for speed and torque control of
315 to 5000 kW / 400 to 6700 hp
squirrel cage induction motors
This document has been checked with care. However, should the user find any errors, they should please be reported to ABB Industrie AG.
The data stated in this manual is for product description purposes and does not represent assured characteristics. As we aim to keep our prod-ucts up to the most modern standard, differences may occur between entries in this technical catalog and the actual product.
Chapter 1 - Overview 7
1.1 Introduction 7
1.2 The Standard Solution 7
1.3 Key Technology 7
1.4 Technical Benefits 8
1.5 ACS 1000 Types 9
Chapter 2 - Main Features 11
2.1 IGCT Power Semiconductors 11
2.2 Fuseless Design 11
2.3 Direct Torque Control 12
2.4 Input Stage 13
2.5 Output Stage 13
2.6 Elementary Diagram 14
Chapter 3 - Hardware Description 17
3.1 Electromagnetic Compatibility 17
3.2 ACS 1000 Cabinet Layout 17
3.2.1 Air-cooled Type 17 3.2.2 Water-cooled Type 19 3.2.3 Power Terminals 20 3.3 Control Equipment 21 3.4 Door Locks 22 3.5 IP Ratings 23 3.6 Lifting Arrangements 23 3.7 Standard Color 23 3.8 Additional Cabinets 23
Chapter 4 - User Interfaces 25
4.1 Overview 25
4.2 CDP 312 Control Panel 25
4.3 Standard I/Os 26
4.4 Fieldbus Adapter Modules 31
5.1 Overview 33
5.2 Suitable Applications for Different Macros 33
5.3 Macro I/O interfaces 36
Chapter 6 - Standard Functions 39
6.1 General 39
6.2 Standard Control Functions 39
6.2.1 General Functions 39
6.2.2 Main Circuit Breaker Control 42
6.2.3 Local and Remote Control 42
6.2.4 Diagnostics 43
6.2.5 Programmable Digital and Analog Outputs 43
6.2.6 Scalable Analog Inputs 44
6.2.7 Input Signal Source Selections and
Signal Processing 44
6.3 Standard Protection Functions 45
6.3.1 Programmable Fault Functions 45
6.3.2 Pre-programmed Protection Functions 47
6.3.3 Other Protection Functions 49
6.4 Other Functions 49
6.4.1 Customer Specific Options 50
Chapter 7 - Options 51 7.1 Environmental Conditions 51 7.2 Converter Enclosure 51 7.3 Input Section 52 7.4 Motor Side 53 7.5 Converter Cooling 56
7.6 Converter Isolators and Bypass 59
7.7 Auxiliary & Control Interfaces 61
7.8 PC Tools 61
Chapter 8 - Selecting the Drive System 63
8.1 Overview 63
8.2 Main Circuit Breaker 63
8.2.1 Main Circuit Breaker Control 63
8.2.2 Tripping Loop 64
8.4.2 Non Quadratic Load Applications 69
8.4.3 ACS 1000 Selection Tables 70
8.5 Motor Selection 73
8.5.1 Load Capacity Curves 73
8.5.2 Selection Criteria 74
8.5.3 Retrofit 74
8.5.4 Torsional Excitation 75
Appendix A - Installation Guidelines 77
Ambient Conditions 77
Mounting 77
Power Equipment Installation 80
General 80
Transformer Primary Cables 81
Transformer Secondary Cables 81
Motor Cables 82
Power Cable Dimensions 82
Equipment Grounding 82
Auxiliary Power Cables 82
Control Cables 83
Cable Routing 83
ACS 1000 Cable Entry and Termination 84
Transformer Connection Diagram for
12-pulse ACS 1000 85
Transformer Connection Diagram for
24-pulse ACS 1000 85
Motor Connection Diagram for
12 / 24-pulse ACS 1000 86
Appendix B - Technical Data 87
Transformer Connection / Converter Input 87
Converter Output / Motor Connection 88
Auxiliary Supply 88
Environmental Aspects 89
Derating of Drive Power 90
Air-cooled Converters 90
Water-cooled Converters 91
Transportation and Storage 91
Cooling 92
Analog Outputs 94
Digital Inputs 95
Digital Outputs 95
Auxiliary Power Output 95
Reference Voltage Output 96
DDCS Fiber Optical Link 96
Enclosures 96
Appendix C - Dimensions and Weights 97
Appendix D - Applicable Codes and Standards 101
CE Marking 101
Low Voltage Directive 101
Machinery Directive 101
EMC Directive 102
Emissions 102
Immunity 102
UL Marking 103
Applicable Codes and Standards 103
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.
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.
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.
1.1
Introduction
1.2
The Standard Solution
• 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.
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.
The ACS 1000 is available as 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
** 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.
1.5
ACS 1000 Types
Motor Voltage (kV) Type of Cooling Rated Motor Power Range** HP Max. cont. Power of ACS 1000 (kVA) Frame Size 2.3 Air 400 - 2250 400 - 2000 A1 - A3 2.3 Water 2500 - 4000 2300 - 3600 W1 - W2 3.3 Air 450 - 2250 400 - 2150 A1 - A3 3.3 Water 2500 - 6700 2400 - 5950 W1 - W3 4.0 Air 400 - 2250 400 - 2000 A1 - A3 4.0 Water 2500 - 6700 2300 - 5800 W1 - W3ABB 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.
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.
2.1
IGCT Power Semiconductors
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.
Figure 2-1 DTC block diagram
2.3
Direct Torque Control
Switch positions Torque reference Speed reference Rectifier = ~ Inverter Torque comparator Flux comparator Adaptive motor model Torque reference controller PID Flux reference controller U f U f T f Speed controller + acceleration compensator Actual speed Internal flux reference Actual torque Actual flux Inverter current DC bus voltage DC bus Flux status Torque status Control signals ASIC Switch position commands Mains Internal torque reference Optimum pulse selector Filter current Output filter (3 measurements) (4 measurements) M 3~
How does DTC differ from PWM Flux Vector Drives?
In DTC, each switching instance is determined separately based on the values of flux and torque, rather than switching in a predetermined pattern as in conventional PWM flux vector drives.
Table 2-1 DTC versus PWM Flux Vector controlled drives
For more information on DTC, please refer to the Technical Guide
No. 1 Direct Torque Control (3AFY 58056685 R0025).
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.
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.
DTC Flux Vector
Switching based on core motor variables Flux and Torque
Switching based on separate control of magnetising and torque producing components of current
Shaft speed and position not required Mechanical speed is essential. Requires shaft speed and position
(either measured or estimated) Each inverter switching is determined
separately (every 25µs).
Inverter switching based on average references to a PWM modulator. This results in delays in response and wasted switchings.
Torque Step Rise Time (open loop) is less than 10 msec.
Torque Step Rise Time Closed Loop 10 to 20 msec. Sensorless 100 to 200 msec.
2.4
Input Stage
• 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 frefre-quency common mode voltage is eliminated).
• Motor insulation is not subject to the common mode voltage typical for other drive topologies.
Figure 2-2 and Figure 2-3 show the elementary circuit diagram of the
12-pulse and the 24-12-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.
Figure 2-2 Elementary diagram - ACS 1000, 12-pulse version
2.6
Elementary Diagram
Diode
Rectifier IntermediateDC Link Three LevelInverter OutputSine Filter Squirrel CageInduction Motor
NP
M
Protection IGCTs 3 Medium Voltage Switchgear Main Circuit Breaker Converter Transformer (Option)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.
Figure 2-4 Voltage and current waveforms at converter output
Diode
Rectifier IntermediateDC Link Three LevelInverter OutputSine Filter Squirrel CageInduction Motor
NP
M
Protection IGCTs 3 Medium Voltage Switchgear Main Circuit Breaker Converter Transformer (Option)ACS 1000
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.
3.2.1 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.
3.1
Electromagnetic Compatibility
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
2 3 4
3.2.2 Water-cooled Type
12-pulse Version The water-cooled type of the ACS 1000 (see Figure 3-2) is equipped with a closed circuit water cooling system. Part of the cooling system is a fan and an air-to-water heat exchanger to maintain cooling of all components which cannot be cooled by water.
As with the air-cooled type, the construction of the inverter stacks allows easy exchange of IGCTs by means of a specially designed tool which is part of the supply.
Figure 3-2 The ACS 1000 water-cooled type (12-pulse)
1 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
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 21). Behind this swing frame and a protective separation door is the drive’s power terminal section with busbars for mains and motor cables. To provide optimum access to the power terminals, the swing frame can be opened more than 120°.
Please refer to Appendix A - Installation Guidelines for further details on cable entry and connection.
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.
Figure 3-3 Control section with open front door
3.3
Control Equipment
Swing frame
Electronic power supply board (EPS)
AMC3 control board
Interface board
IOEC1 board
∆p-transmitters (air- cooled converters only)
Motor starters and circuit breakers Aux. supply transformer Batteries Pulse encoder Fieldbus interface
Figure 3-4 Control section with swing frame removed
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.
IOEC2 board (standard)
Access door to power cable connection section
IOEC3 board (stan-dard for water-cooled converters)
IOEC4 board (optional) Terminals for aux. voltages, control sig-nals and tripping loop
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.
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.
The cabinets are fitted with lifting lugs as standard.
The standard color is RAL 7035 (light grey). Other colors are available on request.
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).
3.5
IP Ratings
3.6
Lifting Arrangements
3.7
Standard Color
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.
The CDP 312 Control Panel is the basic user interface for monitoring, adjusting parameters and controlling the ACS 1000 converter operation.
4.1
Overview
4.2
CDP 312 Control Panel
ACT PAR FUNC DRIVE
ENTER LOC REM RESET REF 1 L -> 1242rpm I SPEED CURRENT TORQUE 76.00 A 1242.0rpm 86.00 %
Enclosure class IP54 when attached to the Control Panel Mounting Platform
Multilingual Alphanumeric Display (4 lines x 20 characters)
Plain text messages available in several languages
Control Panel Mode Selection keys
Double Up Arrow, Up Arrow Enter
Double Down Arrow, Down Arrow Local/Remote, Reset, Reference and Start keys
Forward, Reverse and Stop keys Control Panel Display Control Panel Keypad
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.
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.
4.3
Standard I/Os
Table 4-1 I/O Board configuration with number and type of I/O
Number Signal Type Ratings
4 Analog
Inputs
(AI) 0...20 mA / 4...20 mA or 0...10 V / 2...10 V scalable by parameter setting
2 Analog
Outputs
(AO) 0...20 mA / 4...20 mA scalable by parameter setting
14 Digital
Inputs
(DI) Opto-coupled, rated for 22...250 VAC or 22...150 VDC
6 Digital
Outputs
(DO) With switch-over contact (SPDT), rated for 250 VAC, 2 A
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
* see Chapter 6 - Standard Functions
AI REF VALUE 2 Macro specific I/O
AO SHAFT SPEED ACT VAL Actual speed monitoring output
AO MOT CURRENT ACT VAL /
MOT TORQUE ACT VAL
Actual current / torque monitoring output (programmable)
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 indication
W
Table 4-2 I/O Signals: remote control interface (continued)
DI OIL TEMP ALARM, or
TRAFO WDG TEMP ALARM
Transformer oil temperature alarm indication
Transformer winding temperature alarm indication
W
DI /OIL TEMP TRIP, or
/TRAFO WDG TEMP TRIP
Transformer oil temperature trip indication
Transformer winding temperature trip indication
W
DI BUCHHOLZ ALARM Transformer alarm indication
from Buchholz relay
W
DI /BUCHHOLZ TRIP Transformer trip indication
from Buchholz relay
W AI OIL TEMP, or TRAFO WDG TEMP Temperature measurement of transformer oil Temperature measurement of transformer winding W
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 alarm indication
W
DI MOT COOLING ALARM (External) motor cooling alarm indication
W
DI /MOT COOLING TRIP (External) motor cooling trip indication
W
DI VIBRATION SV ALARM Motor vibration alarm indication
W
DI /VIBRATION SV TRIP Motor vibration trip indication W
DI /OVERSPEED TRIP Motor overspeed trip
(included in hardwired tripping loop)
W
AI MOT WDG TEMP PH U Motor winding temperature
AI MOT WDG TEMP PH V Motor winding temperature
AI MOT WDG TEMP PH W Motor winding temperature
Table 4-4 I/O Signals: transformer (continued)
AI BRG TEMP DE Motor bearing temperature of driven end
W
AI BRG TEMP NDE Motor bearing temperature of
non-driven end
W
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
CLOSED
Status input
AI OUTSIDE AIR TEMP Temperature measurement of
outside air
Table 4-5 I/O Signals: motor (continued)
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.
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.
4.4
Fieldbus Adapter Modules
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
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.
5.1
Overview
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).
Figure 5-1 Example of an application with PID control loop
Actual Value Reference Level Trans-ducer Pump ACS 1000 converter
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.
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.
5.3 Macro I/O interfaces
Table 5-1 Macro specific digital and analog inputs
Macro I/Os I/O functions
Factory Speed
DI MCB open/close commands Start/ stop commands Selection of direction
Selection of 2 accel/decel ramps Selection of 2 const. speeds Process stop or run enable AI 2 speed reference values
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
The pre-set digital and analog outputs available for external use are the same for each macro.
Table 5-2 Macro specific digital and analog outputs
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
Table 5-1 Macro specific digital and analog inputs (continued)
Macro I/Os I/O functions
Macro I/Os I/O functions
Factory Speed PID Torque Sequential Master/Follower DO Drive ready Drive running Drive alarm Drive trip AO Motor frequency Motor torque Motor speed Motor torque filtered
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.
6.2.1 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 Speed
A motor fed by the ACS 1000 can develop short-term motor nominal torque at start-up without any pulse encoder or tachogenerator feedback. This feature is essential for constant torque applications. However, if permanent operation at zero speed is required, a pulse encoder has to be used.
Enhanced Flying Start This feature allows a rotating motor (e.g. a turbo-pump or a fan) to be taken over by the ACS 1000. By means of the flying start function the frequency of the motor is detected and the motor is started-up again by the ACS 1000.
6.1
General
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-Through
If the incoming supply voltage is cut off the ACS 1000 will continue to operate in an active but non-torque producing mode by utilizing the kinetic energy of the rotating motor and load. The ACS 1000 will be fully active as long as the motor rotates and generates energy to the ACS 1000. Power loss ride through can be enabled by parameters.
Auxiliary Ride Through The auxiliary ride through function guarantees correct fault indication and proper trip sequencing, in the event that the auxiliary power source feeding the drive is lost. The function is activated by a parameter. During ride through the power for the control circuits of the ACS 1000 is supplied by internal batteries. The ride through time is limited to 1 sec.
Acceleration and Deceleration Ramps
ACS 1000 provides two user-selectable acceleration and deceleration ramps. It is possible to adjust the acceleration/deceleration times
(0...1800 s) and select the ramp shape. Switching between the two ramps can be controlled via a digital input.
The available ramp shape alternatives are:
Linear: Suitable for drives requiring long acceleration/deceleration where
S-curve ramping is not required.
S1: Suit. for short acc./dec. times. S2: Suit. for medium acc./dec. times S3: Suit. for long acc./dec. times.
S-curve ramps are ideal for conveyors carrying fragile loads, or other applica-tions where a smooth transition is required when changing from one speed to another.
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. Linear 1 t (s) Motor 1.25 2 S1 S2 S3 speed
Each critical speed setting allows the user to define a low and a high speed limit. If the speed reference signal requires the ACS 1000 to operate within this speed range the Critical
Speeds function will keep the
ACS 1000 operating at the low (or high) limit until the reference is out of the critical speed range. The motor is accelerated/decelerated through the critical speed band according to the acceleration or deceleration ramp.
Constant Speeds Up to 15 constant speeds can be programmed and selected by digital inputs. If activated the external speed reference is overwritten. If the Sequential Control Macro is used a standard set of parameter values is selected automatically.
Accurate Speed Control
The static speed control error is typically +0.1% (10 % of nominal slip) of the motor nominal speed, which satisfies most industrial applications.
Accurate Torque Control without Speed Feedback
The ACS 1000 can perform precise torque control without any speed feed-back from the motor shaft. With torque rise time less than 10 ms at 100% torque reference step compared to over 100 milliseconds in frequency converters using sensorless flux vector control, the ACS 1000 is unbeatable.
By applying a torque reference instead of a speed reference, the ACS 1000 will maintain a specific motor torque value; the speed will be adjusted auto-matically to maintain the required torque.
Table 6-1 Typical performance figures for torque control, when Direct Torque Control is used
*When operated around zero frequency, the error may be bigger.
s 1Lows1High s2Lows2High
Speed 540 690 1380 1560 (rpm) 540 690 1380 1560 (rpm) Motor speed reference
Torque Control ACS 1000
no Pulse Encoder
ACS 1000 with Pulse Encoder
Linearity error + 4 %* + 3 %
Torque rise time < 10 ms < 10 ms
100 t(s) T TN < 10 ms 90 10 (%) Tref Tact
TN= rated motor torque
Tref= torque reference
6.2.2 Main Circuit Breaker Control
All functions regarding the control of the main circuit breaker (opening, closing, tripping, monitoring) are included in the ACS 1000.
For detailed information see Chapter 8 - Selecting the Drive System, Main
Circuit Breaker, page 63.
6.2.3 Local and Remote Control
Operation of the ACS 1000 is possible either in local or remote control mode.
Local/remote control is selected directly on the CDP 312 control panel by pushing the LOC/REM push-button. A capital L on the display indicates local control:.
Remote control is indicated with a blank:
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).
LOC REM MotSpeed 0.00 rpm Power 0.0 % 1 L -> 0.0 rpm 0 Status RdyForMCBOn LOC REM MotSpeed 0.00 rpm Power 0.0 % 1 -> 0.0 rpm 0 Status RdyForMCBOn
6.2.4 Diagnostics
Actual Signal Monitoring
Three signals can be displayed simultaneously on the control panel.
Actual signals to be displayed can be selected in parameter group 1 to 5, Actual Signals. For example:
• 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 Outputs
Four digital outputs on the IOEC 2 board can be programmed individually. Each output has floating change-over contacts and can be allocated to an internal binary control or status signal via parameter setting.
Examples are:
• ready, running, fault, warning, motor stall, motor temperature alarm / trip, ACS 1000 temperature alarm / trip, reverse rotation selected, external control selected, preset speed limits, intermediate circuit voltage limits, preset motor current limit, reference limits, loss of reference signal, motor operating at reference speed, process PID controller actual value limits (low, high) etc.
If optional boards IOEC 3 and/or IOEC 4 are installed, a maximum of 12 additional digital outputs (6 on each board) are available.
1 L -> 600.0 rpm 1 Status Running
MotSpeed 600.00 rpm
Programmable Analog Outputs
Two programmable analog outputs on each IOEC board are at the user’s disposal.
Depending on the setting of the corresponding parameters, the analog output signals can represent for example:
• motor speed, process speed (scaled motor speed), output frequency, output current, motor torque, motor power, DC bus voltage, output voltage, application block output (process PID controller output), active reference, reference deviation (difference between the reference and the actual value of the process PID controller). The selected analog output signals can be inverted and filtered. The minimum signal level can be set to 0 mA, 4 mA or 10 mA.
6.2.6 Scalable Analog Inputs
Each analog input can be adapted individually to the type and range of the connected input signal:
• signal type: voltage or current (selectable by DIP switches)
• signal inversion: if a signal is inverted, the maximum input level
cor-responds to the minimum signal value and vice versa
• minimum level: 0 mA (0 V), 4 mA (2 V) or by input tuning function
(ac-tual input value is read and set as minimum)
• maximum level: 20 mA (10 V) or by input tuning function (actual input
value is read and set as maximum)
• signal filtering time constant: adjustable between 0.01..10 s.
The offset of the analog inputs can be calibrated automatically or manually.
6.2.7 Input Signal Source Selections and Signal Processing
Two Programmable Control Locations
The ACS 1000 can receive the Start/Stop/Direction commands and the reference value from the integrated control panel and the Closing/Opening commands for the main circuit breaker from the push buttons on the control section door.
Alternatively it is possible to predefine two separate external control 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 Processing
The ACS 1000 can handle a variety of speed reference schemes in addition to the conventional analog input signal and control panel signals. • The ACS 1000 reference can be given using two digital inputs:
one digital input increases the speed, the other decreases it. The ac-tive reference is memorized by the control software.
• The ACS 1000 can form a reference out of two analog input signals by using mathematical functions: addition, subtraction, multiplication, minimum selection, and maximum selection.
It is possible to override the actual speed reference with predefined constant speeds (see Constant Speeds, page 41).
It is possible to scale the external reference so that the signal minimum and maximum values correspond to a speed other than the nominal minimum and maximum speed limits.
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 Temperature
The motor can be protected from overheating by activating the motor winding temperature monitoring function.
The ACS 1000 standard solution offers three analog inputs for measuring and monitoring the motor winding temperature.
Values for alarm and trip levels can be set.
Motor Stall The ACS 1000 protects the motor if a stall condition is detected. The 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.
2 The drive is in torque limit. The torque limit level is a basic setup parameter that sets maximum drive output torque. Although it indirectly effects operation of the motor stall protection, it should not be considered a motor stall parameter.
3 The frequency and torque levels from
conditions 1 and 2 have been present for a period longer than the set stall time.
Figure 6-1 Stall region of the motor
6.3
Standard Protection Functions
Stall region
Tm.a
Stall Torque
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 reacindica-tion).
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. 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 110% 120% 130% 140% curve 1 curve 2 curve 3 curve 4 curve 5 Torque Speed
6.3.2 Pre-programmed Protection Functions
Motor Phase Loss The phase loss function monitors the status of the motor cable connections. The function is useful especially during motor starting: the ACS 1000 detects if any of the motor phases are not connected and refuses to start.
The phase loss function also monitors the motor connection status during normal operation. The motor operating frequency must be above a minimum level in order for this feature to function. Should a motor phase loss be detected a trip is initiated.
Motor Overload The 3-phase RMS value of the motor current is monitored and compared with three adjustable thresholds. A pickup delay for each threshold can also be set. In case an overload is detected an alarm message will be displayed and the converter will be shut down.
Overvoltage The levels of the positive and negative DC link voltage are monitored to detect whether an improper overvoltage condition develops. If these voltage levels rise above 130% of their nominal levels an overvoltage trip is initiated. On rare occasions, a combination of conditions can result in the motor entering a self excitation mode that can cause the DC link voltage to continue to rise, despite the fact that a trip has been initiated. If this condition occurs and if the DC link voltage levels rise above 135% of their nominal levels, a second overvoltage trip is initiated that causes the inner 6 IGCT’s to be gated simultaneously such, that the motor windings are effectively shunted together. This eliminates the self excitation voltage that is causing the DC link voltage levels to rise. To provide ultimate reliability the second overvoltage trip is implemented both in software and redundantly in hardware (140%).
Short Circuit in the Rectifier Bridge
A short circuit in the rectifier bridge is detected by monitoring the DC link voltage. If a short circuit is detected, a trip is initiated and the drive is disconnected from the supply voltage.
Charging Fault 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 RMSof 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
cooling water pumps, the water level in the expansion vessel and the auxiliary fan are monitored.
Short Circuit of the Inverter
The inverter is monitored to ensure that a short circuit condition does not exist. If a short circuit is detected a trip is initiated.
Ground Fault The current in the output filter ground leg is monitored and compared with two thresholds. The first threshold is set to a fixed percentage of the peak value of the nominal inverter current. The second threshold is adjustable and compared with the RMS value of the ground current. If the ground current exceeds one of the thresholds a corresponding alarm message will be displayed and the drive will be shut down.
Ground faults will be detected in the area between the ACS 1000 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.
6.3.3 Other Protection Functions
External Motor Protection Trip
If the customer uses an external motor protection relay, it can be
connected to a pre-defined protection input of the ACS 1000. The motor protection input is integrated into the tripping loop by a normally closed (NC) contact.
External Transformer Protection Trip
If the customer uses an external transformer protection relay, it can be connected to a pre-defined protection input of the ACS 1000. The trans-former protection input is integrated into the tripping loop by a normally closed (NC) contact.
Line Unbalance Protection Relay
An optional signal input is available to connect a line unbalance protection relay for initiation of a converter trip.
Process Stop A process stop button or relay can be connected to a pre-defined input of the ACS 1000. The actual process stop input must be closed during normal operation. If the digital input opens, the drive control initiates a stop command. The stop mode (ramp stop, stop at torque limit, or coast stop) can be selected by a parameter. When the drive is stopped the main circuit breaker is opened.
External Emergency Off
The normally closed (NC) contacts of external emergency-off buttons can be wired into the tripping loop.
For further details see Chapter 4 - User Interfaces.
Automatic Restart The ACS 1000 can automatically reset itself after an undervoltage has occurred. This function is activated by two parameters one to enable the automatic restart function and one to select the undervoltage waiting time (adjustable between 0 and 600 s).
If the automatic restart feature is activated and an undervoltage is detected in the DC-link, the waiting time is started. If the voltage recovers within the selected time, the fault will be reset automatically and the converter resumes normal operation. If the waiting time has elapsed and the voltage has not recovered the converter is tripped and the MCB is opened.
Monitoring of Limit Values
The values of several user selectable signals can be monitored for adjust-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.
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.
Extended Ambient Temperature: 50 °C
Above 40 °C the converter output power must be derated by 1.5% per 1 °C and filter capacitors, suitable for high operating temperatures, are
supplied.
Corrosion Protected Bus Bars
For certain environmental conditions (e.g. salty air in combination with increased ambient temperature and high humidity) corrosion protected bus bars can be chosen instead of the standard type. This choice is rele-vant for all power and grounding bus bars 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.
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).
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.