ABB ACS2000 AFE 1MVA User Manual
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ABB ACS2000 AFE 1MVA User Manual

Medium voltage drives
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M E D I U M VO LTAG E D R I V E S
ACS2000 AFE 1MVA
User Manual
+
• High reliability due to proven design and low
parts count
• Fuseless design
• Air-cooled
• Application tailored design
• Softstarter
• Arc resistant design
• Direct torque control
• Power range from 250 to 800 kW

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Summary of Contents for ABB ACS2000 AFE 1MVA

  • Page 1 — M E D I U M VO LTAG E D R I V E S ACS2000 AFE 1MVA User Manual • High reliability due to proven design and low parts count • Fuseless design • Air-cooled • Application tailored design •...
  • Page 2 — ABB Sp. z o.o. System Drives Placydowska 27 95-070 Aleksandrow Lodzki Poland Document name ACS2000 AFE 1MVA User Manual Document number 3BHS297030 ZAB E01 Rev. J Issue date 2020-07...

  • Page 3: Table Of Contents

    — Table of contents Terms, trademarks, related 132 CDP control panel documentation 150 Preventive and corrective General information on manual maintenance and drive Important note on main circuit breaker Safety Power electronics and cabinet features Control system Transportation, storage and disposal Mechanical installation Electrical installation...
  • Page 4 — List of figures Drive system overview INU - Inverter unit MCB opening timing diagram EMC filter Safety labels Terminal compartment Drive overview with input Door locks transformer Fan unit types Single-line diagram of direct- to-line configuration Example of fan group 1 Drive overview with input Example for the operating time of the transformer...
  • Page 5 IOEC modules overview 102 Bolted busbar connection IOEC modules location 103 Control cable entry IOEC module terminals 104 Preparing control cables for EMC plates IOEC module identification 105 Preparing control cables for sealing Location of fieldbus and pulse modules encoder interface 105 Preparing control cables for cable Lifting rails glands...
  • Page 6 170 Replacing filter mats Phase modules location Phase module – Dimensions and weight...
  • Page 7 — List of tables 3-1: IOEC module 3-11: Optional digital input signal configuration allocation 3-2: 24 V internal voltage 3-12: Optional analog input signal supply allocatio 3-3: IOEC module 3-13: Optional analog output signal identification allocation 3-4: Standard analog input 4-1: Transport Conditions signal allocation 4-2: Storage conditions...

  • Page 8: Terms, Trademarks, Related

    Terms, trademarks, related documentation...
  • Page 9 Inverter unit of the drive. The INU converts the DC voltage to the required AC motor voltage and frequency. I/O module Term of ABB’s S800 I/O system. The I/O module is an active input or output device for digital or analog signals. Line voltage...
  • Page 10 Resistance temperature detector or device The RTD is a temperature sensor where the change in electrical resistance is used to measure the temperature. Safeline ABB synonym for uninterruptible power supply Supervisory signal Indicates the operating condition of a circuit or device. Software...
  • Page 11 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — Trademarks Names that are believed to be trademarks of other of the legal status of any trademark. The following companies and organizations are designated as registrations and trademarks are used in this man- such.
  • Page 12 3BHS104785 ZAB E01 ABB MVD ACS Motor Specification 3BHS824803 ZAB E01 Technical project Specification Motor 3BHS824804 ZAB E01 ABB MVD ACS High Performance Motor Spec 3BHS824805 ZAB E01 ABB MVD ACS High Speed Motor Spec 3BHS824806 ZAB E01 ACS2000 power cable specification...
  • Page 13 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J...

  • Page 14: And Drive

    General information on manual and drive...
  • Page 15 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — Copyright notice The information in this manual is subject to change permission from ABB Sp. z o.o. without notice. The hardware and software described in this man- This manual and parts thereof must not be repro-...
  • Page 16 Intended use of equipment Those in charge of the drive must ensure that the spare parts recommended and approved by ABB drive is only used as specified in the contractual must be used.
  • Page 17 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J Quality certificates and applicable standards The following certificates and conformity declara- • EC Conformity Declaration tions are available with ABB: • List of the standards the drive complies with. • ISO 9001 / ISO 14001 certificates stating that...
  • Page 18 GENERAL INFORMATION ON MANUAL AND DRIVE Identifying the delivery The drive and accessories are identified by the type code printed on the rating label (7). The rating label is located on the front of the con- trol compartment door. The label provides information on the type of drive, the rated voltage, the frequency and the current of the main and the auxiliary power supply.
  • Page 19 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J...
  • Page 20 Important note on main circuit breaker...

  • Page 21: Drive System Overview

    ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J The main circuit breaker (MCB) is a major protec- — References tion device of the drive. If a serious fault occurs in — the drive, the MCB must disconnect the main 0-1 Drive system overview power supply to the drive immediately.

  • Page 22: Important Note On Main Circuit Breaker

    ISO 13849-1 Safety of machinery - Safety- meet the stipulated minimum requirements of the related parts of control systems - Part 1: Gen- specifications of ABB MV Drives. It is the system eral principles for design, section 6.2.6 Cate- integrator's responsibility to ensure that the mini- gory 3 mum require-ments are met.
  • Page 23 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J Maintenance recommendation The MCB trip circuits should be checked once yearly.
  • Page 24 Chapter 1 Safety Meaning of safety instructions General safety information Possible residual risks Safety labels Cyber Security Requirements...
  • Page 25 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 1.1 Meaning of safety instructions Safety instructions are used to highlight a potential hazard when working on the equipment. Safety instructions must be strictly followed! Non-compliance can jeopardize the safety of personnel, the equipment and the environment.

  • Page 26: Safety

    CHAPTER 1 – SAFETY — 1.2 General safety information To maintain safety and minimize hazards observe the following: • Before the drive is energized, make sure that: all foreign objects are removed from the drive, all internal and external covers are securely fastened and all doors are closed, locked and / or bolted, the manual release of the safety switches is...
  • Page 27 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 1.3 Possible residual risks The following risks can arise from a drive system and pose a hazard to people. These risks must therefore be taken into account by the system integrator and / or the plant owner when assessing the risks of the machinery.

  • Page 28: Safety Labels

    CHAPTER 1 – SAFETY — 1.4 Safety labels Safety labels are attached to the cabinet to alert personnel of potential hazards when working on the equipment. The instructions on the safety labels must always be followed, and the labels must be kept in a perfectly legible condition.
  • Page 29 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 1.5 Cyber Security Requirements 1.5.1 Cyber Security Disclaimer This product is designed to be connected to and to communicate information and data via a network interface. It is Customer's sole responsibility to provide and...

  • Page 30: Power Electronics And Cabinet

    Chapter 2 Power electronics and cabinet features Overview Power supply configurations Drive topology Terminal compartment Cabinet design Door locking system Cooling system...
  • Page 31 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 2.1 Overview The air-cooled ACS2000 is a general purpose frequency converter for the control of standard induction motors. • ACS2000 for direct-to-line connection (DTL) For information on the power and voltage...

  • Page 32: Drive Overview With Input

    CHAPTER 2 – POWER ELECTRONICS AND CABINET FEATURES — 2.2 Power supply configurations The drive requires two independent power supplies: • Main power supply for the power electronic • Integrated — References components The transformer is placed on the left side of the —...
  • Page 33 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J Direct-to-line connection For applications where the line voltage corre- sponds to the motor nominal voltage, the ACS2000 can be connected direct-to-line by employing input reactors instead of an input transformer. The direct-to-line (DTL) configuration is used for 6 to 6.9 KV line voltages.

  • Page 34: Drive Overview With Input

    CHAPTER 2 – POWER ELECTRONICS AND CABINET FEATURES — 2.3 Drive topology This section describes the main design features and introduces the major power electronics components of a typical ACS2000. — References — 2-3 Drive overview with input transformer IFU - input filter unit DTL compartment (not pres- ent in drives for connection to an input transformer)
  • Page 35 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J 2.3.1 IFU - Input filter unit — References The IFU (2-3: 1) is located between the input trans- — 2-4 IFU - Input filter unit former and the AFE. The IFU is a tuned filter that reduces harmonic voltages injected to the supply network.

  • Page 36: Phase Module

    CHAPTER 2 – POWER ELECTRONICS AND CABINET FEATURES 2.3.3 AFE - Active front end — References The active front end of the drive consists of an rec- — tifier for four quadrant operation. The AFE features 2-5 AFE - Active front end the same electrical design as the INU of the drive.
  • Page 37 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J Phase module — References The AFE consists of three identical phase modules — each housing the series-connected IGBT semicon- 2-6 Phase module ductors, the phase capacitor, the gate drivers, and the interface board for communication with the main control circuit board (AMC circuit board) of the AFE.

  • Page 38: Dc-Link

    CHAPTER 2 – POWER ELECTRONICS AND CABINET FEATURES 2.3.4 DC link — References The DC link consists of the charging unit (not — 2-7 DC-link shown), the capacitor (1), and the grounding switch (2). Charging unit Charging The unit charges the DC-link capacitor and the phase capacitors before the MCB is closed to con- nect the drive to the main power supply.

  • Page 39: Grounding Switch

    ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J Grounding switch — References The grounding switch is a safety device that — enables safe access to the AFE-INU compartment 2-8 Grounding switch — of the drive. 2-9 Grounding circuit When the switch is in position grounded, input fil-...

  • Page 40: Grounding The Drive

    CHAPTER 2 – POWER ELECTRONICS AND CABINET FEATURES Grounding the drive is only possible after the main — References power supply has been disconnected and the DC — link has discharged. When the voltage is below 50 V 2-10 Grounding the drive Grounding Switch (DC), press the pushbutton Unlocked...

  • Page 41: Inu - Inverter Unit

    ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J 2.3.5 INU - Inverter unit 2.3.6 EMC filter — References The INU converts the DC voltage to the required AC The INU includes a three-phase du/dt filter con- — motor voltage and frequency.

  • Page 42: Terminal Compartment

    CHAPTER 2 – POWER ELECTRONICS AND CABINET FEATURES — 2.4 Terminal compartment The terminal compartment provides the terminals for the feeder and motor cables and the ground bus for the termination of the ground cable and the cable screens. The cable entry is prepared in the factory for to the —...
  • Page 43 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 2.5 Cabinet design The riveted and folded cabinet construction of the drive ensures a strong, flexible and self-supporting framework. The construction avoids the need for additional skeletal support and provides effective protection against electromagnetic emissions.

  • Page 44: Door Locks

    CHAPTER 2 – POWER ELECTRONICS AND CABINET FEATURES — 2.6 Door locking system To ensure safety and to prevent the doors being — References opened unintentionally, all doors are lockable, and — the doors of compartments where medium volt- 2-14 Door locks ages are present during operation (2-14: 1, 2, 4) bolted or electromechanically secured.

  • Page 45: Fan Unit Types

    ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 2.7 Cooling system 2.7.1 Fan unit configurations — References The drive and the integrated transformer are each — equipped with fan units. Optionally, the drive and 2-15 Fan unit types...

  • Page 46: Example Of Fan Group

    CHAPTER 2 – POWER ELECTRONICS AND CABINET FEATURES 2.7.2 Function Operating intervals — References Fan groups Parameter setting allows to run one of the two — For control reasons, the fan unit(s) of the drive and fans continuously, or to run the fans alternately in 2-16 Example of fan group 1 the integrated transformer are combined to...

  • Page 47: Air Flow Inside The Drive

    ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J Air flow inside the drive — References The fan group of the cabinet feeds the cooling air — to the main power electronic components and 2-18 Air flow inside the drive transfers the heat to the outside of the cabinet.

  • Page 48: Control System

    Chapter 3 Control system Overview Main components I/O interfaces...
  • Page 49 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 3.1 Overview The control compartment incorporates the hardware for the control, monitoring and protection functions of the drive, and the communication interfaces to the local control panel and to the remote control devices.
  • Page 50 CHAPTER 3 – CONTROL SYSTEM — 3.2 Main components This section provides a short functional overview of the main hardware components of the control system and their interconnection. — References — 3-2 Control compartment Shown is the ACS2000 for connection to an input transformer Control compartment Local control panel —...

  • Page 51: Air Pressure Switches

    ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — References — For information on the devices present in 3-3 Control compartment details the control compartment of the drive, see Appendix D – Wiring diagrams. For 24 V circuits the ATO style blade fuses rated 3 A, 32 V are used.
  • Page 52 CHAPTER 3 – CONTROL SYSTEM 3.2.2 AMC circuit board Control tasks — References Overview Each AMC circuit board has specific control and — The AMC circuit board is the major component of closed-loop tasks assigned to it. 3-4 AMC circuit-boards location the control system of the drive and performs gen- •...

  • Page 53: Direct Torque Control

    ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J Parameters Switching of the semiconductors in the INU is The control system is configured, customized, and directly controlled in accordance with the motor tuned with a set of application parameters. The core variables flux and torque.
  • Page 54 IOEC mod- vide extra inputs and outputs for control and — ules. supervision as may be required by ABB or the cus- 3-7 IOEC modules location The standard I/O includes one external module tomer to support various control options.
  • Page 55 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J IOEC module configuration Each IOEC module is configured with both analog and digital inputs and outputs as shown in Table 3-1. — Table 3-1 IOEC module configuration Analog inputs No. of I/O...
  • Page 56 CHAPTER 3 – CONTROL SYSTEM Module terminals — References The IOEC module has terminal blocks for internal — wiring and indicator LEDs for diagnostic and I/O 3-8 IOEC module terminals status. IOEC DigIn adapters The IOEC modules can be equipped with DigIn adapters U3411 and U3412 to limit the input volt- age to a certain level.
  • Page 57 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J I/O device identification — References The I/O modules are identified on the part with an — 3-9 IOEC module identification label (3-9: 1), in the wiring diagram, identification and in the software by the wiring diagram identifi-...
  • Page 58 CHAPTER 3 – CONTROL SYSTEM 3.3.2 Standard internal IOEC1 (A3401) module Analog inputs — Table 3-4 Standard analog input signal allocation Terminal Channel Default setting Parameter group X31-1 +10 V Internal supply voltage — X32-1 X31-2 AI1+ Freely programmable AI1- X32-2 X31-3 AI2+...
  • Page 59 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J Digital inputs — Table 3-6 Standard digital input signal allocation Terminal Channel Default setting Parameter group X11-1 DI01 Freely programmable X11-2 Common X11-3 DI02 Freely programmable X11-4 Common X11-5 DI03 Freely programmable...
  • Page 60 CHAPTER 3 – CONTROL SYSTEM — Table 3-7 Example for digital input signal allocation Terminal Channel Default setting Parameter group X11-1 DI01 External start / stop request 72.06 – 72.09 X11-2 Common X11-3 DI02 Forward / reverse 72.10 – 72.11 X11-4 Common X11-5...
  • Page 61 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J Analog inputs — Table 3-8 Standard analog input signal allocation Terminal Channel Default setting Parameter group X31-1 +10 V Internal supply voltage — X32-1 X31-2 AI1+ Reference value 1 (speed reference)
  • Page 62 CHAPTER 3 – CONTROL SYSTEM 3.3.4 Optional external IOEC4 (A3431) module Digital outputs — Table 3-10 Optional digital output signal allocation Terminal Channel Default setting Parameter group X21-1 DO01 Freely programmable X21-2 X21-3 X22-1 DO02 Freely programmable X22-2 X22-3 X23-1 DO03 Freely programmable (for motor space heater then...
  • Page 63 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — Table 3-11 Optional digital input signal allocation Terminal Channel Default setting Parameter group X13-9 +24 V 24 V control logic +0 V X13-10 Common Analog inputs — Table 3-12 Optional analog input signal allocatio...
  • Page 64 CHAPTER 3 – CONTROL SYSTEM AF 100 Terminal allocation X1A:1 0 V supply in X1B:1 24 V (DC) supply in X1B:2 24 V (DC) supply out X1B:3 Redundant power supply "A" monitoring input X2:1 + Signal X2:2 - Signal Customer connections X2:3 Shield X2:4...
  • Page 65 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J To identify the adapter type installed in the drive, see the applicable Wiring dia- grams. Communication with AMC circuit board The fieldbus adapter is connected to channel 0 of the AMC circuit board via optical fibers.
  • Page 66 CHAPTER 3 – CONTROL SYSTEM 3.3.6 Pulse encoder interface NTAC (option) Overview The pulse encoder is required for constant torque applications. Terminals X1 Terminals X2 Channel A 24 V Channel B 24 / 25 Channel Z Shield +24 V Communication with AMC circuit board The NTAC module communicates with the AMC cir- cuit board of the INU via a fast optical link using the standard DDCS protocol.
  • Page 67 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J...

  • Page 68: Transportation, Storage And Disposal

    Chapter 4 Transportation, storage and disposal Safety Transport conditions Unpacking and inspection Lifting and transportation Storage Storage and handling of spare parts Disposal of packaging materials and components...
  • Page 69 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 4.1 Safety The drive must only be handled by personnel who are skilled and experienced in unpacking and transporting heavy equipment.
  • Page 70 CHAPTER 4 – TRANSPORTATION, STORAGE AND DISPOSAL — 4.2 Transport conditions The transport conditions for the drive are based on IEC 60721-3-2 'Classification of environmental conditions: Classification of groups of environmental parameters and their severities; Transportation'. — Table 4-1 Transport Conditions 2K12 Climatic conditions Low air temperature -45 °C...
  • Page 71 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 4.3 Unpacking and inspection 1. Remove all packaging material carefully. 2. Check the drive and accompanying equipment for damages. 3. Compare the complete delivery with the pur- chase order and the packing list.
  • Page 72 CHAPTER 4 – TRANSPORTATION, STORAGE AND DISPOSAL — 4.4 Lifting and transportation 4.4.2 Using a crane • Use lifting equipment (eg, web slings, chain It is recommended to have the following slings, round slings, safety hooks, shackles ) information at hand before transporting that corresponds to the weight of the cabinet.
  • Page 73 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J 4.4.3 Using a forklift — References — — 4-3 Transporting the Do not lift drives with DTL com- cabinet by forklift partment by a forklift. • Transport the cabinet only with the short side facing in the driving direction.
  • Page 74 0.1 m/s (5 – 200 Hz) The drive can be stored for up to one year in the original packaging as long as it is not damaged or opened. For information on longer storage periods contact the ABB service organization.
  • Page 75 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 4.6 Storage and handling of spare parts 4.6.1 Storage place conditions 4.6.2 Handling precautions • Temperature range: -5 °C – + 55 °C NOTICE • Free of vibration and shock.
  • Page 76 CHAPTER 4 – TRANSPORTATION, STORAGE AND DISPOSAL — 4.7 Disposal of packaging materials and components Dispose of the packaging materials and the com- ponents at the end of the life time of the drive according to local regulations.
  • Page 77 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J...
  • Page 78 Chapter 5 Mechanical installation Safety Overview on installation work General notes on installation Fixing the cabinet to the floor Installing fan units...

  • Page 79: Safety

    ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 5.1 Safety All installation work must be carried out by qualified personnel according to the site and equipment requirements and in compliance with local regulations.

  • Page 80: Mechanical Installation

    CHAPTER 5 – MECHANICAL INSTALLATION — 5.2 Overview on installation work The installation includes the following work: • Preparing the floor • Fixing the cabinet to the floor • Installing fan units...

  • Page 81: General Notes On Installation

    ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 5.3 General notes on installation 5.3.3 Fire protection Suitable fire protection measures should be NOTICE applied to prevent fire spreading into the drive. Foreign matter and particularly metallic dust can 5.3.4 Cable duct material...

  • Page 82: Fixing The Cabinet To The Floor

    CHAPTER 5 – MECHANICAL INSTALLATION — 5.4 Fixing the cabinet to the floor The cabinet provides a hole in each corner of the — References base for floor fixings. — Insert the screws from the ends of the cabinet 5-1 Fixing the cabinet to the floor base (5-1: A)
  • Page 83 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J —...

  • Page 84: Installing Fan Units

    CHAPTER 5 – MECHANICAL INSTALLATION — 5.5 Installing fan units 2. Use the supplied screws to fasten the fan unit(s) to the fan mounting plate(s) on the cabi- For information on the number of fan net roof. units to be installed and their location on the cabinet roof see the applicable Mechanical drawings.
  • Page 85 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J...

  • Page 86: Electrical Installation

    Chapter 6 Electrical installation Safety Overview of installation work Cable requirements Parallel routing of power cables Terminal sizes Ground cable connection and cable shield connections Cables between integrated transformer and drive Cable entries Power cables, ground cables, equipotential bonding conductor Auxiliary power, control and serial communication cables Control and power supply cables for fan units Final checks...
  • Page 87 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 6.1 Safety WARNING Hazardous voltage! Improper work could lead to life-threatening injury or death. The electrical installation must be carried out by qualified personnel according to the site and equipment requirements, and the relevant electrical codes.
  • Page 88 CHAPTER 6 – ELECTRICAL INSTALLATION — 6.2 Overview of installation work The electrical installation includes the following wire and cable connections: • Cables between integrated transformer and drive • Power cables, ground cables, equipotential bonding conductor • Auxiliary power, control and serial communica- tion cables •...
  • Page 89 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 6.3 Cable requirements For information on the requirements for power cables, ground cable and equipo- tential bonding conductor, see: • ACS2000 power cable specification • Power cables engineering guideline For information on the requirements for...
  • Page 90 CHAPTER 6 – ELECTRICAL INSTALLATION — 6.4 Parallel routing of power cables Independent of the distance between the non-integrated transformer and the drive, and the drive and the motor, one single-core cable per each phase must be used. The current carrying capacity must not be increased by laying cables in parallel.
  • Page 91 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 6.5 Terminal sizes — Table 6-1 Auxiliary power terminal sizes Standard three-phase auxiliary power supply Terminal Wire cross section (mm -X1:1 -X1:3 -X1:5 2.5 to 25 Optional single-phase UPS Terminal...
  • Page 92 CHAPTER 6 – ELECTRICAL INSTALLATION — 6.6 Ground cable connection and cable shield connections The cabinet is equipped with a ground busbar (marked PE, Protective Earth) for grounding the armor and shields of the cables, and for the connection of the ground cable. —...
  • Page 93 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — References — 6-2 Grounding the drive system and non- integrated transformer Input transformer Drive Motor Earth electrode Ground cable Cable screen Cable shield Equipotential bonding conductor —...
  • Page 94 CHAPTER 6 – ELECTRICAL INSTALLATION — 6.7 Cables between integrated transformer and drive Cabling of a drive with an integrated transformer includes the following connections: • Transformer primary and secondary cables control cables in the drive cabinet. — References • Temperature sensor cables —...
  • Page 95 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J 1. Connect the power supply of the heating cable. For further information on power supply connections, see the applicable Wiring diagrams. 2. Connect the heating cables of two adjoining transport units with each other.
  • Page 96 CHAPTER 6 – ELECTRICAL INSTALLATION — 6.8 Cable entries The drive is prepared for top or bottom cable entry with one or a combination of the following cable entries: • Cable entry with EMC plates 6.8.2 Cable entry with sealing modules, type 1 •...
  • Page 97 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 6.9 Power cables, ground cables, equipotential bonding conductor 6.9.1 Further information Preparing the cables for EMC plates The orientation of the EMC plates is the same for See the applicable Mechanical drawings...
  • Page 98 CHAPTER 6 – ELECTRICAL INSTALLATION — References — 6-5 Preparing power cables for EMC plates Outer cable sheath Grommet Entry plate EMC sleeve Conductor insulation removed to expose cable shield Cable tie Conductor screen extension to be connected to PE ground busbar Heat-shrinkable termination —...
  • Page 99 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J Preparing the cables for cable entries with sealing — References modules — 6-6 Preparing power • Prepare cables with an outer cable screen or cables for sealing shield for EMC bonding with the metal enclo-...
  • Page 100 CHAPTER 6 – ELECTRICAL INSTALLATION 6.9.3 Connecting the cables NOTICE Risk of flashover! High voltages will be present in the terminal compartment. High voltages can cause flashover between conductors with different electric potential, and between a conductor and earth. Therefore, maintain a minimum clearance of 55 mm between a conductor and the terminals of any other conductor, and between a conductor and earth.
  • Page 101 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J Connections — References Connect the cables to their corresponding bus- — bars: 6-7 Power cable entry • the feeder cable conductors to busbars U1, V1, • the motor cables to busbars U2, V2, W2, •...
  • Page 102 CHAPTER 6 – ELECTRICAL INSTALLATION Bolted connections Lubrication — References Material requirements • If stainless steel bolts and nuts are used, lubri- — Use stainless steel bolts and nuts with the appro- cate the thread and head contact surface of the 6-8 Bolted busbar connection priate steel grade and property class for the con-...
  • Page 103 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 6.10 Auxiliary power, control and serial communication cables 6.10.1 Further information mation, see utility consumption — References — list of the drive. See Appendix C – Mechanical drawings 6-9 Control cable entry for information on: •...
  • Page 104 CHAPTER 6 – ELECTRICAL INSTALLATION Preparing cables for EMC plates 8. Push the cushions together so they fit tightly Top or bottom cable entry around the bare screen and tighten the screws. 1. Remove the grommets. 2. To ensure proper sealing, cut along the marking that corresponds to the cable diameter.
  • Page 105 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J Preparing cables for cable entries with sealing Preparing cables for cable entries with cable — References modules glands — 1. Unscrew the frame and remove the sealing 6-11 Preparing control •...
  • Page 106 CHAPTER 6 – ELECTRICAL INSTALLATION 6.10.3 Connecting the cables — References IOEC modules — • Connect the cables for digital and analog input 6-13 Shield grounding point for encoder cable and output signals to the IOEC modules. Conductors • If a twisted pair cable is used, leave the unshielded cable ends twisted until they reach the terminals.
  • Page 107 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 6.11 Control and power supply cables for fan units DTL fan units (In drives with DTL operation only) Connect the power supply cable the fan unit to the termi- nals inside the corresponding terminal box (see picture below).
  • Page 108 CHAPTER 6 – ELECTRICAL INSTALLATION DTL fan unit Standard fan unit Power supply cable Terminal box Front cable entry Rear cable entry Cable entry on cabinet roof — 6-11...
  • Page 109 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 6.12 Final checks • Check that the entry plates are properly fas- tened. • If EMC entry plates with grommets are used, check that the grommets fit tightly (arrows) prevent water entering the cabinet. If neces-...

  • Page 110: Commissioning

    Chapter 7 Commissioning Required qualification Commissioning procedure Commissioning check list Customer assistance Customer acceptance...

  • Page 111: Commissioning Check List

    ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 7.1 Required qualification Commissioning, parameter adjustments and functional tests of the drive must be carried out only by commissioning personnel certified by ABB. 7.2 Commissioning procedure Information on the commissioning procedure and the start conditions for commissioning can be obtained from ABB.
  • Page 112 CHAPTER 7 – COMMISSIONING — 7.4 Customer assistance During the commissioning period, the customer is requested to provide qualified personnel for assistance, who are • experienced with medium and low voltage • authorized to operate associated medium and equipment and with the local safety regula- low voltage equipment (eg, main circuit tions, breaker, other low and medium voltage switch-...
  • Page 113 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J...
  • Page 114 Commissioning check list...
  • Page 115 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — Mechanical installation Drive installed according to the instructions in the user manual Drive securely fastened to the floor (if applicable) Fan unit or fan units installed Visual inspection: no badly affixed or damaged components...
  • Page 116 COMMISSIONING CHECK LIST — Door interlocking The manual release of the safety switch is in the locked position Main circuit breaker (MCB) Type of MCB selected as per MCB specification High voltage connections completed MCB ready to be tested with drive MCB protection relay settings tested Safety devices (eg, door locks) tested and in operation Input transformer (if applicable)
  • Page 117 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — Motor Motor installed, aligned and alignment protocol available Motor not coupled to driven load Ground connection completed Motor auxiliaries (eg, bearing lubrication, heater cooling) ready Insulation tests All power cables to input transformer, between input transformer and drive, and from drive to motor mea- sured, measured values within the required limits.

  • Page 118: Operation

    Chapter 8 Operation Operating conditions Safety Overview Overview of local operator panel Status messages Starting the drive Stopping the drive Emergency-off...
  • Page 119 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 8.1 Operating conditions The operating conditions for the drive are according to IEC 60721-3-3 ’Stationary use at weather-protected locations’ (deviations from the standard are indicated). — Table 8-1 Operating conditions...
  • Page 120 CHAPTER 8 – OPERATION — 8.2 Safety The drive must only be operated by qualified and authorized personnel, ie, personnel who are familiar with the operation of the drive and the hazards involved.
  • Page 121 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 8.3 Overview The chapter outlines the local operation of the drive. Control of the drive via a PLC or a higher-level con- trol system is not described in this chapter. If the drive is controlled from remote, see the appropri- ate manuals for information.
  • Page 122 CHAPTER 8 – OPERATION — 8.4 Overview of local operator panel The operator panel on the control compartment door enables the operator to control the drive without restrictions if all requirements for normal operation are met. The functions of the operator panel include: •...
  • Page 123 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J For further information on the CDP control panel, — References Chapter 9 - CDP control panel. — 8-1 Local operator panel 8.4.1 Lamp test The lamp test is activated via the CDP control panel by setting parameter 16.7 to LAMP TEST.
  • Page 124 CHAPTER 8 – OPERATION — 8.5 Status messages 8.5.1 Overview on status messages that the drive is energized and ready for operation. The following section lists the status messages of As soon as the start command is initiated, the the main operating states of the drive, the drive motor is magnetized and the drive starts to modu- passes through, when it is put into operation (see late.
  • Page 125 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J 8.5.2 Start sequence of the drive Not ready on Ready on conditions: ■ Auxiliary power supply on ■ AFE - INU door & closed and locked AFE Ready on ■ Drive not grounded ■...
  • Page 126 CHAPTER 8 – OPERATION 8.5.3 Stop sequence of the drive Operation Ready ref Stop command Stopping Speed ramps down INU stops to modulate Ready run Off command Stop command to AFE MCB opens DC link discharges Fan switches off after a delay AFE Ready on Ready on Actions:...
  • Page 127 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J 8.5.4 Emergency-off sequence of the drive — For the sake of simplicity, the flow diagrams of the AFE are omitted in the above diagrams. Operation Ready ref Emergency-off command Stop command to AFE...
  • Page 128 CHAPTER 8 – OPERATION — 8.6 Starting the drive 8.6.3 Starting the drive locally — It is recommended to have the following The motor is controlled by the documents at hand when starting the drive locally for the first time after com- INU of the drive.
  • Page 129 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J emergency-off switch linked to the drive, is 6. Enter the reference value. pressed. If the EMERGENCY RESET pushbutton For further information, see 9.10.2 Entering a continuous flashing, verify that there is no reference value.
  • Page 130 CHAPTER 8 – OPERATION — 8.7 Stopping the drive Press the STOP key on the CDP control panel. The motor stops according to the preset stop function and the drive stops modulating. While the motor stops, the status line of the display shows ReadyRef.
  • Page 131 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 8.8 Emergency-off 8.8.1 Function 8.8.3 Starting the drive after an emergency-off The drive is equipped with a hard-wired emer- 1. To start the drive after an emergency-off refer- gency-off circuit. When an emergency situation...
  • Page 132 Chapter 9 CDP control panel Overview CDP control panel functions CDP control panel modes Identification mode Actual signals mode Parameters mode Functions mode Drive selection mode Local and remote control Operational commands...
  • Page 133 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 9.1 Overview The panel messages and parameter settings used in this chapter are typical examples to illustrate the related instructions and display functions and may therefore differ from the actual messages and parameter settings in the drive.
  • Page 134 CHAPTER 9 – CDP CONTROL PANEL — 9.2 CDP control panel functions The CDP control panel serves as the basic user interface for operating and monitoring the drive when the local operating mode has been selected. The CDP control panel can be attached to or detached from the drive without having to switch off the auxiliary power supply first.
  • Page 135 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 9.3 CDP control panel modes The CDP control panel provides the following modes: • Identification mode • Actual signals mode • Parameters mode • Functions mode • Drive selection mode...
  • Page 136 CHAPTER 9 – CDP CONTROL PANEL — 9.4 Identification mode The identification mode informs the user about the CDP control panel version and the ID number of the drive. The information appears on the display when: • the power supply is switched on, or •...
  • Page 137 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 9.5 Actual signals mode 9.5.1 Overview Control panel overview Two displays can be selected in the actual signals mode: • Actual signals display • Fault memory display The actual signals display appears first when entering the actual signals mode.
  • Page 138 CHAPTER 9 – CDP CONTROL PANEL 9.5.2 Selecting the actual signals display 3. To enter the actual signal selection function, press the ENTER key. To open the actual signals display, press the key. 1 L -> 600.0 rpm 1 ACTUAL SIGNALS 600.0 rpm 1 L ->...
  • Page 139 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J 9.5.6 Displaying a fault and resetting the fault 9.5.7 Displaying and resetting an active fault history 1. To display an active fault, press the ACT key. 1. To open the actual signals mode, press the ACT key.
  • Page 140 CHAPTER 9 – CDP CONTROL PANEL — 9.6 Parameters mode 9.6.1 Overview If the parameter lock is disabled or unlocked (see NOTICE 9.6.3 Enabling / unlocking a parameter lock), the parameters mode allows entering the parameter Running the drive system with incorrect data can settings for the required drive configuration result in improper operation, reduction of control depending on the application.
  • Page 141 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J Control panel overview 3. To select a parameter, press a slow navigation key. 600.0 rpm 1 L -> 75 OPTION MODULES 07 C3P1/AI820 Module DISABLED 600.0 rpm 1 L -> 77 SYSTEM CONFIG 01 INU IdentifySel 4.
  • Page 142 CHAPTER 9 – CDP CONTROL PANEL 9.6.3 Enabling / unlocking a parameter lock Unwanted parameter entry can be prevented by activating the parameter lock function. The corresponding parameters are 16.02 PARAME- TER LOCK and 16.03 PASSCODE and belong to parameter group 16 SYSTEM CTRL INPUTS. Enabling the parameter lock 1.
  • Page 143 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 9.7 Functions mode 9.7.1 Overview 2. To select the contrast adjustment function, The functions mode is used to set the display con- press the slow navigation keys until the blinking trast.
  • Page 144 CHAPTER 9 – CDP CONTROL PANEL 6. To cancel the setting and keep the original set- ting, press any of the mode selection keys. The selected keypad mode is entered. 1 L -> 0.0 rpm UPLOAD <= <= DOWNLOAD => => CONTRAST 9.7.3 Upload and Download functions The Upload and download functions of the CDP are...
  • Page 145 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 9.8 Drive selection mode 9.8.1 Overview Slow navigation key for selecting the AMC cir- The drive selection mode is used to connect the cuit board (AFE or INU) CDP control panel either to the AMC circuit board Enter key for confirming the selection of the AFE or the INU of the drive.
  • Page 146 CHAPTER 9 – CDP CONTROL PANEL — Do not select LOCAL by pressing the LOC-REM key (arrow) when the CDP control panel is con- nected to the AFE. If the drive is in operation, the AFE stops modulat- ing and the drive shuts down. If the drive is stopped and the CDP control panel is set to LOCAL, the drive cannot be started up.
  • Page 147 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 9.9 Local and remote control The local / remote feature of the CDP control panel allows selecting the control location of the drive. Possible are: • Local control • Partial remote control (some commands •...
  • Page 148 CHAPTER 9 – CDP CONTROL PANEL — 9.10 Operational commands For instructions on how to start and stop the drive system from the CDP control panel, see 8.6 Starting the drive 8.7 Stopping the drive 9.10.1 Setting the direction of rotation 2.
  • Page 149 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J...
  • Page 150 Chapter 10 Preventive and corrective maintenance General information Identifying electrical equipment Alarm / fault indications Removing the CDP control panel LEDs and switches on printed circuit boards and I/O devices Corrective maintenance...

  • Page 151: General Information

    ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 10.1 General information 10.1.1 Required qualification During the warranty period of the drive, any main- tenance must be carried out exclusively by ABB ser- vice personnel. After the warranty period, maintenance must only be carried out by certified personnel.

  • Page 152: Identifying Electrical Equipment

    CHAPTER 10 – PREVENTIVE AND CORRECTIVE MAINTENANCE — 10.2 Identifying electrical equipment 10.2.1 Device identification — References To facilitate the identification in wiring diagrams — and parts lists, all devices are labeled in accor- 10-1 Device identification dance with IEC 81346-1. 10.2.2 Cables and wires Cables and wires in the drive are equipped with marker sleeves that carry the same identification...

  • Page 153: Alarm / Fault Indications

    ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 10.3 Alarm / fault indications 10.3.1 Messages 10.3.2 Error message levels — References When a failure occurs in the drive or in the equip- Two error message levels are used in the drive: —...
  • Page 154 4. Save the content of the data logger when a PC is available that has DriveWindow or DriveDe- bug installed. The data logger provides information (eg, waveforms of voltage, current, torque) for effi- cient troubleshooting. 5. Contact ABB service if a fault cannot be recti- fied.

  • Page 155: Removing The Cdp Control Panel

    ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 10.4 Removing the CDP control panel 1. When the panel is removed while the drive is in 2. To remove the panel, proceed as illustrated. operation, check the setting of parameter 31.01 PANEL LOSS SUPERVISION first.

  • Page 156: Leds And Switches On Printed Circuit Boards And I/O Devices

    CHAPTER 10 – PREVENTIVE AND CORRECTIVE MAINTENANCE — 10.5 LEDs and switches on printed circuit boards and I/O devices The following section provides an overview on the meaning of LEDs and switches of the main circuit boards and I/O devices. The LEDs presented in the following section can be checked easily while the auxiliary voltage is switched on without having to remove covers first.
  • Page 157 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J 10.5.2 IOEC I/O modules — References Cluster address — Each IOEC module has a unique cluster address 10-4 IOEC module that identifies the module in the software and links it to a parameter.
  • Page 158 CHAPTER 10 – PREVENTIVE AND CORRECTIVE MAINTENANCE 10.5.3 Serial communication interfaces (option) To identify the serial communication interface in the drive, see the applicable Wiring diagrams. For further information on the device, select the appropriate manual from the list below: •...
  • Page 159 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J Modbus TCP interface — References — 10-6 NETA-21 remote monitoring tool — Table 10-2 NETA-21 LED description Color Meaning No USB mass storage devices attached Green USB mass storage device attached and mounted...
  • Page 160 CHAPTER 10 – PREVENTIVE AND CORRECTIVE MAINTENANCE — Table 10-2 NETA-21 LED description Color Meaning Blinking yellow Card attached, removal in progress Blinking yellow Together with the blinking red STAT LED: System waits for confirmation of reboot operation or network override Card error, for example write protection prevents from writing data to the card Blinking red Card initialization failed.
  • Page 161 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J Modbus RTU interface — References — 10-7 Modbus RTU interface 1. Bus-cable terminals 2. Fiber-optic connectors for communication cable to the drive TXD = transmitter RXD = receiver 3. Status LEDs 4.
  • Page 162 CHAPTER 10 – PREVENTIVE AND CORRECTIVE MAINTENANCE Profibus interface — References — 10-8 Profibus interface 1. Fiber-optic connectors for communication cable to the drive • TXD = transmitter • RXD = receiver 2. Reset button for initialization of module 3. Status LEDs 4.

  • Page 163: Corrective Maintenance

    ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 10.6 Corrective maintenance 10.6.1 Overview on maintenance tasks 10.6.2 Safety • Visual checks on the drive DANGER • Cleaning • Checking wire and cable connections Hazardous voltages! • Replacing filter mats Before starting to work on the drive, make sure •...
  • Page 164 CHAPTER 10 – PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6.3 De-energizing the drive locally 6. Wait until the yellow lamp GROUNDING SWITCH The following section describes how to de-ener- UNLOCKED lights up. gize the drive using the local operator panel of the The lamp lights up when cooling of the drive drive.
  • Page 165 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J 10.6.4 Grounding switch is not released 9. Verify that the drive system is de-energized. When the DC link of the drive has been discharged, 10. Ground the drive with a grounding set (option).
  • Page 166 CHAPTER 10 – PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6.5 Connecting a grounding set — References 1. Connect the enclosure ground clamp (10-10: 1) — 10-9 Four-way grounding to the ground ball stud of the cabinet’s ground- ing frame. 2. Use the telescopic insulating pole to connect the busbar ground clamps (10-9: 3) to the...
  • Page 167 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J The drive is now dead, and safe access is possible. — References — 10-10 Connecting a grounding set — 10-10...
  • Page 168 CHAPTER 10 – PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6.6 Releasing the door safety switch Unlocking The door of the AFE-INU compartment is secured 1. To access the dial of the door safety switch, by a safety switch. The safety switch is tied into an remove the cap in the control compartment.
  • Page 169 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J 10.6.7 Service covers 10.6.9 Cleaning — References — NOTICE CAUTION 10-11 Service covers High temperature! Risk of component damage! Components inside the drive can be hot. • Dust on electrical components and wiring can Before taking off a service cover on the back of the cause failure and damage the components.
  • Page 170 CHAPTER 10 – PREVENTIVE AND CORRECTIVE MAINTENANCE 10.6.10 Checking wire and cable connections Standard Option Vibration can loosen electrical connections and Thickness 10 mm 20 mm cause occasional malfunction or equipment failure. • Check all power and control cable connections and tighten them if necessary.
  • Page 171 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J 10.6.12 Replacing a phase module — References Phase modules location — 10-13 Phase modules location Module tray Dimensions and weight — 10-14 Phase module – Dimensions and weight Tools The following parts are required for the mainte- nance of the phase modules.
  • Page 172 CHAPTER 10 – PREVENTIVE AND CORRECTIVE MAINTENANCE Replacing a phase module 3. Remove the screws on each side of the phase 1. Disconnect all power supplies to the drive and module. ground the drive. For further information, see 10.6.3 De-energiz- ing the drive locally.
  • Page 173 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J — 6. Disconnect all cables from the Phase-INT-circuit board (1) that are going into the cabinet: This cable is only present in phase Auxiliary power supply cable modules of the AFE.
  • Page 174 CHAPTER 10 – PREVENTIVE AND CORRECTIVE MAINTENANCE 11. When all cables have been reconnected, check 5. Remove the fastening screws from the support that the drive control system and the phase plate and the duct ring. module communicate with each other. Switch on the auxiliary power supply.
  • Page 175 ACS2000 AFE 1MVA UM 3BHS297030 ZAB E01 REV. J 11. Lift off the cover and the fan attached to it. 12. Disconnect the cable at the exit of the terminal box, unscrew the locknut of the cable gland, unscrew the cover from the fan.
  • Page 177 ABB Sp. z o.o., Medium Voltage Drives. The hardware and software described in this manual is provided under a license and may be used, copied, or disclosed only in...

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