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ABB MOTION SERVICE

Life Cycle Services for ACS1000

A comprehensive service portfolio to fit your individual needs

© Copyright 2020 ABB. All rights reserved. Document ID.: 3BHS878524 E01 Rev.: A
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ACS1000 Drives

The solution for everyday process control

The industrial all-rounder for a wide variety of applications provides reliable motor control.
The well-proven ACS1000 medium voltage drive ensures high productivity, availability and
efficiency of your operations.
—
ABB Drives Service Portfolio
Services matching your needs

What we offer
Care agreements

End-of-life Technical support

Operational Performance services and repairs
excellence improvement

We together manage your assets, We optimize connectivity,

Training Replacement
operations, and risk to deliver reliability and efficiency of
strategic business results. your assets to increase speed Operational Rapid
and yield. excellence response

Advanced Spares and

Our expertise
services consumables
– Your success

Life cycle Rapid

management response Engineering and Performance Life cycle
consulting improvement management
We guarantee fast and flexible Installations and
We employ powerful tools and commissioning
knowledge to optimize and response to maximize your
extend your equipment life. equipment uptime. Maintenance

Extensions, upgrades
and retrofits

February 7, 2023 Slide 3

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ABB Life Cycle Services for ACS1000
Recommended services
Spare Parts Packages
In case of component
failures, ABB has prepared
various spare parts packages
to ensure maximum
availability of the drive and
to cover short- or mid-term
inventory management.
Replacement
Replacement provides the
most complete renewal of
your asset ensuring the
longest lifetime of your
asset.
February 7, 2023 Slide 4
Preventive Maintenance
A preventive approach to
reduce wear and stress in
the components provides
a cost effective way to
reduce O&M action.
Service Agreements
ABB on-site and remote
services provide the certainty
that you won't be alone in
case of unexpected failures
arise.
Upgrades
Upgrading and enhancing
your converter with the
latest technology adds value
to your installation and
optimizes your operations.
Onsite Services
ABB trained engineers will
executed agreed on-site
maintenance, troubleshooting,
repair, and commissioning
activities ensuring the drive is
performed as they should.
—
Available Type of Service Offerings
Main Characteristics of Spare Part Packages, PM Kits, Upgrades & Replacements

Spare Part Packages PM Kits Upgrades & Replacement

Usually available in 3 variants:
– Minimum
– Standard
– Extended
Those are non-recurring kits and can be
offered whenever customer wants to have
on-site spares.
Content of spare part kits can be adapted
to customer preferences.
The PM kit are recurring kits. The kit
content should not be changed.
The kit are defined based on the interval in
years they have to be applied. Example:
– «2-Y PM Kit ACS1000»
After 8 years, the 2-Y, the 4-Y and the 8-Y
kit have to be applied – if they are available
and required.
Upgrades and Replacement are targeting…
– … to bring the latest state-of-the-art
hardware to extend the life cycle of your
system.
– … to provide new features.
Usually upgrades are more complex and
require engineering effort and re-
commissioning at times.

February 7, 2023 Slide 5

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Physics of Failures
The “bath tub” Curve of Failures

Even if the converter is designed perfectly,

Failure rate FR
failures may happen.

Infant mortality Useful life Wearout Failures happen due to the exposed stress
Early failures Random failures FR increases and wear of the converter.
dFR/dt<0 dFR/dt<0 dFR/dt<0
Reducing exposed levels of stress (like
temperature, humidity, grid failures) and
increasing the resilience (resistance to
wear out) of a system are the only way of
L10 = 10% improving failure rates.
of population
have failed To minimize unpredicted shutdowns in a
Stress matured installed base is the challenge of
any efficient Operation & Maintenance
strategy.

Time

February 7, 2023 Slide 6

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ABB Life-cycle Service for ACS1000

Performance

With upgrades and maintenance

With proper preventive maintenance

Without proper maintenance

Half of the expected life

time

Time

ABB has designed a comprehensive service offering that goes beyond spares and repairs which enables
a higher reliability and performance beyond the one the converter had when it left the factory.

February 7, 2023 Slide 7

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ACS1000 Life Cycle Services
Spare Parts Offering
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Categories of the Recommended Spare Part Packages

Minimum Commissioning spares

A low budget set to help with some fault cases.
Package
This package contains parts to be prepared for the eventuality of issues during commissioning.

Standard For unexpected failures

An emergency on-site parts kit that contains the most common components that are required for a quick
Package problem resolution and can be considered for the “two-years spares” case.

For versatile repair needs

Extended An emergency on-site parts kit that includes a wide range of components for specialists and can be considered
Package for the “five-years spares” case. This allows for the highest degree of independence from the global ABB spare
part stock center.

Customized The customer defines their own package. ABB recommends to start with a generic spare part package and
adapt its contents according to their own needs
Package

February 7, 2023 Slide 9

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Content of the Spare Part Packages
For ACS1000

Minimum package Standard package Extended package

– Selected control electronics – Minimum package + – Standard package +
– Selected IGCT’s, thyristors, and diodes – Full selection of control electronics – Highest quantity count of components
– Selected power supplies – Higher quantity of components – Varistor Kit
– Current transducers – Control panel – Input Current Sensor (for ACS1000i)
– Door lock – Water-cooling spares – Water-cooling unit pump
– Safety relays
– Fuses

Highest
Minimum set Full selection quantity of
of selected of individual parts and
components components full power
modules

Related links:
February 7, 2023 Slide 10
Spare parts packages for ACS1000 drives
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ACS1000 Life Cycle Services
Preventative Maintenance Offering
—
Preventive Maintenance
Keeping your converter in top shape

Various PM kits are created for the re-occurring tasks and are building blocks for the yearly cycles

2 4 6 8 10 12 14 16 Years from commissioning: 2 4 6 8 10 12 14 16 18

years years years years years years years years Fans (control part) R R R R
Fans (power part) R R R
PM 2 PM 2 PM 2 PM 2 PM 2 PM 2 PM 2 PM 2
Water pumps (no redundancy) R R R R
Mechanical seal of water pumps (no redundancy) R R R R R
PM 4 PM 4 PM 4 PM 4 Water pumps (with redundancy) R R
Mechanical seal of water pumps (with redundancy) R R
PM 6 PM 6 Deionizer cartridge and micro filter R R R R R R R R R
Rubber hoses R R
Output filter capacitors R
PM 8 PM 8
PCBA (containing electrolytic capacitors) R
Gate unit boards (of IGCTs) R
PM
10 Power supplies (AUX and insulated supply) R
Batteries R R R R R R R R R
Electrolytic capacitors (auxiliary buffer) R

Related links:
February 7, 2023 Slide 12
ACS1000 Preventive Maintenance Schedule
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ACS1000 Life Cycle Services
Upgrade Offering
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Make a Lifetime Difference
Modernization services for drives

How you benefit from ABB drives modernization services

Tailored solutions for ABB as well as other drive systems securing operational effectiveness and reliability.

Fast project delivery Reduced project risks

With our expertise, we guarantee the best possible time frame for Our expertise and extensive knowhow of installed products significantly
modernization to suit your schedule. reduces modernization risks.

Manage component obsolescence Minimize operational risks with proven technology Secure reliability and improve performance

Improve usability and safety ABB Ability™ Digital Services enabled Extend the lifetime of your drive system

Enhanced features and improved performance with ABB Drives Modernization Services

February 7, 2023 Slide 14

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Using Synergies with Upgrade Services and Preventative Maintenance
Building on and complementing planned maintenance

Coordinated Optimization

Reduced Labor Costs Less scheduled downtime Optimized Material Costs

Upgrade

The installation of upgrades can Upgrades can be implemented The upgrade of components can
substitute for the maintenance and commissioned during the be synchronized with its
labor costs same maintenance shutdowns corresponding replacement
schedule

Planned Preventative Maintenance Activities

Maintenance

Aging components replacements Optical fiber inspection

Auxiliary cooling Spare part assessment
Standard updates Performance verification

February 7, 2023 Slide 15

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Integrating the State-of-the-Art Controls into Proven Technology
ACS1000 Continuous Improvement and Advanced Developments

ACS1000 Life Cycle

The ACS1000 continues to use well-proven, IGCT-based
Active Classic Limited Obsolete
technology. Product sub-types have been introduced to
differentiate the hardware generations and also to identify Limited range of life
control platforms. Replacement and
Full range of life cycle services and support cycle services and
end-of-life services
support
This also easily identifies existing installations where life cycle
upgrades are available:
– ACS1000 (newly manufactured) Serial production has
• Active until further notice Product is in ceased. Product may

Product
active sales and be available for plant Product is no longer Product is no longer
– ACS1000 (Generation 1) manufacturing available. available.
extensions, as a spare
• Limited until 2025 phase or for installed base
– ACS1000 (Generation 1) after Main Board Upgrade renewal
(AMC34)
• Classic until further notice Full Lifecycle support
Limited lifecycle
is guaranteed.
Services
support is available. Replacement and
Full Lifecycle support Product enhancements
is guaranteed. Spare parts availability end-of-life services
may be available are available.
is limited to available
through modernization
For detailed Life Cycle descriptions, refer to each product Life Cycle Statement stock.
available on ABB Library. services.

February 7, 2023 Slide 16

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ACS1000 Upgrade Services
Life cycle
Upgrade

Feature
Fundamental Characteristics of a Drive Upgrade Upgrade

Design
Upgrade

Life Cycle Upgrade Feature Upgrade Design Upgrade

Ensure full Life cycle services and Retrofit additional functionality to the Design related improvements that
prolong the lifetime of the asset by asset in order to respond to specific increases and sustains the reliability of
returning it from Limited or Obsolete to customer needs and/or changed process the asset in addition to the normal
Classic or prolonging Classic phase. requirements. maintenance activity.

Functionality,
Performance Reliability

Active Classic Limited Obsolete

Asset lifetime

Upgrades can be categorized in multiple categories

February 7, 2023 Slide 17

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Overview of ACS1000 Upgrade Offerings
Available Upgrade Services by Fundamental Characteristics

Upgrade offering Offering highlights Life Feature Design

Cycle
Gate Unit PCAB Upgrade Bringing the gate units of the ACS1000W (frames W2 and W3) to an actual X (X)
status.

Auxiliary Power Concept Get rid of maintenance-intense batteries and ensure spare part availability. X (X)
Upgrade
Main Board Upgrade Extend the life cycle support of the drive and unlock other feature upgrades
and options.
X X
WCU Pump Upgrade Upgrade the water cooling system to ensure spare parts availability. X
EC Fan Upgrade Safe energy and reduce noise level by the intelligent air cooling system that
optimises the fan speed.
X
Safe Torque Off (STO) Guarantee torque free motor and a locked out inverter unit while keeping
the MCB closed.
X
Upgrade
Emergency Stop 1 Upgrade Enhance the drive with Emergency Stop category 1 (IEC 60204-1) to bring
the rotating motor to an immediate stand-still and switches the power off
X
afterwards.

February 7, 2023 Slide 18

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Overview of ACS1000 Upgrade Offerings
Dependencies of Upgrade Elements

1. 2. 3.
Prerequisite for the Main Board Unlock potential of the drive and
Tailor the drive to your needs
Upgrade extend the life cycle support

– AbilityTM Digital Services for

– Gate Unit PCBA Upgrade1 Drives
– Auxiliary Power Concept – EC Fan Upgrade
– Main Board Upgrade
Upgrade – Safe Torque Off (STO)
– WCU Pump Upgrade2 Upgrade
– Emergency Stop 1 Upgrade

1Only required for the water-cooled main frames W2 and W3.

February 7, 2023 Slide 19 2 Technicallyit is not mandatory to perform the WCU Pump Upgrade as prerequisite for the Main Board Upgrade. But no life cycle service
extension is provided after the Main Board Upgrade if the WCU Pump Upgrade is omitted.
—
ACS1000 Upgrades
Life cycle
Upgrade

Feature
Main Board Upgrade Prerequisite: Gate Unit PCAB Upgrade Upgrade

Design
Upgrade

Benefits of improved gate unit design

For W2 and W3 frame sizes, new gate unit boards are a mandatory
pre-condition for the Auxiliary Power Concept Upgrade and the Main
Board Upgrade.

Additional choke coil was added to support additional switching.

The new gate unit version can be see by checking the used IGCT
number.
Each IGCT power semiconductor has a gate unit board with
electrolytic capacitors for switching the main semiconductor on/off.
These electrolytic capacitors age and have a limited life. ABB
recommends replacing the gate unit board during schedule
maintenance after 10 years.

First mandatory step for further upgrades in W2 and W3 drives

February 7, 2023 Slide 20

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ACS1000 Upgrades
Life cycle
Upgrade

Feature
Main Board Upgrade Prerequisite: Auxiliary Power Concept Upgrade Upgrade

Design
Upgrade

Opening new potential, solving lifecycle issues, and improved design

The ACS1000 is designed to withstand short auxiliary power losses.

In the old concept, using EPS, internal back-up batteries energize

the drive during the power loss ride-through function. In addition to
replacing the obsolete EPS board, the back-up batteries have been
replaced with a new concept.

– Extended auxiliary power loss ride-through capabilites to ensure

reliable and continuous operation

– Easy installation
With Auxiliary Power Concept Upgrade the non-availability of old
auxiliary components is mitigated and the maintenance of internal
back-up batteries (every 2 years) will not be required anymore.

The basis for further upgrades and options

February 7, 2023 Slide 21

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ACS1000 Upgrades
Life cycle
Upgrade

Feature
Main Board Upgrade Prerequisite: WCU CHI to CM Pump Upgrade Upgrade

Design
Upgrade

Replace obsolete pumps

The older CHI pump is no longer manufactured by Grundfos. The
new used type CM can be installed but the WCU piping needs to be
modified.
For ACS1000 drives delivered before 2003 a complete WCU
replacement is required.

Maintain consistent operation

February 7, 2023 Slide 22

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ACS1000 Main Board Upgrade
Life cycle
Upgrade

Feature
Overview Upgrade

Design
Upgrade

Opening new potential, solving lifecycle issues, and improved design

The Main Board Upgrade is a compilation of PCBA’s and software
that enhances the capabilities of the ACS1000 to bring it to the
latest control design.
– Improved performance
– Further robustness
– Unlock potential of AbilityTM digital services for drives.
– Advanced troubleshooting and support
– Availability of further hardware options
– Assurance of spare part availability
– Optimized protection of diodes and input isolation transformer

The basis for further upgrades and options

February 7, 2023 Slide 23

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ACS1000 Main Board Upgrade
New Features – Improved Troubleshooting Capabilities

Blackbox – Key to efficient troubleshooting

The AMC34 has been further developed to include a second Flash
memory to contain the Blackbox information:
– It is a dedicated memory for data loggers, faults, events,
switched vectors, parameter and software change logs, and
even analog values.
– The FIFO (first-in, first-out) buffer features allotment for 10,000
events and 14 pairs of data loggers.

Reduce production loss by shorter mean time to repair (MTTR)

February 7, 2023 Slide 24

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ACS1000 Main Board Upgrade
New Features – Fast Rectifier Supervision

Opening new potential, solving lifecycle issues, and improved design

In normal condition, both rectifiers supply about the same voltage.
If there is a fault in one rectifier or the supply connected to a
rectifier has a short circuit, the voltage supplied by the effected
rectifier will be reduced. This will be detected and trip the drive.
– Triggering of protection reaction (trip)
– Improved robustness of the unit means more safety
– Optimized protection of diodes and input isolation transformer
reduces costs

Improved protection and higher safety

February 7, 2023 Slide 25

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ACS1000 Feature Upgrades
Life cycle
Upgrade

Feature
Safe Torque Off (STO) Upgrade Upgrade

Design
Upgrade

A Key to a Simpler Maintenance Process

The Safe Torque Off option is the easiest way to guarantee a
torque free motor and a locked out inverter unit.
Stop category 2 (IEC 60204-1); A controlled stop with power left
available and if process is stopped with hardware disconnection
(isolator, ground switch) of drive and motor.
– Complies with EN, IEC and ISO norms (EN IEC 61800-5-2, EN ISO
13849-1, etc.)
– Improved human and operational safety!

*Note: The Main Board Upgrade is a prerequisite for this upgrade.

Reduce maintenance & operational downtime

February 7, 2023 Slide 26

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ACS1000 Power Upgrade
Life cycle
Upgrade

Feature
Converter Power Upgrade Upgrade

Design
Upgrade

Maximize Full Potential of Your Asset

The most direct approach to maximize the performance is a power upgrade.
Depending on the converter, it can be implemented fast and simple by exchanging a few components.
For more details, ABB Drives Service can assess your asset to discuss the possibilities.

Examples:
– Electrical engineering
– Mechanical design
– Interface enhancements
– Network adaptions

Reach new heights for production by further empowering your converter

February 7, 2023 Slide 28

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ACS1000 Life Cycle Services
Service Agreement Offering
—
ABB Drive Care
A specific service agreement offering for each life cycle phase of a drive

February 7, 2023 Slide 30

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ABB Drive Care Agreements for ACS1000
Highlights

Initial Care – More than warranty Complete Care – Long-term life cycle agreement

Initial Care is a free of charge service available for a newly
purchased ACS1000 or an ACS1000 drive with Main Board
Upgrade, during the first year of the warranty period.
It complements the warranty support with ABB AbilityTM for
Drives, including…
– ABB Ability™ Remote Assistance for Drives
– ABB Ability™ Remote Condition Monitoring for Drives
Explore ABB’s digital offering free of charge for a limited time of
one year and decide afterwards, whether you want to enter the
ABB AbilityTM contract.
ABB Drive Care agreement is designed for the ACS1000 to let you
focus on your core business. With a fixed-price Life cycle
agreement matching your needs you gain efficiency in handling
routine and emergency maintenance and have improved cost
control.
ABB Drives Complete Care contract includes:
– Maintenance & repair parts
– Labor for on-site service actions
– Biennial on-site inspection
– ABB Ability™ Remote Assistance for Drives

Service budget

ABB Drives Warranty Condition + ABB AbilityTM for Drives

Initial Care 1 2 3 4 5 6 7 8 9 10 YEARS

February 7, 2023 Slide 31

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ABB Drive Care
A more powerful commitment

Reasons to choose ABB Drive Care

Efficiency
⎯ Avoid hassle, wasted time and unnecessary
bureaucracy in handling routine and emergency
maintenance.

Cost Control
⎯ Maintenance and other support activities are offered
at a fixed annual price, regardless of how often they
are used.

Focus on core activities

⎯ Remove the burden and distractions of non-core
activities, and work secure in the knowledge that
your drives are well maintained.

February 7, 2023 Slide 32

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Initial Care Scope
More than just a warranty – A promise that we care

Standard Initial Care scope Subject to local availability

Spare On Site Telephone Technical Remote Spares Priority Telephone Annual Site Life Remote myABB
Parts Repair Support Escalation Assistance Fast Site Support Visual cycle Assistance portal
5x8 & RCM Access Response 24 x 7 Inspection Audit &RMC
For MVs* For LVs*

     O O O O O O O
Warranty Engineer on Access to Escalation to Remote Access to Defined Access to Annual Visual One off Life Remote Access to
Exchange of site to telephone global experts Support in local spare maximum round the inspection. cycle audit Support in case drive
faulty parts. diagnose and support for who handle case of failure part stocks response clock local Timed at of site of failure and related
repair faulty advice, specialist and condition for fast time to site telephone ABB’s installed condition myABB
unit guidance and support, when monitoring turnaround by engineer support with discretion, base. One monitoring content
issue needed data via portal i.e. 3 days defined non intrusive day ‘lite’ LCA data via portal
resolution response time
during normal
working hours

All complementary services are just one registration away

February 7, 2023 Slide 33

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ABB AbilityTM Services for Drives
Enabling ABB Ability™ Services for Drives

ABB Ability™ Remote Assistance for Drives (RA) ABB Ability™ Condition Monitoring for Drives (CMD)

Remote Condition
or + Monitoring Portal
Remote Expert support Local connectivity
connectivity + upon request

Rapid solution in case of problems
Should a fault be detected within a drive, ABB specialist provides
rapid support by using the drive’s data which is stored remotely.
Alerts and information, for customer to react
ABB Ability Condition Monitoring for Drives is a service that
delivers you accurate, real-time information about drive condition
and events to ensure your equipment is available, reliable and
maintainable.

February 7, 2023 Slide 34

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ABB AbilityTM Services for Drives
Customer Needs
Make the best decisions
You know your process, we
know the drives.
Our monitoring system
provides you with data and
information from the drives for
your best decisions.
February 7, 2023 Slide 35
Shorter downtime
Rapid identification and
resolution of failure leads to
reduced downtime.
Reduce the risks
You have the information when
needed most.
Our monitoring system is
continuously collecting data for
you to set warning limits and
to trouble-shoot potential
problems.
ABB is here to help
Available 24/7 depending on
your service contract.
Our experts are always on hand
to consult with you.
Drive performance data stored
remotely. An ABB specialist
guides you on the phone so you
can get your process up and
running again quickly.
—
ABB AbilityTM Services for Drives
Delivery Concept

Condition Monitoring Remote Assistance

Customer’s Site Cloud storage ABB

1
Connected Global technical
drives support

2 4

3
Data, reports
& alerts
End Country
User Expert
RCM Data 6 Expert 5 RCM Full
Monitoring reports Features
+ Optional
Features Ad hoc expert
7 support

Contact your local ABB to check availability and enable this service
February 7, 2023 Slide 36 Application and drive dependent. Subject to hardware compatibility and available internet connection on-site.
—
ACS1000 Drives

The solution for everyday process control

The industrial all-rounder for a wide variety of applications provides reliable motor control.
The well-proven ACS1000 medium voltage drive ensures high productivity, availability and
efficiency of your operations.
—
ACS1000 Drives
Based on long-term experience and in-depth knowledge

> 45 years 2012

ACS5000 second generation
2014
ACS580MV introduction
in China
2017
ACS6080 all-compatible
MV multidrive
experience
2009
ACS2000 MV drive for
direct-to-line connection

1999 2005
ACS6000 first MV multidrive ACS5000 first MV drive
with PEBB technology with VSI-MF topology
1997
ACS1000 first IGCT-
based MV drive

1995
Direct Torque
Control (DTC)
1969 1985
AC drive Megastar 3-level PWM 1993
development started MV drive with vector control Self-healing
capacitors
—
ACS1000 Drives
Complementing our broad portfolio of drive solutions

Energy efficiency – emission reduction Process Control

ACS580MV ACS5000 / LCI ACS1000 / ACS2000 ACS6080 / PCS6000

Applications:
• pumps, fans
Segments:
• Infrastructure, water, HVAC
• Auxiliary applications in heavy
industry, metals, cement,
power generation, ..
Focus:
• Non-specification driven
• Non-critical applications (can run
without drive in bypass mode)
• Capex – energy savings made
affordable
Applications:
Applications: Applications: • Mills, conveyors, propulsion, wind
mills, hoists, ..
• Large compressors, pumps, • Pumps, fans, mills, conveyors,
fans, GT starters extruders, mixers, hoists, ..
Segments: Segments: Segments:
• Oil & gas • Mining, Cement • Metals, mining, marine
• Power generation • Oil &Gas, petrochemical • Test stands, special applications
• Water • Marine, offshore • Renewable power gen.
• Power generation, water
Focus: Focus: Focus:
• High power • Flexible to configure for the specific • Flexible to configure for specific needs
• High reliability and availably needs • High performance
• Highest level of personal • High reliability and availably • High reliability and availably
safety • Highest level of personal safety • Highest level of personal safety

February 7, 2023 Slide 39

—
Increase your drive’s lifetime with all available Life Cycle Services
Continue operation with secured operational reliability

Highest reliability for many years to come

February 7, 2023 Slide 40