHHOLZ ALARM Transformer alarm indication W


from Buchholz relay

DI /BUCHHOLZ TRIP Transformer trip indication W


from Buchholz relay

AI OIL TEMP, or Temperature measurement of W


transformer oil
TRAFO WDG TEMP Temperature measurement of
transformer winding

Table 4-5 I/O Signals: Motor

Type Signal Name Remarks Standard

DI /EXT MOT PROT TRIP Initiates a main circuit breaker


trip (included in hardwired
tripping loop)

DI EXT MOT PROT ALARM (External) motor protection W


alarm indication

DI MOT COOLING ALARM (External) motor cooling W


alarm indication

DI /MOT COOLING TRIP (External) motor cooling trip W


indication

DI VIBRATION SV ALARM Motor vibration alarm W


indication

DI /VIBRATION SV TRIP Motor vibration trip indication W

DI /OVERSPEED TRIP Motor overspeed trip W


(included in hardwired
tripping loop)

AI MOT WDG TEMP PH U Motor winding temperature

AI MOT WDG TEMP PH V Motor winding temperature

AI MOT WDG TEMP PH W Motor winding temperature

ACS 1000 Technical Catalog 27 / 104


Chapter 4 - User Interfaces

Table 4-5 I/O Signals: Motor (continued)

Type Signal Name Remarks Standard

AI BRG TEMP DE Motor bearing temperature of W


driven end

AI BRG TEMP NDE Motor bearing temperature of W


non-driven end

Table 4-6 I/O Signals: Process

Type Signal Name Remarks Standard

DI /PROCESS STOP Remote process stop input to


stop the drive (signal active
when low)

DI /INT/EXT EMERGENCY OFF Emergency OFF (signal


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

Table 4-7 I/O Signals: Others

Type Signal Name Remarks Standard

DI /SUPPL VOLT UNBALANCE Trip from external voltage


unbalance relay (signal active
when low)

DI EXT WTR COOLING ALARM Alarm indication from external


water cooling unit

DI /EXT WTR COOLING TRIP Trip (active when low) from


external water cooling unit

DI BRAKE CHOP FAN ALARM Alarm signal from braking


chopper

DI BRAKE CHOP TEMP TRIP Trip signal from braking


chopper

DI INPUT ISOLATOR OPEN Status input

DI INPUT ISOLATOR CLOSED Status input

DI OUTPUT ISOLATOR OPEN Status input

DI OUTPUT ISOLATOR Status input


CLOSED

AI OUTSIDE AIR TEMP Temperature measurement of


outside air

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Chapter 4 - User Interfaces

4.4 Fieldbus Adapter Modules

A fieldbus module may be used for controlling and monitoring the


ACS 1000 instead of using the conventional hard-wired I/Os. There are
several fieldbus adapter modules available for the ACS 1000.
For further details, see Chapter 7 - Options.

4.5 PC Tools

DriveWindow offers several functions for commissioning and monitoring


ABB products. All the functions are available from the Menubar or the
Toolbar of the program. In DriveWindow the user has the choice between
two special displays and six different tools.
For further details, see Chapter 7.8 PC Tools.

ACS 1000 Technical Catalog 29 / 104


Chapter 4 - User Interfaces

30 / 104 ACS 1000 Technical Catalog


Chapter 5 - Parameters and Application Macros

5.1 Overview

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

5.2 Suitable Applications for Different Macros

Factory The Factory Macro is the default-set macro. It covers most of the common
applications, such as:
• Pump, fan and other industrial processes with a square torque char-
acteristic
• Conveyors and other industrial drives requiring constant torque.

ACS 1000 Technical Catalog 31 / 104


Chapter 5 - Parameters and Application Macros

Speed Control The Speed Control Macro is essentially the same as the Factory Macro.
The only difference to the Factory Macro is that a loading of the Speed
Control Macro will not affect the currently set motor control parameters
(when loading the Factory Macro all parameters will be reset to their
default value).

Hand/Auto The Hand/Auto Macro is suitable for applications where the speed has to
be controlled automatically by a process control system and manually by
an external control panel. The active control location is selected via a
digital input.
The macro is also recommended when the drive has to be controlled from
two external control stations. The active control station for starting /stop-
ping and setting of the reference value is selected via a digital input.

PID Control The PID macro is intended for the use with closed loop control systems
such as pressure control, level control and flow control. For example:
• Booster pumps of municipal water supply systems
• Booster pumps of district heating systems
• Automatic level control of water reservoirs
• Speed control of different types of material handling systems where
the material flow has to be regulated.
The PID controller is incorporated into the ACS 1000 software. It is acti-
vated by selecting the PID macro.
A process reference value is set via an analog input or by using the control
panel of the ACS 1000. The actual process value is connected to a dedi-
cated analog input.
The internal PID controller of the ACS 1000 eliminates the need of a sepa-
rate PID controller (no additional installation and wiring required).
ACS 1000 Converter

Reference

Level
Trans-
ducer

Actual Value

Pump

Figure 5-1 Example of an Application with PID Control Loop

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Chapter 5 - Parameters and Application Macros

Torque Control The macro is intended for processes requiring torque control, e.g. mixers
and slave drives. The torque reference comes from a process automation
system or a control panel.

Sequential Control The Sequential Control Macro is aimed for processes where different
constant speed settings and/or different acceleration/deceleration ramps
are required in addition to an adjustable speed reference value. The
different settings can be selected automatically by a process control
system or they can be activated manually by selector switches which are
connected to the corresponding digital inputs.

Master/Follower The Master/Follower Macro is designed for applications with several


ACS 1000 where the motor shafts are coupled to each other by gearing,
chain, belt etc. Thanks to the Master/Follower macro the load can be
evenly distributed between the drives or depending on the process at
some other ratio.

User 1 / User 2 The User Macro 1 and 2 allows to save a complete set of customized
parameters and to recall it at a later instant or to download it to another
ACS 1000.

5.3 Macro I/O interfaces

The following tables give an overview of the pre-set digital and analog
inputs and outputs, regarding opening/closing the main circuit breaker,
starting/stopping the drive system, setting reference values and status
feedback signals. All other customer interface signals are the same for
each application macro, see Chapter 4 - User Interfaces.
All macro specific I/Os are available on the standard IOEC boards. Only
the PID macro requires IOEC 4 board.

Table 5-1 Macro Specific Digital and Analog Inputs

Macro I/Os I/O functions

Factory DI MCB open/close commands


Speed Start/ stop commands
Selection of direction
Selection of 2 accel/decel ramps
Selection of 2 const. speeds
Process stop or run enable

AI 2 speed reference values

ACS 1000 Technical Catalog 33 / 104


Chapter 5 - Parameters and Application Macros

Table 5-1 Macro Specific Digital and Analog Inputs (continued)

Macro I/Os I/O functions

Hand/Auto DI Selection of hand/auto mode


MCB open/close commands in hand mode
MCB open/close commnands in auto mode
Start/ stop commands in hand mode
Start/stop commands in auto mode
Selection of 1 const. speed
Process stop or run enable

AI Speed reference value in hand mode


Speed reference value in auto mode

PID DI MCB open/close commands


Start/stop commands
Selection of direction
Selection of reference value
Selection of 2 accel/decel ramps
Selection of 3 const. speeds
Process stop or run enable

AI Reference value
Actual value, process feedback
Actual value process feedback

Torque DI MCB open/close commands


Start/stop commands
Selection of speed/torque control
Selection of 2 accel/decel ramps
Selection of 1 constant speed
Process stop or run enable

AI Speed reference value


Torque reference value

Sequential DI MCB open/close commands


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

AI Reference value

Master Follower DI MCB open/close command


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

AI Speed reference value

User 1 / User 2 Depends on application

The pre-set digital and analog outputs available for external use are the
same for each macro.

34 / 104 ACS 1000 Technical Catalog


Chapter 5 - Parameters and Application Macros

Table 5-2 Macro Specific Digital and Analog Outputs

Macro I/Os I/O functions

Factory DO Drive ready


Speed Drive running
PID Drive alarm
Torque Drive trip
Sequential
Master/Follower AO Motor frequency
Motor torque
Motor speed
Motor torque filtered

ACS 1000 Technical Catalog 35 / 104


Chapter 5 - Parameters and Application Macros

36 / 104 ACS 1000 Technical Catalog


Chapter 6 - Standard Functions

6.1 General

The ACS 1000 is configured and customized by means of application


parameters. These parameters can be altered by the user, either by
means of the integrated CDP 312 control panel or by using a PC and the
DriveWindow software package, as described in Chapter 7 - Options.
Control and monitoring functions of the ACS 1000 can be activated by
setting parameters one by one or by invoking an Application Macro (see
Chapter 5 - Parameters and Application Macros) which is optimized for a
particular application. Therefore some of the functions described in this
chapter will be configured automatically if an application macro is
selected.
This chapter provides information about the standard control, monitoring
and protection functions for the ACS 1000. A description of the basic I/O
devices and the application macros of the ACS 1000 can be found in
Chapter 4 - User Interfaces and Chapter 5 - Parameters and Application
Macros.

6.2 Standard Control Functions

6.2.1 General Functions

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

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

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

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Chapter 6 - Standard Functions

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

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

Auxiliary Ride Through The auxiliary ride through function guarantees correct fault indication and
proper trip sequencing, in the event that the auxiliary power source
feeding the drive is lost. The function is activated by a parameter. During
ride through the power for the control circuits of the ACS 1000 is supplied
by internal batteries. The ride through time is limited to 1 sec.

Acceleration and ACS 1000 provides two user-selectable acceleration and deceleration
Deceleration Ramps ramps. It is possible to adjust the acceleration/deceleration times
(0...1800 s) and select the ramp shape. Switching between the two ramps
can be controlled via a digital input.
The available ramp shape alternatives are:
Linear: Suitable for drives requiring long acceleration/deceleration where
S-curve ramping is not required.
S1: Suit. for short acc./dec. times. Motor
speed
S2: Suit. for medium acc./dec. times
S1
S3: Suit. for long acc./dec. times. Linear

S-curve ramps are ideal for conveyors


carrying fragile loads, or other applica- S2
tions where a smooth transition is S3
required when changing from one
speed to another.
1 1.25 2 t (s)

Critical Speed There is a Critical Speed function available for applications where it is
necessary to avoid certain motor speeds or speed bands, for example due
to mechanical resonance problems. The ACS 1000 makes it possible to
set up five different speed settings or speed bands which will be avoided
during operation.

38 / 104 ACS 1000 Technical Catalog


Chapter 6 - Standard Functions

Each critical speed setting allows the Motor


speed
user to define a low and a high speed (rpm)
limit. If the speed reference signal 1560
requires the ACS 1000 to operate
1380
within this speed range the Critical
Speeds function will keep the
ACS 1000 operating at the low (or 690
high) limit until the reference is out of 540
the critical speed range. The motor is Speed
reference
accelerated/decelerated through the (rpm)
critical speed band according to the s 1 Low s1 High s2 Low s2 High
acceleration or deceleration ramp. 540 690 1380 1560

Constant Speeds Up to 15 constant speeds can be programmed and selected by digital


inputs. If activated the external speed reference is overwritten. If the
Sequential Control Macro is used a standard set of parameter values is
selected automatically.

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

Accurate Torque The ACS 1000 can perform precise T (%)


TN
Control without Speed torque control without any speed feed-
Tref
Feedback back from the motor shaft. With torque 100

rise time less than 10 ms at 100% 90


Tact

torque reference step compared to


over 100 milliseconds in frequency
converters using sensorless flux
vector control, the ACS 1000 is
unbeatable.
By applying a torque reference instead
of a speed reference, the ACS 1000 10
will maintain a specific motor torque t(s)
< 10 ms
value; the speed will be adjusted auto-
TN = Rated Motor Torque
matically to maintain the required
Tref = Torque Reference
torque.
Tact = Actual Torque

Table 6-1 Typical Performance Figures for Torque Control, when Direct
Torque Control is used

ACS 1000 ACS 1000


Torque Control
no Pulse Encoder with Pulse Encoder

Linearity error + 4 %* +3%

Torque rise time < 10 ms < 10 ms

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

ACS 1000 Technical Catalog 39 / 104


Chapter 6 - Standard Functions

6.2.2 Main Circuit Breaker Control


All functions regarding the control of the main circuit breaker (opening,
closing, tripping, monitoring) are included in the ACS 1000.
For detailed information see Chapter 8 - Selecting the Drive System, Main
Circuit Breaker, page 61.

6.2.3 Local and Remote Control


Operation of the ACS 1000 is possible either in local or remote control
mode.
Local/remote control is selected directly on the CDP 312 control panel by
pushing the LOC/REM push-button. A capital L on the display indicates
local control:.

1 L -> 0.0 rpm 0


LOC Status RdyForMCBOn
REM MotSpeed 0.00 rpm
Power 0.0 %

Remote control is indicated with a blank:

1 -> 0.0 rpm 0


LOC
Status RdyForMCBOn
REM MotSpeed 0.00 rpm
Power 0.0 %

Local Control If the converter is in local control, local operation using the push-buttons
on the converter front door and the CDP 312 control panel is possible. In
local operation mode no remote control command will be accepted.

Remote Control If remote control is selected, local operation from the push-buttons on the
converter front door and from the CDP 312 control panel is not possible.
Instead all commands for closing and opening the main circuit breaker or
starting and stopping the drive are received via digital inputs from a remote
control station. The speed reference value is given as an analog input
signal.
Alternatively all remote control signals can be exchanged via an optional
fieldbus interface.
Changing the control mode from local to remote and vice versa can be
disabled by setting digital input “DISABLE LOCAL” (see also Table 4-2).

40 / 104 ACS 1000 Technical Catalog


Chapter 6 - Standard Functions

6.2.4 Diagnostics

Actual Signal Three signals can be displayed


Monitoring simultaneously on the control
1 L -> 600.0 rpm 1
panel. Status Running
Actual signals to be displayed MotSpeed 600.00 rpm
can be selected in parameter Power 75.0 %
group 1 to 5, Actual Signals.
For example:
• ACS 1000 output frequency, current, voltage and power
• Motor speed and torque
• DC Link voltage
• Active control location (Local / External 1 / External 2)
• Reference values
• ACS 1000 inverter air temperature
• Cooling water temperature, pressure and conductivity
• Operating time counter (h), kWh counter
• Digital I/O and analog I/O status
• PID controller actual values (if the PID Control Macro is selected)

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

6.2.5 Programmable Digital and Analog Outputs

Programmable Digital Four digital outputs on the IOEC 2 board can be programmed individually.
Outputs Each output has floating change-over contacts and can be allocated to an
internal binary control or status signal via parameter setting.
Examples are:
• ready, running, fault, warning, motor stall, motor temperature alarm /
trip, ACS 1000 temperature alarm / trip, reverse rotation selected,
external control selected, preset speed limits, intermediate circuit
voltage limits, preset motor current limit, reference limits, loss of
reference signal, motor operating at reference speed, process PID
controller actual value limits (low, high) etc.
If optional boards IOEC 3 and/or IOEC 4 are installed, a maximum of 12
additional digital outputs (6 on each board) are available.

ACS 1000 Technical Catalog 41 / 104


Chapter 6 - Standard Functions

Programmable Analog Two programmable analog outputs on each IOEC board are at the user’s
Outputs disposal.
Depending on the setting of the corresponding parameters, the analog
output signals can represent for example:
• motor speed, process speed (scaled motor speed), output frequency,
output current, motor torque, motor power, DC bus voltage, output
voltage, application block output (process PID controller output),
active reference, reference deviation (difference between the
reference and the actual value of the process PID controller).
The selected analog output signals can be inverted and filtered. The
minimum signal level can be set to 0 mA, 4 mA or 10 mA.

6.2.6 Scalable Analog Inputs

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

6.2.7 Input Signal Source Selections and Signal Processing

Two Programmable The ACS 1000 can receive the Start/Stop/Direction commands and the
Control Locations reference value from the integrated control panel and the Closing/Opening
commands for the main circuit breaker from the push buttons on the
control section door.
Alternatively it is possible to predefine two separate external control loca-
tions (EXT1 and EXT2) for these signals. The active external control loca-
tion can be changed via the control panel or via a digital input.
The control panel always overrides the other control signal sources when
switched to local mode.
Optionally, the converter can be equipped with a fieldbus adapter module,
see Chapter 7 - Options.

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

42 / 104 ACS 1000 Technical Catalog


Chapter 6 - Standard Functions

• The ACS 1000 reference can be given using two digital inputs:
one digital input increases the speed, the other decreases it. The
active reference is memorized by the control software.
• The ACS 1000 can form a reference out of two analog input signals
by using mathematical functions: addition, subtraction, multiplication,
minimum selection, and maximum selection.
It is possible to override the actual speed reference with predefined
constant speeds (see Constant Speeds, page 39).
It is possible to scale the external reference so that the signal minimum
and maximum values correspond to a speed other than the nominal
minimum and maximum speed limits.

6.3 Standard Protection Functions

The ACS 1000 offers several programmable fault functions and other non-
user adjustable pre-programmed protection functions.

6.3.1 Programmable Fault Functions

Motor Winding The motor can be protected from overheating by activating the motor
Temperature winding temperature monitoring function.
The ACS 1000 standard solution offers three analog inputs for measuring
and monitoring the motor winding temperature.
Values for alarm and trip levels can be set.

Motor Stall The ACS 1000 protects the motor if a stall condition is detected. The moni-
toring limits for stall frequency (speed) and stall time can be set by the
user. The user can also select whether the stall function is enabled and
whether the drive responds with an alarm or a trip when a stall is detected.
The protection is activated if all the following conditions are fulfilled
simultaneuously:

1 The output frequency is below the set


stall frequency.
Torque
2 The drive is in torque limit. The torque
limit level is a basic setup parameter Stall region
that sets maximum drive output torque. Tm.a
Although it indirectly effects operation of
the motor stall protection, it should not
be considered a motor stall parameter.
3 The frequency and torque levels from
conditions 1 and 2 have been present Stall
Frequency
f (Hz)
for a period longer than the set stall
time.
Figure 6-1 Stall Region of the Motor

ACS 1000 Technical Catalog 43 / 104


Chapter 6 - Standard Functions

Underload Loss of motor load may indicate a process malfunction. The ACS 1000
provides an underload function to protect the machinery and the process
in such a serious fault condition. This monitoring function checks if the
motor load is above the specified load curve. 5 different load curves can
be selected by the customer.
Monitoring limits: underload curve and underload time can be chosen as
well as the drive response to the underload condition (alarm / trip indica-
tion and stop the drive / no reaction).

Torque
0.8

0.7

0.6

0.5 curve 1
curve 2
0.4 curve 3
curve 4
0.3 curve 5

0.2

0.1

0
Speed
10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

110%

120%

130%

140%
Figure 6-2 Load Curves for Underload Function
The protection is activated if all the following conditions are fulfilled simul-
taneously:
1 The motor load is below the underload curve selected by the user
(see Figure 6-2).
2 The motor load has been below the selected underload curve longer
than the time set by the user (Underload time).

Overspeed The motor speed as determined by DTC is monitored. If the motor speed
exceeds the maximum permitted motor speed (user adjustable) a trip is
initiated. In addition, an input for connection of an external motor over-
speed trip is available. A converter trip is also initiated, if the external
motor overspeed trip is activated (signal active when low).

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

44 / 104 ACS 1000 Technical Catalog


Chapter 6 - Standard Functions

6.3.2 Pre-programmed Protection Functions

Motor Phase Loss The phase loss function monitors the status of the motor cable
connections. The function is useful especially during motor starting:
the ACS 1000 detects if any of the motor phases are not connected and
refuses to start.
The phase loss function also monitors the motor connection status during
normal operation. The motor operating frequency must be above a
minimum level in order for this feature to function. Should a motor phase
loss be detected a trip is initiated.

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

Overvoltage The levels of the positive and negative DC link voltage are monitored to
detect whether an improper overvoltage condition develops. If these
voltage levels rise above 130% of their nominal levels an overvoltage trip
is initiated. On rare occasions, a combination of conditions can result in
the motor entering a self excitation mode that can cause the DC link
voltage to continue to rise, despite the fact that a trip has been initiated. If
this condition occurs and if the DC link voltage levels rise above 135% of
their nominal levels, a second overvoltage trip is initiated that causes the
inner 6 IGCT’s to be gated simultaneously such, that the motor windings
are effectively shunted together. This eliminates the self excitation voltage
that is causing the DC link voltage levels to rise. To provide ultimate
reliability the second overvoltage trip is implemented both in software and
redundantly in hardware (140%).

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

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

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

Overcurrent The overcurrent trip limit for the ACS 1000 is 2.2 x IN RMS of the nominal
inverter current. If this level is exceeded, a trip is initiated.

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

Cooling Circuit The operating condition of the cooling circuit is monitored. If any of the
monitored signals such as water temperature, water pressure or conduc-
tivity exceed a preset limit, a trip is initiated. In addition, the status of the

ACS 1000 Technical Catalog 45 / 104


Chapter 6 - Standard Functions

cooling water pumps, the water level in the expansion vessel and the
auxiliary fan are monitored.

Short Circuit of the The inverter is monitored to ensure that a short circuit condition does not
Inverter exist. If a short circuit is detected a trip is initiated.

Ground Fault The current in the output filter ground leg is monitored and compared with
two thresholds. The first threshold is set to a fixed percentage of the peak
value of the nominal inverter current. The second threshold is adjustable
and compared with the RMS value of the ground current. If the ground
current exceeds one of the thresholds a corresponding alarm message
will be displayed and the drive will be shut down.
Ground faults will be detected in the area between the ACS 1000 trans-
former secondary side and the motor.

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

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

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

Battery Test The back-up batteries are checked periodically by applying a known load
and by measuring the resulting voltage drop. If the charge of the batteries
is deficient, a fault message is displayed and either a normal stop or an
alarm is initiated.

ID-Run Fault During commissioning an identification run has to be carried out. The
nominal data for identification of the system parameters has to be entered.
If incorrect values are used and therefore the system parameters cannot
be determined, a trip is initiated. In this case the identification run has to
be repeated after the correct data has been entered.

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Chapter 6 - Standard Functions

6.3.3 Other Protection Functions

External Motor If the customer uses an external motor protection relay, it can be
Protection Trip connected to a pre-defined protection input of the ACS 1000. The motor
protection input is integrated into the tripping loop by a normally closed
(NC) contact.

External Transformer If the customer uses an external transformer protection relay, it can be
Protection Trip connected to a pre-defined protection input of the ACS 1000. The trans-
former protection input is integrated into the tripping loop by a normally
closed (NC) contact.

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

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

External Emergency The normally closed (NC) contacts of external emergency-off buttons can
Off be wired into the tripping loop.
For further details see Chapter 4 - User Interfaces.

6.4 Other Functions

Automatic Restart The ACS 1000 can automatically reset itself after an undervoltage has
occurred. This function is activated by two parameters one to enable the
automatic restart function and one to select the undervoltage waiting time
(adjustable between 0 and 600 s).
If the automatic restart feature is activated and an undervoltage is
detected in the DC link, the waiting time is started. If the voltage recovers
within the selected time, the fault will be reset automatically and the
converter resumes normal operation. If the waiting time has elapsed and
the voltage has not recovered the converter is tripped and the MCB is
opened.

Monitoring of Limit The values of several user selectable signals can be monitored for adjust-
Values able low and high limits.
Adjustable limits can be set for: two speed values, a current value, two
torque values, two reference values and two actual values of the PID
controller. The digital status of the active limit appears on the control panel
display and can also be allocated to digital output.

ACS 1000 Information The software version and the serial number of the ACS 1000 can be
displayed on the CDP 312 control panel.

ACS 1000 Technical Catalog 47 / 104


Chapter 6 - Standard Functions

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

6.4.1 Customer Specific Options


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

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Chapter 7 - Options

7.1 Environmental Conditions

Extended Ambient Above 40 °C the converter output power must be derated by 1.5% per
Temperature: 45 °C 1 °C and filter capacitors, suitable for high operating temperatures, are
supplied.

Extended Raw Water The extended raw water temperature is +27...+38 °C (+80...+100 °F). For
Temperature deratings refer to Appendix B - Technical Data, Derating for Raw Water
Temperature, page 89.

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

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

7.2 Converter Enclosure

Converter Enclosure The standard IP classes of the converter enclosures are given in Appendix
A - Installation Guidelines.
The following IP ratings are optional:
• IP22, IP31, IP32 and IP42 (for air-cooled converters)
• IP54 (for water-cooled converters)

Door Interlocking The ACS 1000 is equipped with an electromechanical door interlocking
system as standard.
Alternative optional interlocking:
• Kirk key interlocking
If this option is required, contact your ABB representative.

Cabinet Color The standard color for the ACS 1000 converter is RAL 7035, “Light Grey”.
Other RAL colors are available optionally and must be specified explicitly
when ordered.

Cabinet Paint Finish The standard converter has painted front doors. Optionally, the entire
cabinet exterior is available with painted surfaces (see also Cabinet
Color).

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Chapter 7 - Options

Split Cabinet The water-cooled ACS 1000 can be delivered with a shipping split for easy
transportation. All materials necessary for joining the two parts are
supplied with the drive.

Extended Grounding The standard grounding busbar which is located in the power cable
Busbar termination section of the ACS 1000 can be an extended throughout the
medium voltage sections of the ACS 1000.

7.3 Input Section

Input Bridges The following input rectifier bridges are available:


• 12-pulse diode rectifier (standard)
This type is sufficient for most network conditions to fulfill the network
harmonic requirements according to IEEE 519-1992.
It is the ideal solution for a small converter footprint and if an outdoor
transformer can be used.
• 24-pulse diode rectifier with integrated or external transformer
configuration
This type is recommended if superior network behavior is required.
The 24-pulse diode rectifier is applicable if outdoor transformers are
not required. In this case there is no need for an oil pit and no addi-
tional cabling between transformer and converter is needed which
can substantially reduce construction and installation costs.

Motor and Transformer Refer to Sections Extended Motor Monitoring Interface, page 52 and
Protection Extended Transformer Monitoring Interface, page 50.

Extended Transformer In addition to the standard signal “Transformer Protection Trip” (wired into
Monitoring Interface tripping loop) the signals according to Table 7-1 can be included optionally
in the signal interface between the transformer and the ACS 1000.
Note: This option requires the IOEC 3 board. The option is standard for
water-cooled converters (see Chapter 4 - User Interfaces, I/O Signals:
Transformer, page 26).

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Chapter 7 - Options

Table 7-1 I/O Signals for Extended Transformer Monitoring

Type Signal Name Remarks

DI OIL LEVEL ALARM Transformer oil level alarm


indication

DI OIL TEMP ALARM, or Transformer oil temperature alarm


indication

TRAFO WDG TEMP ALARM Transformer winding temperature


alarm indication

DI /OIL TEMP TRIP, or Transformer oil temperature trip


indication
/TRAFO WDG TEMP TRIP Transformer winding temperature
trip indication

DI BUCHHOLZ ALARM Transformer alarm indication from


Buchholz relay

DI /BUCHHOLZ TRIP Transformer trip indication from


Buchholz relay

AI OIL TEMP, or Temperature measurement of


transformer oil
TRAFO WDG TEMP Temperature measurement of
transformer winding

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

Line Unbalance A signal from a line unbalance protection relay can be monitored by wiring
Protection Relay it into the tripping loop of the ACS 1000. If the signal is low the main circuit
breaker is tripped immediately.

Common Mode Choke This option is needed if the cable length between the converter trans-
former and the ACS 1000 exceeds the following limits:
• 30 m (98 ft) for ACS 1000, 12-pulse versions and
• 20 m (66 ft) for ACS 1000, 24-pulse versions.
If the cables are longer than the limits below, the ABB representative
should be contacted:
• 200 m (656 ft) for ACS 1000, 12-pulse versions and
• 150 m (492 ft) for ACS 1000, 24-pulse, (water-cooled types only).
The DC link common mode choke functions like a transformer. Together
with the common mode damping resistor it provides damping of the

ACS 1000 Technical Catalog 51 / 104


Chapter 7 - Options

common mode voltages and limits the common mode currents experi-
enced by the main power transformer and transformer secondary cables.

7.4 Motor Side

Extended Motor In addition to the standard signal “Motor Protection Trip” (wired into trip-
Monitoring Interface ping loop) the signals according to Table 7-2 can be included optionally in
the signal interface between the motor and the ACS 1000.
Note: This option requires the IOEC 3 board. The option is standard for
water-cooled converters (see Chapter 4 - User Interfaces, I/O Signals:
Motor, page 27),
Table 7-2 I/O Signals for Extended Motor Monitoring

Type Signal Name Remarks

DI EXT MOT PROT ALARM (External) motor protection alarm


indication

DI MOT COOLING ALARM (External) motor cooling alarm


indication

DI /MOT COOLING TRIP (External) motor cooling trip


indication

DI VIBRATION SV ALARM Motor vibration alarm indication

DI /VIBRATION SV TRIP Motor vibration trip indication

DI /OVERSPEED TRIP Motor overspeed trip (included in


hardwired tripping loop)

AI BRG TEMP DE Motor bearing temperature of


driven end

AI BRG TEMP NDE Motor bearing temperature of non-


driven end

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

Ex-Zone Signal For motor installations in hazardous areas (Ex-Zone) all interface signals
Interface for Motor from the motor have to be connected to Zener Barriers mounted in the
Measurements (Zener converter. This applies to the winding temperature and bearing
Barriers) temperature measurements as well as to all digital signals e.g. external
motor protection alarm and trip and external overspeed trip.
If this option is required, contact your ABB representative.

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

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Another application for a pulse encoder would be for motors running at


speeds below 5 Hz for longer periods.
The requirements for a pulse encoder are as follows:
• Supply voltage 12 VDC or 24 VDC (supplied by the module)
• Single ended or differential connection can be used
• Available signal channels: A, A inverted, B (90° electr. phase shift to
A), B inverted (Z (zero channel), Z inverted - optional)
• The encoder should provide 2n pulses/revolution. The recommended
pulse train is 2048 pulses/revolution. Maximum signal frequency
should not exceed 100 kHz.
The module is fed from the ACS 1000 internal control power supply.

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

Braking Chopper Effective motor braking and short deceleration times can be achieved by
using resistor braking. For resistor braking, the ACS 1000 converter must
be equipped with a braking chopper and a braking resistor.
Braking choppers are available for all ACS 1000 types. The choppers can
be ordered factory-installed or as add-on kits.
The operation of the braking chopper is controlled by the ACS 1000
control system. The braking chopper hardware is located in an additional
cabinet.
The input currents of the braking chopper are monitored for overcurrent
and unbalance in order to detect any defective component in the circuit. In
case a short circuit or an unsymmetry in the braking chopper is detected
a converter trip is initiated.
Braking chopper and braking resistors are each monitored for
overtemperature by means of thermal models. Alarm and trip levels are
determined and set during commissioning.
For more information about braking chopper and braking resistor, see the
resistor specification or contact your ABB representative.

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

Circuit Breaker for A motor space heater can be connected directly to a single-phase auxiliary
Motor Space Heater power circuit breaker, installed in the converter cabinet. Based on the
power rating of the heater, one of the circuit breaker sizes as indicated in
Table 7-3 can be used.

ACS 1000 Technical Catalog 53 / 104


Chapter 7 - Options

Table 7-3 Power Ratings for Different Circuit Breaker Sizes

Auxiliary Voltage (Single Phase)

Circuit Breaker Rating 120 VAC (50/60 Hz) 240 VAC (50/60 Hz)

0.5 A 60 W 120 W

1.0 A 120 W 240 W

2.0 A 240 W 480 W

3.0 A 360 W 720 W

4.0 A 480 W 960 W

5.0 A 600 W 1200 W

6.0 A 720 W 1440 W

10.0 A 1200 W 2400 W

Motor Starter for Motor A motor cooling fan or pump can also be connected directly to an auxiliary
Cooling Fan / Pump motor starter installed in the converter. Based on the power rating of the
cooling fan or pump, one of the following motor starter sizes can be
chosen:

Table 7-4 Power Ratings for Different Starter Sizes

Auxiliary Voltage (Three Phase)

Overload 400 VAC 480 VAC 575 VAC


Current Rating 50/60 Hz 60 Hz 60 Hz

2.5 - 4.0 A 750 W - 1500 W 1100 W - 2000 W 1200 W - 2600 W


(1.0 - 2.0 hp) (1.5 - 2.7 hp) (1.6 - 3.5 hp)

4.0 - 6.3 A 1500 W - 2200 W 2000 W - 3000 W 2600 W - 3600 W


(2.0 - 3.0 hp) (2.7 - 4.0 hp) (3.5 - 4.8 hp)

6.3 - 10.0 A 2200 W - 4000 W 3000 W - 4000 W 3600 W - 6000 W


(3.0 - 5.4 hp) (4.0 - 5.4 hp) (4.8 - 8.0 hp)

7.5 Converter Cooling

Redundant Cooling The redundant cooling fan is an option intended for applications where
Fan (Air-cooled enhanced reliability of the installation is required.
ACS 1000)
The redundant fan unit is supplied as a separate unit to be mounted on top
of the ACS 1000 converter. If delivered together with the ACS 1000, both
fans are already mounted in the unit. As add-on kit, only the redundant fan
is supplied and the standard fan must be transferred from the converter
cabinet to the redundant fan unit.

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Chapter 7 - Options

With this option continuous operation of the drive is guaranteed even if


one fan fails. Switch-over from the faulty to the stand-by device takes
place automatically. To replace the faulty unit the converter must be
stopped. The replacement of a fan takes about 30 minutes.

Control Box Rectifier Inverter

Figure 7-1 Standard Cooling Fan Unit

Air Duct

Control Box Rectifier Inverter

Figure 7-2 Redundant Cooling Fan Unit (Functional Principle)


If this option is ordered the derating of the drive output power needs to be
considered (see Appendix B - Technical Data, Environmental Aspects,
page 87).

Redundant Cooling The water-cooled ACS 1000 can be ordered with a redundant cooling fan,
Fan (Water-cooled if continuous operation is required in case a fan fails.
ACS 1000)
The redundant fan unit is supplied as a separate unit and is mounted on
top of the ACS 1000. If the redundant fan unit is ordered and delivered
together with the ACS 1000, the cut-outs on the roof and the mounting
holes are already prepared. If the redundant fan is purchased separately,
the roof cut-outs and the mounting holes have to be prepared on side.

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

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Chapter 7 - Options

Three-way Valve The cooling unit of the ACS 1000 can be ordered with a three-way valve
(Water-cooled [B14] in the raw water circuit. This option is recommended, if the raw water
ACS 1000) flow must be kept at a constant rate. If the cooling unit is equipped with a
three-way valve, the water-to-water heat exchanger [E1] is bypassed and
the total raw water flow is kept constant even if the water flow in the heat
exchanger varies.

Cooling Unit (Water- From the cooling water circuit below the interface connections towards the
cooled ACS 1000) ACS 1000 and the raw water supply can be seen. The components shown
are part of the ACS 1000 cooling unit.

Pressure B11 Conductivity B12 B13 Temperature


AI 1.3 AI 1.2
P
AI 1.4
Q T ACS 1000 CABINET
I V5 I I
to converter Valve identification:
nipple
V13 open (normal operation)

closed (normal operation)


8 PA
expansion C2
Non-return valve
12 PA

vessel
Control valve

L Z2 (microfilter) M
B10
V11 5 l/min
Z1 (strainer)
12 PA
from converter V14 raw water inlet
nipple 40 mm C1 nipple 33 mm
C
S1 E1
A

air to water
make-up water
heat
ISO-R1/2
ion exchanger exchanger
water to water E2
vessel heat
M11 exchanger
M
V82
V1 V3 130 l/min

P1
12 PA
24 l/min
OPTION
M M12
B14
V2 V4 raw water outlet
controlled by:
M DO 3.3 nipple 33 mm
DO 3.4
P2
V80 V81
OPTION COOLING UNIT

Figure 7-3 Cooling Unit of the Water-Cooled ACS 1000

Space Heater for A space heater is typically required in places/countries with high ambient
Tropicalized Version humidity. It is switched on automatically when the converter is not in
operation in order to prevent condensation.
The heater consists of several heating elements with a rated power of
100 W each rated for 110...240 VAC supply voltage (50 / 60 Hz).

Monitored Air Filter The air-cooled ACS 1000 can be supplied with air filter mats which have a
(Air-cooled ACS 1000) finer mesh than the standard air filter mat. There are filter mats available
with a 10 µm and a 12 µm fine mesh.
The optional air filter mats should be selected if the air contamination level
exceeds IEC 721-3-3, Class 3C2 (for chemical gases) or IEC 721-3-3,
Class 3S1 (for solid particles).
Air filter mats with finer mesh are monitored by measuring the pressure
difference across the filter. An alarm is displayed if the filter is clogged.

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The filter mat which is mounted at the converter air intake can be changed
while the converter is in operation.
If the ACS 1000 is ordered with an air filter with finer mesh the derating of
the drive output power needs to be considered (see Appendix B - Tech-
nical Data, Environmental Aspects, page 87)

7.6 Converter Isolators and Bypass

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

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Chapter 7 - Options

Mains Supply

MCB Transformer
ACS1000 Frequency Converter
12 Pulse Three Level Output
Rectifier Inverter Filter
Sm1
=

=
U2

ACS 1000 Control

Synchronized
Bypass
Controls

MCB 1 Transformer 1

U11 M1
3-Ph
Sbp1
(if necessary)

Mains Supply Sm2

MCB 2 Transformer 2
U12
M2
3-Ph
Sbp2
(if necessary)

Figure 7-4 Synchronized Bypass, Single Line Diagram

Input Isolator Used in addition to the main circuit breaker, the input isolator provides a
visible break between the transformer and the rectifier section when the
input isolator is in the open position.
The input isolator is located in an additional cabinet next to the converter.
If this option is required, contact your ABB representative.

Output Isolator The output isolator is normally used in combination with a converter
bypass and provides the possibility to isolate the converter visibly from the
motor.
The output isolator is located in an additional cabinet next to the converter.
If this option is required, contact your ABB representative.

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Chapter 7 - Options

7.7 Auxiliary & Control Interfaces

Fieldbus Adapter A fieldbus module may be used for controlling and monitoring the
Modules converter instead of using conventional hard-wired I/Os.
There are several fieldbus adapter modules available for the ACS 1000:
• Profibus DP
• Modbus
• Modbus+
• Allen-Bradley Device Net
• ABB Advant Fieldbus 100
• ABB Procontic CS31
• Interbus S
The fieldbus is connected to the adapter module via a twisted pair bus
(RS 485) or via BNC-connectors (for ABB AF100). The adapter
communicates with the ACS 1000 control board via a fast (4 Mbit/s)
Duplex Fiber Optic Link.
All fieldbus modules require 24 VDC power. In all cases power is supplied
by the ACS 1000 internal control power supply (EPS).

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

7.8 PC Tools

DriveWindow DriveWindow offers several advanced, yet easy-to-use tools for


commissioning and control of the ACS 1000.
• The parameter and signal tool with a full set of device specific data
either in online or offline mode to check, study and change the
parameters
• The monitor tool as a graphic interface for monitoring digital and
analog signals
• The data logger as a versatile way of tracing fast and accurate events
• The fault logger displaying a fault history
• The application tools presenting the pin values in order to debug
application software and force constants

ACS 1000 Technical Catalog 59 / 104


Chapter 7 - Options

With its component structure, enhanced flexibility is achieved to allow


working with several different types of products through different target
and communication drivers (The look and feel of the DriveWindow
program remains the same even when the product changes).

DriveSupport The DriveSupport tool offers an advanced level of servicing, maintaining


and trouble shooting of a drive system. Versatile features are provided for:
• Diagnosing faults and warnings
• Testing and verifying possible causes of faults
• Locating of faulty components
• Performing step-by step replacement procedures
• Recording maintenance activities.
The DriveSupport works on-line together with the DriveWindow tool.

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Chapter 8 - Selecting the Drive System

8.1 Overview

The excellent performance of the ACS 1000 makes it suitable for most
variable speed drive applications.
In order to dimension and configure an ACS 1000 drive system, the driven
load has to be clearly specified and an appropriate motor must be
selected. The driven load together with the selected motor basically
determines the size of the ACS 1000 as well as the size of the required
converter input transformer.

8.2 Main Circuit Breaker

8.2.1 Main Circuit Breaker Control


The Main Circuit Breaker (MCB) must be controlled exclusively by the
ACS 1000. This means that a closing request or command is sent from a
customer’s local or remote control station to the ACS 1000. The actual
closing command is then released from the converter to the MCB.
The closing command from the converter to the MCB (duration can be pre-
set) can be a continuous signal or a single pulse, which is reset as soon
as the status feedback MCB IS CLOSED has been received from the
switchgear. If this status feedback has not arrived after a pre-set time, the
closing command is reset and a trip of the MCB is initiated.
The MCB is opened by :
• an MCB OPEN command, either given from the push button on the
ACS 1000 or from a remote control station via digital inputs or through
a fieldbus adapter
• the hardwired tripping loop (see Tripping Loop, page 62).
The opening command from the converter to the MCB - pulse or steady
state signal - is reset as soon as the status feedback MCB IS OPEN has
been received. If the feedback signal has not arrived after a preset time
the command MCB ORDER TRIP is initiated to open the MCB.
The MCB ORDER TRIP is a steady state true signal. When in low status
it directly opens the MCB.

MCB Control Fault All opening and closing commands to the MCB are monitored for time-out
An alarm or fault message comes up on the display of the CDP 312 control
panel if there is something wrong in connection with the control of the
MCB.

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Chapter 8 - Selecting the Drive System

8.2.2 Tripping Loop

General The tripping loop is a hardwired control circuit provided to trip the MCB
directly either via the tripping coil or via the opening coil. Depending on
which coil is available, the tripping coil or the opening coil has to be
connected to the tripping loop.
Signals from customer devices can (but do not have to) be wired into this
loop. Each of these signals is monitored by a digital input. These signals
can be connected to a terminal strip in the control section of the
ACS 1000. If one or several of the signals are not used a jumper must be
put across the corresponding terminals.

Customer side Control section of ACS 1000


22...250 VAC X 300
control voltage 22...150 VDC 1
provided by customer
2
emergency off
(one or more emergency off
*
3
connected in series)
4
transformer protection trip *
5
6
motor protection trip *
8
overspeed trip *
9
10
supply voltage unbalance trip *
11
optional IOEC board 3 required

jumper when signal is not used


*
12

MCB
tripping coil

13

Figure 8-1 Tripping Loop: Principle Diagram

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Chapter 8 - Selecting the Drive System

ACS 1000 Tripping The following ACS 1000 contacts are wired to the tripping loop:
Loop Signals
• the digital output "MCB ORDER TRIP"
• the emergency-off button on the ACS 1000 front door.
The digital output "MCB ORDER TRIP" is initiated:
• if the grounding isolator is closed or not not completely opened
• after an off command and there is no feedback signal within a pro-
grammable time lapse
• when switching off the main circuit breaker and a signal discrepancy
between off command and feedback signal is detected
• by main circuit interface board of the ACS 1000 in case of a trip.

Customer Signals The following signals from customer devices can (but do not need to) be
wired to the tripping loop terminals:
• external emergency-off
• transformer protection trip
• motor protection trip
• overspeed trip
• supply voltage unbalance.
The following signals require the optional IOEC 3 board:
• overspeed trip
• supply voltage unbalance.

8.2.3 Main Circuit Breaker Features

General Requirements The MCB has to be specified according to the rated primary voltage and
for MCB current of the converter transformer. It should also meet the specific drive
requirements (some items require proper coordination with the instrumen-
tation and protection equipment). The MCB must be capable:
• to connect and maintain nominal load currents and clear short-circuit
currents
• to tolerate the transformer inrush current without tripping
• to clear transformer secondary short circuits within 250 ms (the time
includes the pick-up time of the protection relay and the opening time
of the MCB)
• close in response to a close command
• open within 160 ms in response to an open command (signal active
when high)
• open within 160 ms in response to a trip command (signal active
when low)

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Chapter 8 - Selecting the Drive System

• provide a status output which indicates MCB closed


• provide a status output which indicates MCB open
• provide a status output which indicates MCB not available (vacuum
circuit breaker in test position or vacuum controller disconnect switch
in open position).

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


• vacuum or gas insulated (SF6) circuit breakers
• load disconnectors with fuse
• vacuum or gas insulated (SF6) controllers / medium voltage starters.

MCB Control Signal A possible signal interface between the ACS 1000 and a vacuum
Interface controller or vacuum circuit breaker is indicated in the schematic diagrams
below.

vacuum cir cuit breaker


trip sig nals
52
MCB not available

clo se command
open command

50
51N
MCB clo sed

51
MCB open

tripping loop
AC tim e resid ua l
overcurrent rela y

in stantaneous / AC tim e
overcurrent relay

ACS 1000

Figure 8-2 Connection Scheme with Vacuum Circuit Breaker

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Chapter 8 - Selecting the Drive System

non lo ad-break dis connector

fast actin g current lim it in g fuse


vacuum contactor
trip sig nals

MCB not available

clo se command
open command
50

MCB clo sed


51N
MCB open 51

tripping loop
AC tim e resid ua l
overcurrent rela y

in stantaneous / AC tim e
overcurrent relay

ACS 1000

Figure 8-3 Connection Scheme with Vacuum Controller

MCB Instrumentation Appropriate current transformers and protection relaying must be provided
and Protection to protect transformer and transformer primary cables. The intended
Equipment approach for protection is shown in Figure 8-4. As shown in the figure the
protection can be considered to consist of three areas. The first area
identified as Transformer Primary Fault Protection is an instantaneous trip
area that protects against short circuits in the transformer primary
windings or in the cables supplying the transformer primary. The lower
level of the trip threshold should be adjusted high enough to insure that
nuisance tripping does not occur due to transformer inrush currents. The
second area identified as Transformer Secondary Fault Protection is a
short delay trip area that protects against short circuits in the transformer
secondary windings, the cables from the transformer secondaries to the
ACS 1000, or in the input rectifier stages of the ACS 1000. The short time
delay provided should be adjustable and should be set long enough to
insure that the protection does not trip due to transformer inrush current.
The trip level should be adjusted low enough to insure that tripping will
occur within 250 ms (including MCB delay time) even if transformers with
high input impedance are used. The final area identified as Overload
Protection should provide long term overload protection with an inverse
time characteristic. This area is intended to protect the transformer and
cables from long term overload conditions.

ACS 1000 Technical Catalog 65 / 104


Chapter 8 - Selecting the Drive System

The protection described can be provided with individual protection relays


or with a single microprocessor based unit. Required current transformers
should be sized in accordance with the rated current levels of the
transformer. Basic protection configuration and connection should be as
previously shown in Figure 8-2 and Figure 8-3.

Current

x 20 Transformer Primary Fault Protection

Transformer Secondary Fault Protection

x 10
Overload Protection

Adjustable Time Delay


x1
Time
10 ms 250 ms 1s 10 s 100 s

Figure 8-4 Sample Protection Scheme

8.3 Converter Input Transformer Selection

All ACS 1000 converters must be supplied from an isolation transformer


with multiple phase-shifted secondary windings, designed in accordance
with the pulse number of the input bridge. For 12-pulse systems the
secondary side of the transformer has one star and one delta winding.
This creates the 30° phase shift between the two 3-phase secondary
windings, that is necessary to facilitate 12-pulse input bridge operation.
The secondary windings of transformers for ACS 1000 converters with 24-
pulse rectifier bridge are to be designed to provide a 15° phase shift.
A second purpose of the transformer is to provide sufficient impedance to
limit the line harmonics to acceptable levels.
The transformer may be an oil-immersed or a dry type. Based on
installation requirements of the application, the transformer may be
located remote from the ACS 1000 drive equipment or nearby, even
integration into the drive is possible. For requirements regarding the
maximum cable length between transformer and ACS 1000 see Appendix
B - Technical Data .
The transformer may be supplied from ABB or alternatively from a third
party supplier in accordance with the specifications provided by ABB. The
design of the transformer must take into account site-specific line
conditions (voltage, short circuit capacity, existing harmonics, etc.) to

66 / 104 ACS 1000 Technical Catalog


Chapter 8 - Selecting the Drive System

insure compliance with harmonic standards invoked by the specifications.


Transformer quality is critical with respect to effecting proper limitation of
harmonic currents and voltages.
When determining the power rating of the transformer, power and
efficiency of the motor, power factor and efficiency of the ACS 1000
converter and harmonic loading of the transformer must all be considered.
For selecting an appropriate ABB ACS 1000 transformer or for specifiying
a generic transformer, please contact your ABB representative.

8.4 Selection of the ACS 1000 Converter

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

8.4.1 ACS 1000 Output Filter


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

8.4.2 Non Quadratic Load Applications


For constant torque or constant power applications a high overloadability
(start-up torque) is usually required. This overloadability, together with

ACS 1000 Technical Catalog 67 / 104


Chapter 8 - Selecting the Drive System

possibly needed derating for low speed operation, requires some


additional calculations for drive selection. To determine the appropriate
ACS 1000 please contact your ABB representative.

8.4.3 ACS 1000 Selection Tables

Selection Table for ACS 1000 rated for 2.3 kV have output ratings based on horsepower (HP).
Air / Water-cooled Equivalent output ratings in kilowatt (kW) are approximate and listed for
ACS 1000 with reference only.
2.3 kV Motors
Note: The load capacity (current and power) decreases if the environ-
mental conditions at site do not comply with the limits given in Appendix B
- Technical Data, Environmental Aspects, page 87. The resulting derating
factors are specified in Appendix B - Technical Data, Derating of Drive
Power, page 88.

Table 8-1 ACS 1000 Ratings for 2.3 kV Motors, 50 Hz and 60 Hz Supply (12/24-Pulse)

Max. cont. Rated Equival. Rated


Motor
Type of Converter Motor Motor Output Frame
Voltage Converter Type*
Cooling Power Power** Power** Current Size
(kV)
(kVA) (HP) (kW) (A)

2.3 ACS10x2-A1-A0-00 Air 400 400 _ 100 A1

2.3 ACS10x2-A1-B0-00 Air 400 450 315 100 A1

2.3 ACS10x2-A1-C0-00 Air 450 500 355 113 A1

2.3 ACS10x2-A1-D0-00 Air 550 600 450 138 A1

2.3 ACS10x2-A1-E0-00 Air 650 700 500 163 A1

2.3 ACS10x2-A1-F0-00 Air 750 800 560 188 A1

2.3 ACS10x2-A1-G0-00 Air 800 900 630 201 A1

2.3 ACS10x2-A1-H0-00 Air 900 1000 710 226 A1

2.3 ACS10x2-A2-J0-00 Air 1150 1250 900 289 A2

2.3 ACS10x2-A2-K0-00 Air 1350 1500 1120 339 A2

2.3 ACS10x2-A3-L0-00 Air 1550 Please contact ABB

2.3 ACS10x2-A3-M0-00 Air 1800 Please contact ABB

2.3 ACS10x2-A3-N0-00 Air 2000 Please contact ABB

*, ** See note at end of this Section on page 70

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Chapter 8 - Selecting the Drive System

Selection Table for ACS 1000 rated for 3.3 kV have output ratings based on kilowatt (kW).
Air / Water-cooled Equivalent output ratings in horsepower (HP) are approximate and listed
ACS 1000 with for reference only.
3.3 kV Motors

Table 8-2 ACS 1000 Ratings for 3.3 kV Motors, 50 Hz and 60 Hz Supply (12/24-Pulse)

Max. cont. Rated Equival. Rated


Motor
Type of Converter Motor Motor Output Frame
Voltage Converter Type*
Cooling Power Power** Power** Current Size
(kV)
(kVA) (HP) (kW) (A)

3.3 ACS10x3-A1-A0-00 Air 400 450 315 70 A1

3.3 ACS10x3-A1-B0-00 Air 450 500 355 79 A1

3.3 ACS10x3-A1-C0-00 Air 500 550 400 87 A1

3.3 ACS10x3-A1-D0-00 Air 550 600 450 96 A1

3.3 ACS10x3-A1-E0-00 Air 600 700 500 105 A1

3.3 ACS10x3-A1-F0-00 Air 700 750 560 122 A1

3.3 ACS10x3-A1-G0-00 Air 750 800 630 131 A1

3.3 ACS10x3-A1-H0-00 Air 850 900 710 149 A1

3.3 ACS10x3-A2-J0-00 Air 950 1000 800 166 A2

3.3 ACS10x3-A2-K0-00 Air 1100 1250 900 192 A2

3.3 ACS10x3-A2-L0-00 Air 1200 1350 1000 210 A2

3.3 ACS10x3-A2-M0-00 Air 1350 1500 1120 236 A2

3.3 ACS10x3-A2-N0-00 Air 1500 1650 1250 262 A2

3.3 ACS10x3-A2-P0-00 Air 1700 1750 1400 297 A2

3.3 ACS10x3-A3-Q0-00 Air 1900 2000 1600 332 A3

3.3 ACS10x3-A3-R0-00 Air 2150 2250 1800 376 A3

3.3 ACS10x3-W1-S0-00 Water 2400 2500 2000 420 W1

3.3 ACS10x3-W1-T0-00 Water 2700 3000 2250 472 W1

3.3 ACS10x3-W1-U0-00 Water 3000 3350 2500 525 W1

3.3 ACS10x3-W2-V0-00 Water 3350 3500 2800 586 W2

3.3 ACS10x3-W2-W0-00 Water 3750 4000 3150 656 W2

3.3 ACS10x3-W2-X0-00 Water 4250 4500 3550 744 W2

3.3 ACS10x3-W3-Y0-00 Water 4750 5000 4000 831 W3

3.3 ACS10x3-W3-Z0-00 Water 5350 6000 4500 936 W3

3.3 ACS10x3-W3-10-00 Water 5950 6700 5000 1041 W3

*, ** See note at end of this Section on page 70

ACS 1000 Technical Catalog 69 / 104


Chapter 8 - Selecting the Drive System

Selection Table for ACS 1000 rated for 4.0 kV have output ratings based on horsepower (HP).
Air / Water-cooled Equivalent output ratings in kilowatt (kW) are approximate and are listed
ACS 1000 with for reference only.
4.0 kV Motors

Table 8-3 ACS 1000 Ratings for 4.0 kV Motors, 50 Hz and 60 Hz Supply (12/24-Pulse)

Max. cont. Rated Equival. Rated


Motor
Type of Converter Motor Motor Output Frame
Voltage Converter Type*
Cooling Power Power** Power** Current Size
(kV)
(kVA) (HP) (kW) (A)

4.0 ACS10x4-A1-A0-00 Air 400 400 _ 58 A1

4.0 ACS10x4-A1-B0-00 Air 400 450 315 58 A1

4.0 ACS10x4-A1-C0-00 Air 450 500 355 65 A1

4.0 ACS10x4-A1-D0-00 Air 550 600 450 79 A1

4.0 ACS10x4-A1-E0-00 Air 650 700 500 94 A1

4.0 ACS10x4-A1-F0-00 Air 750 800 560 108 A1

4.0 ACS10x4-A1-G0-00 Air 800 900 630 115 A1

4.0 ACS10x4-A1-H0-00 Air 900 1000 710 130 A1

4.0 ACS10x4-A2-J0-00 Air 1150 1250 900 166 A2

4.0 ACS10x4-A2-K0-00 Air 1350 1500 1120 195 A2

4.0 ACS10x4-A3-L0-00 Air 1550 1750 1250 224 A3

4.0 ACS10x4-A3-M0-00 Air 1800 2000 1400 260 A3

4.0 ACS10x4-A3-N0-00 Air 2000 2250 1600 289 A3

4.0 ACS10x4-W1-P0-00 Water 2300 2500 1800 332 W1

4.0 ACS10x4-W1-Q0-00 Water 2700 3000 2250 390 W1

4.0 ACS10x4-W2-R0-00 Water 3100 3500 2500 447 W2

4.0 ACS10x4-W2-S0-00 Water 3600 4000 2800 520 W2

4.0 ACS10x4-W2-T0-00 Water 4000 4500 3150 577 W2

4.0 ACS10x4-W2-U0-00 Water 4500 5000 3550 650 W2

4.0 ACS10x4-W3-V0-00 Water 4900 5500 4000 707 W3

4.0 ACS10x4-W3-W0-00 Water 5300 6000 4500 765 W3

4.0 ACS10x4-W3-X0-00 Water 5800 6700 5000 837 W3

* "x" stands for: "1" = 12-pulse rectifier (air / water-cooled ACS 1000)
"2" = 24-pulse rectifier (air-cooled ACS 1000)
** The power ratings apply to typical 4 pole motors. For those motors the
ACS 1000 has a built-in overloadability of 10%. When selecting the
ACS 1000 it should be observed that the rated current of the ACS 1000
must be higher than or equal to the rated motor current in order to
achieve the rated motor power given in the table.

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Chapter 8 - Selecting the Drive System

8.5 Motor Selection

8.5.1 Load Capacity Curves


This chapter provides the necessary information regarding the selection
criteria of the motor, to match the ACS 1000.
In the example below the rated frequency and the field weakening point
for the motor are based on 50 Hz.

Curve 1: Typical continous load capacity curve of an IEC34 self-


ventilated motor, controlled by the ACS 1000.
Curve 2: Load capacity of the ACS 1000, rated for normal use (i.e.
100% continous, 110% for 1 min. every 10 min.).

T/TN
2.0
1.9
1.8
1.7
1.6
1.5
1.4
1.3
1.2 Curve 2
1.1 ACS 1000 Loadability
1.0
0.9
0.8
0.7
0.6
0.5 Curve 1
0.4 Motor Loadability
0.3
0.2
0.1
0.0
0 10 20 30 40 50 60 70 80 90 100 f (Hz)
p = number of poles p=2
0 600 1200 1800 2400 3000 3600 n (rpm)
T = load torque p=4
TN = rated motor torque 0 300 600 900 1200 1500 1800 2100 2400 n (rpm)
n = speed p=6
0 200 400 600 800 1000 1200 1400 1600 n (rpm)
f = output frequency of p=8
ACS 1000 0 150 300 450 600 750 900 1050 n (rpm)

Figure 8-5 Load Capacity Curves

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Chapter 8 - Selecting the Drive System

8.5.2 Selection Criteria


Generally speaking the motor must be selected and sized as required by
the load. Supplying an additional power margin to compensate for PWM
inverter operation is not required with the ACS 1000 due to its sinusoidal
output waveform. After the motor has been selected (or if an existing
motor is being applied) the following parameters are relevant to select the
converter and the transformer:
• load characteristic (the most common characteristic is square torque;
for other loads like constant torque or constant power applications,
please contact your ABB representative)
• overloadability requirements
• motor voltage
• number of motor poles
• shaft power (nominal)
• shaft speed (nominal)
• rated current (nominal)
• motor efficiency
• motor power factor.
Special attention must be paid to the motor cooling in variable speed
applications. If the motor is self-ventilated, long-time operation at low
speeds will usually require some derating to compensate for the reduced
cooling.
Depending on the mechanical configuration of the motor, load, gear-box
and shaft there may be some critical speeds within the operating speed
range of the drive. The critical speeds have to be known and if they have
to be avoided the appropriate parameter settings have to be made.
Special attention has to be paid to variable speed applications using two-
pole motors, since there is usually a critical motor speed below its rated
speed. For more information see Chapter 6 - Standard Functions, Critical
Speed.

8.5.3 Retrofit
Due to its specific topology the ACS 1000 can supply standard medium
voltage motors (existing or new) without applying thermal derating factors.
In addition, due to its sinusoidal output waveform, standard medium
voltage winding insulation is sufficient.
To avoid risk of bearing currents and related consequential damages, one
motor bearing should be insulated (the one at the non-driven shaft end).
This is actually a typical accessory even for most direct on-line operated
motors. If, nevertheless, such a bearing is not available (e.g. for older
existing motors), a grounding brush can be installed on either shaft end.

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Chapter 8 - Selecting the Drive System

Although from an electrical point of view no restrictions exist for variable


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

8.5.4 Torsional Excitation


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

ACS 1000 Technical Catalog 73 / 104


Chapter 8 - Selecting the Drive System

74 / 104 ACS 1000 Technical Catalog


Appendix A - Installation Guidelines

Ambient Conditions

Ambient conditions may require to derate the drive due to the presence of
elevated air temperature, altitude, or cooling water temperature. Sufficient
air flow must be available. Other ambient factors such as relative humidity,
air contamination, shock and vibration must also be in compliance with
stated maximum permissible levels.
See Appendix B - Technical Data for load capacity derating factors and
other requirements related to ambient conditions.

Converter Enclosure The standard IP protection classes for the converter enclosure according
to IEC 529 are:
• IP21 (for air-cooled converters)
• IP31 (for water-cooled converters).
Higher IP-protection classes for the converter enclosure are optional.
Please refer to Chapter 7 - Options.

Mounting

Space Requirements All units must be mounted in an upright position with adequate free space
provided in accordance with Table A-1.
Table A-1 Required Free Space in Front and Above Converter

Type of Above Below Left / Right Front Back


Cooling mm / (in.) mm / (in.) mm / (in.) mm / (in.) mm / (in.)

Air 500 (1)(2)(3) 0 (1) 0 (5) 1000 (4) 0 (6)


(20") (0") (0") (39.4") (0")

Water 0 / 700 (1)(2) 0 (1) 0 (5) 1000 (4) 0


(0")/(27.6") (0") (0") (39.4") (0")

(The dimensions given are minimum values)


Notes:
1 Dimensions do not include space for cable entry
which can be from top or from below.
2 Dimensions are above the blower hood or above the
redundant fan unit.
3 This is a general recommendation to ensure proper
air flow.

ACS 1000 Technical Catalog 75 / 104


Appendix A - Installation Guidelines

4 Dimensions indicate required door swing area. Addi-


tional space may be needed to meet local installation
regulations and requirements.
5 Dimensions do not include space for moving the cab-
inet, nor for cable and water entries (which can be
from top or from below).
6 For service reasons a minimum clearance of 400 mm
(15.75") is recommended but not required.

500 mm / 20 in. 400 mm / 15.75 in.

Front view

Top view

1000 mm / 39.4 in. 1000 mm / 39.4 in.

Air-cooled ACS 1000 Water-cooled ACS 1000

Figure A-1 ACS 1000 Free Space Requirements

For cabinet dimensions refer to Appendix C - Dimensions and Weights.

76 / 104 ACS 1000 Technical Catalog


Appendix A - Installation Guidelines

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

2846 78

800
37.5 2856 78
20

12

Figure A-2 Foundation Plan with Position of Anchoring Holes: ACS 1000
12-Pulse / 24-Pulse, Air-Cooled

585.5 2760/3260 * 802.5


1080.5

38
685

800
70
181
432
50
20

12

Figure A-3 Foundation Plan with Position of Anchoring Holes: ACS 1000
12-Pulse, Water-Cooled

Figure A-4 Foundation Plan with Position of Anchoring Holes: ACS 1000
24-Pulse, Water-Cooled

ACS 1000 Technical Catalog 77 / 104


Appendix A - Installation Guidelines

The cabinet should be fixed with anchor bolts and lock washers (recom-
mended size M12, not part of supply) as shown in Figure A-5 below. The
anchor holes in the base mounting channels can be accessed through the
cabinet.

Anchoring Holes

Figure A-5 Cabinet Mounting with Bolts and Lock Washers

Floor Levelling and • The ACS 1000 cabinet must be installed in upright position.
Cable Ducts
• The maximum allowable overall unevenness is ≤ 5 mm. If the floor is
uneven, it must be levelled.
• The floor must be of non-flammable material, with smooth and non-
abrasive surface, protected against humidity diffusion and able to
support the weight of the converter (min. 1’000 kg/m2).
• Cable ducts must be of non-flammable material, with non-abrasive
surface and protected against humidity, dust and penetration of
animals.

Power Equipment Installation

General
The connection from the mains supply to the ACS 1000 drive consists of
six basic elements:
• Main circuit breaker / controller
• Instrumentation and protection equipment
• Transformer primary cables
• Transformer
• Transformer secondary cables
• Cable termination - ACS 1000.
Recommendations for the installation of each of these elements are given
below. All applicable manufacturer’s instructions and local regulations
must be followed when installing this equipment. If any specific instruction

78 / 104 ACS 1000 Technical Catalog


Appendix A - Installation Guidelines

as stated in this manual appears to be in conflict with the requirements,


please contact your local ABB representative for further assistance.
For information regarding Main Circuit Breaker / Controller,
Instrumentation and Protection Equipment refer to Chapter 6 - Standard
Functions and Chapter 8 - Selecting the Drive System.

Transformer Primary Cables


The cables from the Main Circuit Breaker (MCB) to the Transformer
primary side has no special requirements. It should carry a voltage rating
consistent with the voltage present in the primary circuit. The ampacity
rating should be consistent with the size of the transformer being supplied
and the protection settings of the protection equipment. Derating of cable
ampacity in accordance with maximum expected ambient temperature,
raceway fill factors and any other factors required by local electrical codes
should be applied. Installation should be in compliance with standard
industrial practice for medium voltage equipment.
If required by local electrical code, an equipment safety ground wire
should be supplied either separately or by including it in the 3- core cable.
The ampacity of this conductor should be in accordance with the code.

Transformer Secondary Cables


The cables from the transformer secondary windings to the ACS 1000
main power input buses, are exposed to common mode voltages, resulting
from normal inverter operation. For this reason it is necessary to use
cables rated for insulation levels of 5 kV (phase to earth) or higher for all
transformer secondary connections, regardless of the transformer
secondary voltage level (1327 V, 1903 V, or 2305 V). Cables rated for 5 kV
are typically used in North America, in Europe and Asia cables rated for
6kV/10 kV are common.
In order to insure compliance with EMC requirements and to provide a low
impedance, high frequency path through which the common mode
currents can flow, a shielded cable is recommended. Shields should be
terminated and grounded at the shortest possible way at both cable
termination points. The ACS 1000 includes a vertical ground bus within
the cable termination section in order to facilitate above requirement.
A non-shielded cable with a continuous corrugated aluminum armor may
be used as an alternative to the shielded cable described above. Steel
wire armored or interlocked aluminum armored cables without extra shield
should not be used. Cable terminal ends with electrical contact all around
its periphery to the armor should be used to terminate the cable ends to
the ground.
The ampacity rating of the cable should be in consistency with 125% of the
transformer nominal output current and the settings of the protection
equipment in order to allow for the harmonic content. Derating of cable
ampacity in accordance with maximum expected ambient temperature,
raceway fill factors and any other factors required by local electrical codes

ACS 1000 Technical Catalog 79 / 104


Appendix A - Installation Guidelines

should be applied. Installation should be in compliance with standard


industrial practice for medium voltage equipment.
If required by local electrical code, an equipment safety ground wire
should be supplied separately. The ampacity of this conductor shall be in
accordance with the code.
For information regarding the maximum length of the transformer
secondary cables see Appendix B - Technical Data.

Motor Cables
There are no special requirements to be considered for the motor cables.
The maximum cable length is limited to 1000 m (3281 ft). A voltage rating
consistent with the voltage present at the motor must be selected. The
ampacity rating should be consistent with the size of the motor being
supplied and the overload settings of the motor protection software.
Derating of cable ampacity in accordance with maximum expected
ambient temperature, raceway fill factors, and any other factors required
by local electrical codes should be applied. Installation should comply with
standard industrial practice for medium voltage equipment.
Cable screening is not required for the motor cables, since the converter
output voltage and current are sinusoidal. Therefore no measures against
common mode currents are needed.
If required by local electrical code an equipment safety ground wire should
be supplied separately. The ampacity of this conductor shall be in accor-
dance with the code.
Motor cables are terminated within the ACS 1000 cabinet in the same way
as the transformer secondary cables (see Figure A-6).

Power Cable Dimensions


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

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

Auxiliary Power Cables


A 3-phase cable without neutral connector is required for auxiliary power
supply. Type and ratings are to be selected according to local regulations.
For ratings see also Appendix B - Technical Data.

80 / 104 ACS 1000 Technical Catalog


Appendix A - Installation Guidelines

Control Cables
Control cables should be in accordance with Table A-2. Cable shields
should be terminated on the ACS 1000 end only. Either single or multiple
twisted pair cables may be used.
Table A-2 Control cable requirements

Cross-Section
Signal Type General Cable Type
(I/O Termination)

Analog In Twisted pair(s) - Overall Shield 0.5 to 2.5 mm2 /


AWG 20 to AWG 12

Analog Out Twisted pair(s) - Overall Shield 0.5 to 2.5 mm2 /


AWG 20 to AWG 12

Digital In Twisted pair(s) 0.5 to 2.5 mm2 /


AWG 20 to AWG 12

Digital Out Twisted pair(s) 0.5 to 2.5 mm2 /


AWG 20 to AWG 12

Cable Routing

Power Cables Routing of mains and motor cables must be carried out in compliance with
the local regulations and according to the specifications and recommen-
dations of the cable manufacturer.
• For best EMC performance, shielded three phase cables are
recommended.
• If single phase cables are used, the cables with the three different
phases must be grouped close together to ensure best EMC
performance.
• Phase interchange must be accomplished according to local
regulations.
• For high power ratings, a maximum of two cables per motor phase
can be accommodated by the gland plates of the ACS 1000.
• If the cross-section of the cable shielding is less than 50% of the
cross-section of one phase, an additional grounding wire should be
laid along the power cables to avoid excessive heat losses in the ca-
ble shieldings. Please refer to the local regulations for further details.

Cable Termination Cables must be terminated with connectors according to the cable manu-
facturer’s requirements.

Grounding Wire Routing of the grounding connection must comply with local regulations.

Control Cables Control cables should not be laid in parallel to the power cables. If this
cannot be avoided, a minimum distance of 30 cm (12 inches) must be
maintained between control and power cables.
Control and power cables should be crossed at an angle of 90°.

ACS 1000 Technical Catalog 81 / 104


Appendix A - Installation Guidelines

ACS 1000 Cable Entry and Termination


Access to the power termination section of the ACS 1000 is via the control
cabinet, located on the left of the converter. A bolted access door is
located behind the control swing frame. Once the access door is opened
all power terminations are readily available. As an aid to interfacing the
main power connections, removable bus stubs are included.
Figure A-6 shows a typical example of how transformer and motor cables
are connected to the internal bus system of the ACS 1000.
Cables can be entered through the cabinet roof or from the bottom. If the
cable entry is from below, the gland plates mounted on top of the cable
termination section must be relocated to the bottom and the bottom cover
plate must be fixed to the top of the cabinet.

2U1
Front Side
of Cabinet 2V1
2W1
U2
V2
W2
1U1
1V1
1W1

Side View Front View

Figure A-6 Principle of Power Cable Entry (Water-Cooled Type)

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Appendix A - Installation Guidelines

Table A-3 Maximum Number of Cables per Phase

2.3 kV 3.3 kV 4.0 kV

A1 1 1 1

A2 2 1 1

A3 2 2 1

W1 - 2 2

W2 - 2 2

W3 - 3 2

The figures indicated in Table A-3 are valid for transformer and motor
cables. The maximum cable diameter (to fit through the gland holes) is
45 mm.

Transformer Connection Diagram for 12-Pulse ACS 1000

PE
Transformer
Factory
Ground

a1 b1 c1 a2 b2 c2

Shielding Armouring

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

Factory
Ground

PE
ACS 1000

Figure A-7 Typical 3-Line Transformer Connection Diagram.

ACS 1000 Technical Catalog 83 / 104


Appendix A - Installation Guidelines

Transformer Connection Diagram for 24-Pulse ACS 1000

PE
Transformer
Factory
Ground

a1 b1 c1 a2 b2 c2 a3 b3 c3 a4 b4 c4

Shielding Armouring

1U1 1V1 1W1 2U1 2V1 2W1 3U1 3V1 3W1 4U1 4V1 4W1

Factory
Ground

PE ACS 1000

Figure A-8 Typical 3-Line Transformer Connection Diagram

Motor Connection Diagram for 12 / 24-Pulse ACS 1000

ACS 1000

Factory V2
Ground U2 W2
PE

V
U W
Factory PE
M
Ground

Figure A-9 Typical 3-Line Motor Connection Diagram

84 / 104 ACS 1000 Technical Catalog


Appendix B - Technical Data

Transformer Connection / Converter Input

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

Secondary Side Transformer secondary side / converter input voltages (no load) for
Voltage 12 / 24-pulse ACS 1000:
• 1327 VAC, ± 10% for 2.3 kV motors
• 1903 VAC, ± 10% for 3.3 kV motors
• 2305 VAC, ± 10% for 4.0 kV motors
Safe operation with reduced output power is possible down to -25%.

Phase Shift Phase shift between transformer secondary windings:


• 30° for 12-pulse ACS 1000
• 15° for 24-pulse ACS 1000

Frequency Range 50 / 60 Hz

Voltage Unbalance max. ± 2% (Umax - Umin ) / Uavg

Fundamental Power cos ϕ1 > 0.97


Factor

Total Power Factor cos ϕT > 0.95

Transformer Depending on the presence of a Common Mode Choke (CMC) in the


Secondary Cables ACS 1000, the maximum permitted length for the transformer secondary
cables is as follows:
Table B-1 ACS 1000 without CMC

ACS 1000 Types Rectifier Type Max. cable length

Air-cooled 12-pulse 30 m (98 ft)

Water-cooled 12-pulse 30 m (98 ft)

Air-cooled 24-pulse 20 m (66 ft)

Water-cooled 24-pulse 20 m (66 ft)

ACS 1000 Technical Catalog 85 / 104


Appendix B - Technical Data

Table B-2 ACS 1000 with CMC

ACS 1000 Types Rectifier Type Max. cable length

Air-cooled 12-pulse 200 m (656 ft)

Water-cooled 12-pulse 200 m (656 ft)

Air-cooled 24-pulse Not available with CMC

Water-cooled 24-pulse 150 m (492 ft)

Converter Output / Motor Connection

Nominal Voltage UNom: 2.3 kVAC, 3.3 kVAC, 4.0 kVAC

Operational Voltage UOut: 0…UNom, 3-phase, sinusoidal, symmetrical

Output Frequency 0...66 Hz (optional: 0...82.5 Hz)

Frequency Resolution 0.01 Hz

Short Term Overload 1 min/10 min: 110% of rated current


Capacity

Field Weakening Point ≥ 45 Hz

Switching Frequency 1 kHz (3-level inverter, operating at 2 x 500 Hz)

Maximum Motor Cable 1000 m (3281 ft)


Length

Acceleration Time 0…1800 s

Deceleration Time 0…1800 s

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

Auxiliary Supply

Auxiliary Voltage Level • 400 VAC, 50 or 60 Hz, 3 phase ± 10% or


• 480 VAC, 60 Hz, 3 phase ± 10% or
• 575 VAC, 60 Hz, 3 phase ± 10%

86 / 104 ACS 1000 Technical Catalog


Appendix B - Technical Data

Auxiliary Power Table B-3 Auxiliary Power Consumption


Consumption
Air-Cooled Types Water-Cooled Types Power Consumption

ACS1012-A1 5.3 kW *
ACS1013-A1
ACS1014-A1

ACS1012-A2 7.3 kW*


ACS1013-A2
ACS1014-A2
ACS1012-A3
ACS1013-A3
ACS1014-A3

ACS1012-W1 4.3 kW *
ACS1013-W1

ACS1012-W2 4.6 kW *
ACS1013-W2
ACS1013-W3
ACS1014-W2
ACS1014-W3

ACS1014-W1 4.9 kW *

*) without optional heaters / coolers

Environmental Aspects

Ambient Temperature The permitted temperature range for the ACS 1000 is:
• +1…+40 °C (34…104 °F) for air-cooled types
Note: If the temperature is higher than +40 °C (+104 °F) the output
power of the air-cooled ACS 1000 types decreases. For derating
factors see section Derating of Drive Power, page 88.
• +1…+50 °C (34…122 °F) for water-cooled types

Contamination Levels The maximum permitted contamination levels for printed circuit boards
without coating, installed in the ACS 1000, comply with the following stan-
dards:
• IEC 721-3-3, Class 3C2 for chemical gases
• IEC 721-3-3, Class 3S2 for solid particles.

Installation Site Altitude The maximum possible installation site altitude for the ACS 1000 is:
• 5500 m (18045 ft) above sea level for 2.3 kV motor voltage
• 4000 m (13124 ft) above sea level for 3.3 kV motor voltage
• 3000 m (9843 ft) above sea level for 4.0 kV motor voltage.
Note: If the installation site is more than 2000 m (6562 ft) above sea level
the derating of the output power needs to be considered for the air-cooled

ACS 1000 Technical Catalog 87 / 104


Appendix B - Technical Data

ACS 1000 types. For derating factor see section Derating of Drive Power,
page 88.
Water-cooled types do not have a derating for the installation site altitude.

Relative Humidity The permitted ranges for relative humidity are:


• 5…95%, no condensation is allowed
• 5…60%, if corrosive gases are present.

Vibration The ACS 1000 can be exposed to the following maximum values for vibra-
tion:
• 0.3 mm (2…9 Hz)
• 1 m/s2 (2…200 Hz), sinusoidal (according to IEC 721-3-3).

Sound Pressure Level • < 75 dB (A) for air-cooled types


• < 70 dB (A) for water-cooled types.

Derating of Drive Power

Air-Cooled Converters

Ambient Temperature The derating factor for air-cooled converters with enclosure class IP21 is
as follows:
Above +40 °C (+104 °F) the rated output current is decreased by 1.5 %
for each additional 1 °C (0.85 % for each 1 °F) up to the maximum
permitted temperature of +45 °C (+113 °F).
Example: If the ambient temperature is 45 °C the derating factor is calcu-
lated as 100% - 1.5 %/°C · 5 °C = 92.5%. Hence, the maximum output
current is 92.5% of the rated value.

Derating for Air Filters Depending on the mesh size of the filter mat the derating factors as stated
in Table B-4 apply to the rated output power:
Table B-4 Derating Factors for Air Filters:

Mesh Size Remark Derating in %

18 µm Standard 0

12 µm Option 5

10 µm Option 10

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

88 / 104 ACS 1000 Technical Catalog


Appendix B - Technical Data

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

Water-Cooled Converters

Derating for Raw Water If the raw water temperature exceeds 27 °C (81 °F) the derating factors as
Temperature stated in Table B-5 apply to the rated output power:
Table B-5 Derating Factors for Raw Water Temperature

Rated Motor Cooling Water Derating


Converter Type
Power (kW) Inlet Temp. Range in % / K

ACS1013-W1 2000…2500 27°C to max. 38°C 0

ACS1013-W2 2800…4000 27°C to max. 38°C 0

ACS1013-W3 4500…5000 27°C to max. 38°C 0.4

ACS1014-W1 1800…2250 27°C to max. 38°C 0.6

ACS1014-W2 2500…3550 27°C to max. 38°C 0

ACS1014-W3 4000…5000 27°C to max. 38°C 1.35

Derating for If glycol is added to the make-up water, the derating factors as stated in
Frostproofing Table B-6 apply to the rated output power:
Table B-6 Derating Factors for Glycol

Frostproofing Glycol Concentration Derating in %

- 10°C 20 % 4.5

- 20°C 34 % 7

- 30°C 44 % 9

- 40°C 52 % 11.5

Transportation and Storage

Storage Temperature -25…+55 °C (-13…+131 °F), class 1K4 (IEC 721-3-1)

Transportation -25…+55 °C (-13…+131 °F), class 2K3 (IEC 721-3-2)


Temperature
up to 70 °C (158 °F) for up to 24 hours

Relative Humidity 5...95%, class 1K3 (IEC 721-3-1)


(Storage)

Relative Humidity < 95% at +40 °C (+110 °F)


(Transportation)

ACS 1000 Technical Catalog 89 / 104


Appendix B - Technical Data

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

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

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

Cooling

Air-Cooled Converters

Cooling Method Air cooling with internal fan

Power Losses < 2 % of nominal output power

Cooling Air Flow • 1.7 m3/s (3600 cu ft/min) for ACS 1000 - A1
• 2.5 m3/s (5300 cu ft/min) for ACS 1000 - A2/A3

Water-Cooled Converters

Cooling Method Water-cooled closed loop system with superimposed closed circuit air
cooling.

Heat Dissipation to approx. 1 kW


Environment

Raw Water +4…+27 °C (+40…+80 °F)


Temperature

Raw Water Pressure 1…10 bar (14.22…144.2 lb/sq in)

Extended Raw Water +27…+38 °C


Temperature

Raw Water Flow • ≥ 80 l/min (21.1 gal/min for ACS 1000 - W1) or
• ≥ 150 l/min (39.6 gal/min for ACS 1000 - W2/W3)

90 / 104 ACS 1000 Technical Catalog


Appendix B - Technical Data

Water Quality Table B-7 Make-up Water (Drinking Water) Quality Requirements

Parameter Value

pH 6 – 8.5

conductivity < 300 µS / cm

hardness 3 – 10 dH

chloride (Cl) < 100 mg/l

copper (Cu) < 0.1 mg/l

total dissolved solids (TDS) < 300 mg/l

suspended solids < 5 mg/l

Table B-8 Raw Water (Industrial Water) Quality Requirements

Parameter Value

pH 6–9

conductivity < 500 µS / cm

hardness 3 – 15 dH

chloride (Cl) < 300 mg/l


above 300 mg/l titanium stabilized
exchanger plates are required

total dissolved solids (TDS) recommended: < 300 mg/l


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

suspended solids < 10 mg/l

Protection Functions

The drive provides a wide range of protection, fault and alarm functions
including:
• Motor temperature monitoring
• Motor stall
• Underload
• Overspeed
• Undervoltage
• Battery condition monitoring
• Motor phase loss
• Overvoltage

ACS 1000 Technical Catalog 91 / 104


Appendix B - Technical Data

• Short circuit in the rectifier bridge


• Charging fault
• Supply phase loss
• Overcurrent
• Short circuit of the inverter
• Measurement loss
• Communication fault
• Cooling circuit monitoring (water-cooled converters)
• Earth fault monitoring

Analog Inputs

Analog Input (AI) Floating, galvanically isolated inputs


• Signal Level: 0…20 mA / 4…20 mA or 0…10 V / 2…10 V,
individually scalable by parameter setting
• Input Resistance: Rin = 100 Ω for current input
Rin = 210 kΩ for voltage input

Common Mode Voltage max. 48 V

Isolation Voltage 350 VAC

Common Mode > 80 dB at 50 Hz


Rejection Ratio

Resolution 0.1% (10 bit)

Accuracy ± 0.25% (Full Scale Range) at 25 °C (±30 mV offset)


Protection No internal damage up to 250 VAC/DC input voltage (for voltage inputs)

Input Updating Time 100 ms (with standard application software)

Terminal Block Size Cables 0.5…2.5 mm2 (up to AWG12)

Analog Outputs

Analog Output (AO) Floating, galvanically isolated outputs

Signal Level 0…20 mA / 4…20 mA individually scalable by parameter setting

Isolation Voltage 350 VAC

Resolution 0.03% (12 bit)

Accuracy ± 0.25% (Full Scale Range) at 25 °C (± 50 µA offset)

92 / 104 ACS 1000 Technical Catalog


Appendix B - Technical Data

Max. Load Impedance 250 Ω

Protection No internal damage up to 250 VAC/DC input voltage, short circuit proof

Output Updating Time 250 ms (with standard application software)

Terminal Block Size Cables 0.5…2.5 mm2 (up to AWG12)

Digital Inputs

Digital Input (DI) Floating, galvanically isolated inputs (opto-coupled)

Signal Level 22…250 VAC / 22…150 VDC

Logical Thresholds < 12 VAC/DC “0”, > 20 VAC/DC “1”

Input Current at 24 V: 13 mA at 250 V, 10 mA

Filtering Time Constant 20 ms

Isolation Individually isolated

Isolation Test Voltage (for 1minute) 2300 VAC input / input


1350 VAC input / logic
1350 VAC input / ground

Input Updating Time 250 ms (with standard application software)

Terminal Block Size Cables 0.5…2.5 mm2 (up to AWG12)

Digital Outputs

Digital Output (DO) With switch-over contact (SPDT)

Switching Capacity • AC: 6 A switching, 4 A steady state up to 250 V


• DC: at 24 V: 8 A, at 48 V: 1A, at 120 V: 0.4 A

Contacts Encapsulated Contacts

Isolation Voltage 4 kVAC, 1 minute

Output Updating Time 250 ms (with standard application software)

Terminal Block Size Cables 0.5…2.5 mm2 (up to AWG12)

ACS 1000 Technical Catalog 93 / 104


Appendix B - Technical Data

Auxiliary Power Output

Voltage 24 VDC +15% / -10%

Maximum Current 180 mA (per I/O-board)

Protection Short circuit proof

Terminal Block Size Cables 0.5…2.5 mm2 (up to AWG12)


This voltage can be used for the digital inputs of ACS 1000 and / or to
supply external measurement transmitters for analog inputs.
An external 120 VAC / 240 VAC supply can be used instead of the internal
24 VDC supply.

Reference Voltage Output

Voltage 10 VDC ±10%

Maximum Current 10 mA

Protection Short circuit proof

Terminal Block Size Cables 0.5…2.5 mm2 (up to AWG12)


This reference voltage can be employed to supply external potentiometers
used for reference values.

DDCS Fiber Optical Link

High speed, DDCS protocol fiber optic serial data bus.

Connectors A pair of fiber optic connectors (transmitter and receiver)

Fiber Optic Cable Plastic core optic fiber, Ø 1 mm (0.04 in), max. length 10 m (33 ft), min.
bend radius 25 mm (1 in) (short-term) or 35 mm (1.4 in) (long-term)

Enclosures

Standard Enclosure IP21 (for air-cooled types)


Classes
IP31 (for water-cooled types)

94 / 104 ACS 1000 Technical Catalog


Appendix C - Dimensions and Weights
Dimensions and weights of the basic ACS 1000 cabinets are given in
Table C-1 to Table C-3. The dimensions and weights of additional equip-
ment and converter options are given in Table C-4.

Table C-1 Dimensions and Weights of 12/24-Pulse ACS 1000 Air-Cooled and 12-Pulse ACS 1000
Water-Cooled (24-Pulse ACS 1000 Water-Cooled see Table C-4)
Motor Voltage 2.3 kV

Motor Type
Voltage Converter Type of Dimensions and Weights
(kV) Cooling

Length Depth Height Weight**

(mm) (ft/in) (mm) (ft/in) (mm) (ft/in) (kg) (lbs)

2.3 ACS1012-A1-A0-00 Air

2.3 ACS1012-A1-B0-00 Air

2.3 ACS1012-A1-C0-00 Air

2.3 ACS1012-A1-D0-00 Air

2.3 ACS1012-A1-E0-00 Air

2.3 ACS1012-A1-F0-00 Air

2.3 ACS1012-A1-G0-00 Air

2.3 ACS1012-A1-H0-00 Air 3000 9’10’’ 900 3’0’’ 2005 6’7’’ * 1600 3530

2.3 ACS1012-A2-J0-00 Air

2.3 ACS1012-A2-K0-00 Air 3000 9’10’’ 900 3’0’’ 2005 6’7’’ * 1750 3860

2.3 ACS1012-A3-L0-00 Air

2.3 ACS1012-A3-M0-00 Air Please contact ABB


2.3 ACS1012-A3-N0-00 Air

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


**) approximate values

ACS 1000 Technical Catalog 95 / 104


Appendix C - Dimensions and Weights

Table C-2 Dimensions and Weights of 12/24-Pulse ACS 1000 Air-Cooled and 12-Pulse ACS 1000
Water-Cooled (24-Pulse ACS 1000 Water-Cooled see Table C-4)
Motor Voltage 3.3 kV

Motor Type
Voltage Converter Type of Dimensions and Weights
(kV) Cooling

Length Depth Height Weight**

(mm) (ft/in) (mm) (ft/in) (mm) (ft/in) (kg) (lbs)

3.3 ACS1013-A1-A0-00 Air 3000 900 2005 1600

3.3 ACS1013-A1-B0-00 Air 3000 900 2005 1600

3.3 ACS1013-A1-C0-00 Air 3000 900 2005 1600

3.3 ACS1013-A1-D0-00 Air 3000 900 2005 1600

3.3 ACS1013-A1-E0-00 Air 3000 900 2005 1600

3.3 ACS1013-A1-F0-00 Air 3000 900 2005 1600

3.3 ACS1013-A1-G0-00 Air 3000 900 2005 1600

3.3 ACS1013-A1-H0-00 Air 3000 9’10’ 900 3’0’’ 2005 6’7’’ * 1600 3530

3.3 ACS1013-A2-J0-00 Air 3000 900 2005 1750

3.3 ACS1013-A2-K0-00 Air 3000 900 2005 1750

3.3 ACS1013-A2-L0-00 Air 3000 900 2005 1750

3.3 ACS1013-A2-M0-00 Air 3000 900 2005 1750

3.3 ACS1013-A2-N0-00 Air 3000 ’ 900 2005 1750

3.3 ACS1013-A2-P0-00 Air 3000 9’10’ 900 3’0’’ 2005 6’7’’ * 1750 3860

3.3 ACS1013-A3-Q0-00 Air

3.3 ACS1013-A3-R0-00 Air 3000 9’10’ 900 3’0’’ 2005 6’7’’ * 2000 4410

3.3 ACS1013-W1-S0-00 Water

3.3 ACS1013-W1-T0-00 Water

3.3 ACS1013-W1-U0-00 Water 4200 13’10 902 3’0’’ 2002 6’7’ 3300 7260

3.3 ACS1013-W2-V0-00 Water

3.3 ACS1013-W2-W0-00 Water

3.3 ACS1013-W2-X0-00 Water

3.3 ACS1013-W3-Y0-00 Water

3.3 ACS1013-W3-Z0-00 Water

3.3 ACS1013-W3-10-00 Water 4700 15’5’’ 902 3’0’’ 2002 6’7 3680 8100

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


**) approximate values

96 / 104 ACS 1000 Technical Catalog


Appendix C - Dimensions and Weights

Table C-3 Dimensions and Weights of 12/24-Pulse ACS 1000 Air-Cooled and 12-Pulse-ACS 1000
Water-Cooled (24-Pulse ACS 1000 Water-Cooled see Table C-4)
Motor Voltage 4.0 kV

Motor Type
Voltage Converter Type of Dimensions and Weights
(kV) Cooling

Length Depth Height Weight**

(mm) (ft/in) (mm) (ft/in) (mm) (ft/in) (kg) (lbs)

4.0 ACS1014-A1-A0-00 Air

4.0 ACS1014-A1-B0-00 Air

4.0 ACS1014-A1-C0-00 Air

4.0 ACS1014-A1-D0-00 Air

4.0 ACS1014-A1-E0-00 Air

4.0 ACS1014-A1-F0-00 Air

4.0 ACS1014-A1-G0-00 Air

4.0 ACS1014-A1-H0-00 Air 3000 9’10’’ 900 3’0’’ 2005 6’7’’ * 1600 3530

4.0 ACS1014-A2-J0-00 Air

4.0 ACS1014-A2-K0-00 Air 3000 9’10’’ 900 3’0’’ 2005 6’7’’ * 1750 3860

4.0 ACS1014-A3-L0-00 Air

4.0 ACS1014-A3-M0-00 Air

4.0 ACS1014-A3-N0-00 Air 3000 9’10’’ 900 3’0’’ 2005 6’7’’ * 2000 4410

4.0 ACS1014-W1-P0-00 Water

4.0 ACS1014-W1-Q0-00 Water 4200 13’10 902 3’0’’ 2002 6’7’’ 3300 7260

4.0 ACS1014-W2-R0-00 Water

4.0 ACS1014-W2-S0-00 Water

4.0 ACS1014-W2-T0-00 Water

4.0 ACS1014-W2-U0-00 Water

4.0 ACS1014-W3-V0-00 Water

4.0 ACS1014-W3-W0-00 Water

4.0 ACS1014-W3-X0-00 Water 4700 15’5’’ 902 3’0’’ 2002 6’7’’ 3680 8100

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


**) approximate values

ACS 1000 Technical Catalog 97 / 104


Appendix C - Dimensions and Weights

Table C-4 Dimensions and Weights of the ACS 1000 and Optional Equipment

Description Dimensions and Weights

ACS 1000 Length Depth Height Weight**


Type (mm) (ft/in) (mm) (ft/in) (mm) (ft/in) (kg) (lbs)

Air-exhaust fan cover Air-cooled 654 2’ 2"** 733 2’ 5" 278 - -

Redundant cooling fan unit Air-cooled 2000 6’ 7""* 870 2’10"" 800 300 660

Braking chopper 644 2’ 1" 902 3’ 2005/ 6’ 7"/ 460 1012


(placed on the right side) 2070* 6’ 10"*

Synchronous bypass 644 2’ 1" 902 3’ 2005/ 6’ 7"/ 460 1012


(placed on the left side) 2070* 6’ 10"*

24-pulse extension Water- 844 2’ 9""* 902 3’ 2005/ 6’ 7"/ 350 770
(placed on the left side) cooled 2070* 6’ 10"*

Redundant fan unit Water- 650 2’ 2" 865 2’10"" 312 1’ ** 100 220
cooled

*) including lifting lugs


**) approx. values

98 / 104 ACS 1000 Technical Catalog


Appendix D - Applicable Codes and Standards

CE Marking

The ACS 1000 frequency converter is marked with a CE symbol. The CE


marking indicates that the ACS 1000 complies with the basic technical
requirements and conformity valuation criteria and is an essential
requirement of the relevant EC Directives.
The CE marking is mainly for the benefit of authorities throughout the
Common European Market.

Low Voltage Directive


Low Voltage Directive73/23 EEC modified by 93/68 EEC.
This directive concerns all electrical equipment with nominal voltage levels
of 50..1000 VAC and 75..1500 VDC.
The aim of the directive is to protect against electrical, mechanical, fire and
radiation hazards. It tries to insure that safe products are placed on the
market.

Compliance with the The ACS 1000 fully complies with the Low Voltage Directive as far as
Low Voltage Directive enclosure, auxiliary supply and I/O ports are concerned. The Declaration
of Conformity will be enclosed in the ACS 1000 delivery.
The Low Voltage Directive is not applicable for the medium-voltage
section of the ACS 1000. However, the medium-voltage section fulfills the
requirements of the standard EN 50178 (Electronic equipment for use in
power installations).

Machinery Directive
89/392 EEC modified by 91/368; 93/44, 93/68 and 98/37EEC.
This directive concerns all combinations of mechanically joined compo-
nents, where at least one part is moving.

ACS 1000 Technical Catalog 99 / 104


Appendix D - Applicable Codes and Standards

Compliance with the On its own, the ACS 1000 does not have a functional value to the user: It
Machinery Directive always needs its motor coupled to the driven load before it can function
effectively.
Therefore, the Machinery Directive is not applicable for the ACS 1000.

EMC Directive
89/336 EEC modified by 91/263; 92/31; 93/68 and 93/97EEC.
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/
electronic equipment to operate without problems within an
electromagnetic environment. Likewise, the equipment must not disturb or
interfere with any other neighboring electrical equipment or system.

Emissions
The source of high-frequency emission of frequency converters is fast
switching of IGCTs and control electronics. The high-frequency emission
can propagate by conduction and radiation.

Immunity
Electrical equipment should be immune to high-frequency and low-
frequency phenomena. High-frequency phenomena include electrostatic
discharge (ESD), fast transient burst, radiating electromagnetic field,
conducting radio frequency disturbance and electrical surge. Typical low
frequency phenomena are mains voltage harmonics, notches and
imbalance.

Compliance with the The EMC Directive applies to the ACS 1000 as far as the enclosure, the
EMC Directive auxiliary supply and the I/O ports are concerned. The Declaration of
Conformity for industrial environment signed by ABB is enclosed in the
ACS 1000 delivery. The two applicable standards, EN 50081-2 (Emis-
sions) and EN 50082-2 (Immunity) have been met.
As far as the medium-voltage ports are concerned the EMC Directive is
not applicable. The standard IEC 1800-3: Adjustable speed electrical
power drive systems - Part 3: EMC product standard including specific test
methods, states: “For supply voltages higher than 1000 VAC rms, EMC
requirements result from agreement between manufacturer / supplier and
user.”
In order to make sure that the whole system is electromagnetically
compatible within its surrounding the installation regulations have to be
strictly observed. Following the grounding regulations, instructions for
cable entries as well as for cable laying is extremely important.
The ACS 1000 is installed with screened control and main power supply
cables that are specified in Appendix A - Installation Guidlines.
The installation of the ACS 1000 shall be performed as described in the
ACS 1000 User’s Manual.

100 / 104 ACS 1000 Technical Catalog


Appendix D - Applicable Codes and Standards

UL Marking

The ACS 1000 is UL and Canadian UL listed under "Power Conversion


Equipment", File E176716.

Applicable Codes and Standards

The ACS 1000 Converter complies with the following codes and
standards:
• IEC 22B/88/CD Draft revision of IEC 146-2: Self-
commutated convertors including
direct DC convertors and
IEC 146-3: Semiconductors direct DC
convertors DC chopper convertors
• IEC 146-1-1 Semiconductor convertors
• IEC 529 Degrees for protection provided by
enclosures (IP-Code)
• IEC 664-1 Insulation coordination for equipment
within low-voltage systems
• IEC 721-3-1 A1 Classification of environmental condi-
tions
Part 3: Storage
• IEC 721-3-2 A2 Classification of environmental condi-
tions
Part 3: Transportation
• IEC 721-3-3 A1 Classification of environmental condi-
tions
Part 3: Stationary use at weatherpro-
tected locations
• IEC 1000-4-2 Electrostatic immunity test
- contact discharge 4 kV
- air discharge 8 kV
• IEC 1000-4-4 Fast Transient immunity test
- Aux-Supply Power-Ports:
2 kV, 5 kHz
- Signal-Ports: 2 kV, 5 kHz
• IEC 1000-4-5 Surge immunity test
- Aux-Supply Power Ports
- Line to Line 2 kV
- Line to Earth 4 kV
- Signal-Ports 1 kV

ACS 1000 Technical Catalog 101 / 104


Appendix D - Applicable Codes and Standards

• EN 50081-2 Electromagnetic compatibility (EMC)


generic emission standard part 2:
Industrial environment
• EN 50082-2 Electromagnetic compatibility (EMC)
generic immunity standard part 2:
Industrial environment
• EN 50178 Electronic equipment for use in power
installations
• EN55011; A2 Suppression of Radio disturbances
caused by electrical appliances and
systems
- Aux-Supply Power-Ports
conducted emission 0.15 - 30 MHz
Class A
• ENV 50141 Radio frequency common mode
- Aux-Supply Power-Ports
- Signal-Ports
AM 0.15 - 80 MHz 10 V (rms)
• UL 347 High Voltage Industrial Control Equip-
ment
• UL 347A Medium Voltage Power Conversion
Equipment
Proposed first edition of the standard
• UL 508C Power Conversion Equipment
• IEEE 519 Recommended Practices and
Requirements for Harmonic Control in
Electrical Power Systems

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Appendix E - ACS 1000 Type Code

1 A Product Category
A = AC Drive

2/3 C S Product Type


CS = Standard xx = OEM

4 1 ACS Product Family


1 = ACS 1000

5 Variation
0 = Standard 1 = Non-Standard Options included (to be specified separately)

6 Input Bridge
0 = 6-Pulse Rectifier 1 = 12 Pulse Rectifier 2 = 24 Pulse Rectifier
3 = 12-Pulse Rect. with Integrated Transformer 4 = 24-Pulse Rect. with Integrated Transformer

7 - Voltage Rating
2 = 2.3 kV 3 = 3.3 kV 4 = 4.0 kV 6 = 6.6 kV

8/9 - Frame Size


A1, A2 and A3 for Air Cooled Converters W1, W2 and W3 for Water Cooled Converters

10 Sub-Frame Size See Option Sheet


See ACS 1000 rating tables

11 - Extended Ambient Air / Raw Water Temperature See Option Sheet


0 = None x = extended ambient air / raw water temperature

12 Maximum Output Frequency


0 = 66 Hz (Standard) 2 = 82.5 Hz x = Other options will follow later

13 - Field Weakening
0 = 1 : 1.1 (Standard) 1 = max. FW 1 : 1.2 2 = max. FW 1 : 1.3 3 = max. FW 1 : 1.4
4 = max. FW 1 : 1.5

14 Filter Equipment
F = Sine Filter and Common Mode Choke S = Sine Filter (without Common Mode Choke)

15 Output Filter Choke


Output Filters are motor specifically selected

16/17 - Output Filter Capacitor


Output Filters are motor specifically selected

18 Auxiliary Voltage Rating (indicated values +/- 10%)


1 = 400 VAC / 50 Hz 2 = 480 VAC / 60 Hz 3 = 575 VAC / 60 Hz 4 = 400 VAC / 60 Hz

Example: ACS 1014-A1-B0-00-F101-2…


Note: The ACS 1000 is identified by the type code which represents all stan-
dard features and available options by one of the 36 digits. The type code is
also printed on the name plate of each drive. Options, presently not available,
are shaded on the type code sheet. The example of the type code sheet shows
only a part of the type code. For the complete type code please use the soft-
ware based ACS 1000 configurator tools or contact the factory.

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Appendix E - ACS 1000 Type Code

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