ABB

ACS 1000
Medium Voltage AC Drives

Preventive Maintenance Work Instruction for

Air-cooled ACS 1000

Document No.: 3BHS207555 ZAB E01 Rev. -

Issued: 28.10.2004

ABB Switzerland Ltd. All Rights Reserved.

 ABB reserves all rights to this document, also in the event of patent issue
or registration of any other industrial property protection right. Misuse, in
particular duplication and forwarding to third parties, is not permitted.
This document has been checked with due care and attention. However,
should the user find any errors, these should be reported to ABB.
ABB aims to maintain the most modern standard, therefore, entries in this
manual may differ from the actual product.

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Table of Contents
CHAPTER 1 - GENERAL .....................................................................................................................5
1.1 SAFETY INSTRUCTIONS....................................................................................................................5
1.2 ELECTROSTATIC DISCHARGE ..........................................................................................................5
1.3 NECESSARY TOOLS..........................................................................................................................5
1.4 NECESSARY DOCUMENTENTS .........................................................................................................6
CHAPTER 2 - INSPECTION OF THE DRIVE AND AMBIENT CONDITIONS ..........................7
CHAPTER 3 - INSPECTION OF SOFTWARE AND EPLD REVISIONS, FAULT LOGGER
AND PARAMETERS ...................................................................................................................................8
CHAPTER 4 - VISUAL CHECKING OF FREQUENCY CONVERTER AND INSPECTION OF
TERMINAL CONNECTIONS ....................................................................................................................9
4.1 VISUAL CHECKING OF FREQUENCY CONVERTER ...........................................................................9
4.2 CLEANING OF FREQUENCY CONVERTER.......................................................................................10
4.3 INSPECTION OF TERMINAL CONNECTIONS ....................................................................................10
CHAPTER 5 - INSPECTION OF OPTIC FIBERS...........................................................................11
CHAPTER 6 - INSPECTION OF BATTERIES................................................................................12
CHAPTER 7 - INSPECTION OF COOLING FANS AND AIR FILTER ......................................13
7.1 COOLING FAN ................................................................................................................................13
7.2 AIR FILTERS ...................................................................................................................................13
CHAPTER 8 - INSPECTION OF CAPACITORS ............................................................................14
8.1 VISUAL CHECKING OF POWER CAPACITORS (C, CR AND CF) ......................................................14
8.2 MEASURING OF DC LINK CAPACITORS (C) ..................................................................................14
8.3 MEASURING OF RECTIFER PROTECTION CIRCUIT CAPACITORS (CR)...........................................15
8.4 MEASURING OF THE OUTPUT FILTER CAPACITORS (CF)..............................................................15
8.5 VISUAL CHECKING OF OTHER CAPACITORS (CCL, CM AND CB)..................................................16
8.6 MEASURING OF OTHER CAPACITORS (CCL, CM AND CB)..............................................................16
CHAPTER 9 - INSULATION TEST...................................................................................................17
CHAPTER 10 - SPECIAL CHECK LIST FOR FIRST MAINTENANCE ......................................18
CHAPTER 11 - TEST RUN ...................................................................................................................19
CHAPTER 12 - INSPECTION OF SPARE PARTS AND DOCUMENTATION ............................20
CHAPTER 13 - REPORTING...............................................................................................................21

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ABB
Chapter 1 - General
This instruction contains a general maintenance schedule that lists all
scheduled maintenance and replacement actions that must be carried
out by specialised ABB service staff. All maintenance work must be
carried out according to the maintenance schedule, on time, in the
described sequence and by authorised personnel. Unless agreed
otherwise in a service contract, it is the owner’s responsibility.

1.1 Safety Instructions

Safety instructions, safety concept, warnings, intended audience,

required qualification, responsibilities etc. apply according to the
ACS 1000 User’s Manual.

1.2 Electrostatic Discharge

Warning
The components of printed circuit boards are very sensitive to static
electricity. Be careful when handling circuit boards so that electronic
components are not damaged. When handling circuit boards avoid
unnecessary touching and always use a grounding wristband and an
antistatic carpet.

1.3 Necessary Tools

• Toolbox with normal tools like screwdrivers, spanners etc.

• Torque spanner 10 - 75 Nm for hexagon head screws M6 to M12
• ESD-classified vacuum cleaner, for example SV-497 ABF -
VACUUM 3M 220V from 3M
• ESD-brush
• Cloths and cleaning brush
• Dissolvent
• Eye shields and dust respirator filter
• Personal computer with NDPA-02 PCMCIA-card, NDPC-12 optical
transmitter / receiver, optical cables and DriveWindows or
DriveDebug

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Chapter 1 - General
ABB
• Multimeter with test wires and clips, for example Fluke 87
• 5 kV Megger, for example AVO BM11D
• Capacitance meter, for example Wavetek CR50
• Fiber optic cable tester, for example Tempo 253B (transmitter) and
Tempo 557B (receiver)

1.4 Necessary Documentents

• Preventive Maintenance Work Instruction (this document)

• Preventive Maintenance Inspection Record
• ACS 1000 User’s Manual

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Chapter 2 - Inspection Of The Drive And Ambient
Conditions
• Enter the basic information of the customer, the drive and the
application to the inspection record template
• Enter the values of the specified signals according to the inspection
record template
• Enter the actions and observations you have done during the work
to the inspection record template
Measure, check and enter the information concerning the surroundings
mentioned in the inspection record. Pay special attention to the
following items:
• Air temperature and general quality of the air (corrosive gases,
visible dust etc.)
• Air conditioning in the electrical room
• General dustiness of the electrical room (conductive, corrosive
components etc.)
• Humidity
• Oiliness
• Corrosion
Collect all possible information of drive’s history from the customer. Pay
special attention to the following items:
• Occurred warnings
• Occurred faults (trips)
• Abnormal behaviour of the drive

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Chapter 3 - Inspection Of Software And EPLD Revisions,
Fault Logger And Parameters ABB

Chapter 3 - Inspection Of Software And EPLD

Revisions, Fault Logger And Parameters
• Check that the actual software-version in the drive is an allowed
version according to the software release notes on the MV AC
Drives Portal/After Sales/ACS 1000/Software/Software Release
Notes
• Check the EPLD-version in the drive according to the instruction on
the MV AC Drives Portal/After Sales/ACS 1000/Software/
Recommended SW and EPLD Version, upgrade the EPLD to the
recommended version if possible
• Save the content of the Fault logger and clear it
• Save the parameters (parameter groups 1 to 210) in txt or dwp file
formats (note that with DriveDebug all parameters can be saved in
one file but with DriveWindows the parameters must be saved in
two different files, one with groups 112 and 190 and one with all
other parameter-groups over 100)
• If you have the old parameter file of the drive, compare it with the
current parameters with the Compare-function in DriveWindows or
DriveDebug and save the result of the comparison in txt file format
• Make a backup of the software in pac, bpg or tar file format

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Chapter 4 - Visual Checking Of Frequency Converter
And Inspection Of Terminal Connections
Before starting the maintenance work make sure that:
• The main supply voltage cannot be switched on during the work,
lock the MCB in open position and mark the MCB with an
appropriate sign
• The main supply and the converter are grounded
• The auxiliary voltage is switched off and it cannot be switched on
during work, lock the switch in open position and mark the switch
with an appropriate sign
• The tripping loop voltage (provided from the MCB) is switched off
and it cannot be switched on during work, lock the switch in open
position and mark the switch with an appropriate sign
• There are no other external voltages connected to the frequency
converter e.g. motor and / or converter space heater (check the
drawings of the whole equipment)
Measure that:
• The auxiliary supply voltages are 0 VAC (phase- and main voltage),
the voltages have to be measured from terminal X10
• The tripping loop voltage is 0 VAC / VDC, the voltage has to be
measured from terminal X300
• Other voltages e.g. motor and converter space heaters (terminal
X20) and external control voltages (terminal X302) are 0 VAC.
Check the drawings of the whole equipment, to point out terminals,
where voltages have to be measured

4.1 Visual Checking Of Frequency Converter

Check visually the condition of every cubicle. Note especially the

following:
• Degree of dustiness inside the converter
• Cables and wires are appropriately fastened and do not wear out or
touch live parts
• The condition of insulation materials
• Possible signs of overheating in components, wires, cables or
busbars
• The used external signal- and power cables are the correct type
• Signs of corrosion on the boards, connectors or busbars

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Chapter 4 - Visual Checking Of Frequency Converter And
Inspection Of Terminal Connections ABB

4.2 Cleaning Of Frequency Converter

Clean the inside of the cubicles with a vacuum cleaner (ESD protected)
and cleaning cloths. If needed, clean the boards with special care by
using an ESD-protected brush and an ESD-vacuum cleaner.
Use compressed air if necessary. Pay special attention to the following
items:
• The purity and pressure of the compressed air
• The work has to be done with special care
Clean the cubicles on the outside by using a vacuum cleaner and
cleaning cloths. Use dissolvent if necessary.

4.3 Inspection Of Terminal Connections

Check the tightness of mains cables and PE-joints with a torque

wrench.
Check the tightness of internal main circuit connections with a torque
wrench.
Note! Do not touch the terminals on the capacitors yet
Tightening torques:
M6 6 – 9 Nm
M8 15 – 22 Nm
M10 30 - 44 Nm
M12 50 - 75 Nm
Check the terminal connections of control cables and relays by pulling
them one by one. Tighten them if necessary.

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Chapter 5 - Inspection Of Optic Fibers
Check visually the condition of the fiber optics cables. Note especially
the following:

• Signs of cracks on fibre core or on the outer casing
• Sharp bending of fibre
• Condition of the fibre connectors (both male & female)
• Installation on sharp edges
• Too tight tightening of tiewraps
Optical Inspection by using a light source and a receiver to measure the
condition of the fibers.
Instruments used (for example):
• Tempo 253B Led source (set to 660nm, no modulation)
• Tempo 557B Power Meter (set to 630nm, dBm)
• 10ZP Adapter
Testing procedure:
• Connect the source to one end of the fiber and the receiver to the
other end. Gently jiggle the fiber to see if the reading changes
(indicates a crack)
• Perfect fibers measure less than –9 dBm. Acceptable fibers
measures less than –12dBm. Above –12 dBm can be concidered
as suspicious
• If other types of meters are used, measure all fibers and calculate
the average value and compare all fibers with the average value

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Chapter 6 - Inspection Of Batteries
ABB
Chapter 6 - Inspection Of Batteries
The ACS 1000 is equipped with 2 or 4 12 VDC sealed (dry type)
maintenance free lead acid batteries. The auxiliary supply voltage for
the drive’s internal control electronics is backed up using electronic
power supply board(s) supplied by these batteries.
Replace the batteries after 17 000 hours (about 2 years) time of use.
See detailed replacement instructions in the ACS 1000 User’s Manual
Chapter 9 – Preventive Maintenance.

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Chapter 7 - Inspection Of Cooling Fans And Air Filter

7.1 Cooling Fan

Note! The supply voltage for the fan must be disconnected and
secured. The protection relays -Q11 and -Q12 must be opened.
Manually check that the cooling fans rotate smoothly (bearings) and
visually check the general condition of the cooling fans.
Later, during the drive test run, the cooling fan operation must be
observed once again audibly (healthy sound, no heavy vibration
expected).
Replace the fan after 40 000 hours (about 4½ years) time of use. See
detailed replacement instructions in the ACS 1000 User’s Manual
Chapter 9 – Preventive Maintenance.
In case a redundant fan is installed.
Replace the main fan after 70 000 hours (about 8 years) time of use (of
the frequency converter) and the redundant fan after 100 000 hours
(about 12 years) time of use (of the frequency converter). See detailed
replacement instructions in the ACS 1000 User’s Manual Chapter 9 –
Preventive Maintenance.

7.2 Air Filters

The lifetime of the air filter depends on the ambient air quality, i.e.
dustiness. The recommended change interval for the filter is 1 year but
it may need to be changed more often if the filter gets dirty. See detailed
replacement instructions in the ACS 1000 User’s Manual Chapter 9 –
Preventive Maintenance.

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Chapter 8 - Inspection Of Capacitors
ABB
Chapter 8 - Inspection Of Capacitors
The ACS 1000 has power capacitors in the DC link (C), in the protection
circuit of the rectifier (Cr) and in the output filter (Cf).
The DC link (C) and rectifier protection circuit (Cr) capacitors are of a
self-healing design. Because of their design the capacitance can
decrease due to ageing. Voltage and temperature are the two main
stress factors that influence the lifetime of the capacitors. Less than 2 %
reduction of capacitance from capacitors individual manufacture value is
allowed. The capacitors nominal capacitance (name plate value) is
not the manufacture value. The manufacture tolerance is 0…+10 % of
nominal value.
The output filter capacitors (Cf) are made of aluminium foils with a
polypropylene dielectric. There is no such aging behaviour like in the
self-healing capacitors.
ACS 1000 frequency converter has also capacitors in the snubber
circuit (Cm) to protect the rectifier diodes and in the clamping circuit
(Ccl) to protect the inverter diodes.
The clamping capacitors (Ccl) are of self-healing design and therefore
regular measurements are recommended.
In case the drive is equipped with a 24-pulse supply bridge, the
additional snubber capacitors (Cb) must also be checked. These
capacitors (Cb) are self-healing design.

8.1 Visual Checking Of Power Capacitors (C, Cr and Cf)

Check visually the condition of every power capacitor. Note especially

the following:
• Are there any leaks
• Are there any bulges. The capacitors can be little bulged (about 10
mm) but if the capacitor has expanded too much, it must be
replaced with a new one

8.2 Measuring Of DC Link Capacitors (C)

Measure the capacitance of the DC link capacitors (C) annually. It is

recommended to perform the first measurement during the
commissioning to get a reference value for the next measurements.
It is not necessary to measure each DC link capacitor separately; it is
enough to measure the total capacitance of the DC link with two
measurements (one for the positive side and one for the negative side)

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For the measurement:
• If the manufacture values of each capacitor are not available, the
first measurement can be used as a reference for the following
preventive maintenances
• Disconnect the wires / busbars connecting the DC link capacitors to
the rectifier / inverter
• Perform the measurements according the inspection record. If
possible, write down the serial number of each capacitor in the
inspection record template
• Connect the wires / busbars from the rectifier / inverter with the
marked tightening torque (see separate sticker on the capacitor). If
the tightening torque is not specified on the capacitor, use 20 Nm
tightening torque
If the capacitance is more than 2 % off the manufacture capacitance,
replace the capacitor.

8.3 Measuring Of Rectifer Protection Circuit Capacitors (Cr)

Measure the capacitance of the rectifier protection circuit capacitors (Cr)

annually. It is recommended to perform the first measurement during
the commissioning to get a reference value for the next measurements.
For the measurement:
• If the manufacture values of each capacitor are not available, the
first measurement can be used as a reference for the following
preventive maintenances
• Disconnect the wires / busbars
• Perform the measurements according the inspection record. If
possible, write down the serial number of each capacitor in the
inspection record template
• Connect the wires / busbars with the marked tightening torque (see
separate sticker on the capacitor). If the tightening torque is not
specified on the capacitor, use 20 Nm tightening torque
If the capacitance is more than 2 % off the manufacture capacitance,
replace the capacitor.

8.4 Measuring Of The Output Filter Capacitors (Cf)

Note! The output filter capacitors (Cf) are not of self-healing design and
therefore it is not possible to detect any aging in them and it is also not
necessary to perform annual measurements on them.

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Chapter 8 - Inspection Of Capacitors
ABB
8.5 Visual Checking Of Other Capacitors (Ccl, Cm and Cb)

Check visually the condition of the Ccl and Cm capacitors annually.

Note especially the following:
• Are there any signs of overheating
• Are there any bulges

8.6 Measuring of other capacitors (Ccl, Cm and Cb)

Measure the capacitance of the capacitors annually. It is recommended

to perform the first measurement during the commissioning to get a
reference value for the next measurements.
For the measurement:
• Disconnect the wires / busbars
• Perform the measurements according to the inspection record
• Connect the wires / busbars, use 10 Nm tightening torque for the
connections (bolt size M8 10 Nm, bolt size M6 6 Nm)

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Chapter 9 - Insulation Test
Make the insulation test every 2nd year for the frequency converter,
supply transformer and motor. The power cables to the converter
(incoming and outgoing) need to be disconnected for the test.
For the measurement:
• Perform the test according to the ACS1000 Commissioning
Instruction
• Enter the insulation resistance values of each measurement in the
inspection record template

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Chapter 10 - Special Check List For First Maintenance ABB

Chapter 10 - Special Check List For First Maintenance

During the first preventive maintenance, check all special items
according to the PRU' s information (for more information see the MV
AC Drives Portal/After Sales/ACS 1000/Service Instructions & Hints).
Pay special attention to the following items:
• SOA supervision parameters in software versions older than
MSOC3030
• Minimum speed limit / speed step in software versions older than
MSOC3030
• The lot of the drive'
s current transducers, the numbers must not be
between 99000xxx and 99120xxx
• Wiring of the 2nd EPS board (if installed)

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Chapter 11 - Test Run
After the maintenance a test run must be performed. Before starting, pay
special attention to the following items:
• Make sure that all cables and terminals are properly in their positions
and there are no foreign objects inside the frequency converter before
closing the doors
• There is no harm or risk to run the motor / process
• Possible auxiliary groundings have been removed
Monitor (using DriveWindows or DriveDebug) the behaviour of the DC
voltage during charging by recording the following signals:
• 2.07 DC VOLTAGE Udc 1 + Udc 2
• 2.03 DC VOLTAGE Udc 1
• 2.05 DC VOLTAGE Udc 2
Observe the function of the drive with its normal load. Record (using
DriveWindows or DriveDebug) the following signals during the test:
• 1.02 MOTOR SPEED
• 1.08 MOTOR TORQUE FILT
• 3.13 USED TORGUE REF
• 1.07 MOTOR CURRENT
• 2.07 DC VOLTAGE Udc 1 + Udc 2
• 2.15 SW FREQ ACT

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Chapter 12 - Inspection Of Spare Parts And Documentation
ABB
Chapter 12 - Inspection Of Spare Parts And
Documentation
Check the customers spare parts and documentation. Pay special
attention to the following items:
• That the software version of the spare AMC3 flash memory
corresponds to the actual software version in the drive. If needed,
load the correct software version and set the basic parameters
according the drive’s parameter
• That the EPLD chip on spare INT board corresponds to the actual
drive EPLD version
• That the Signal and Parameter Table of the ACS 1000 User’s
Manual corresponds to the actual software of the drive
• That all spare boards are of the latest accepted versions

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Chapter 13 - Reporting
Send the following files by email to MV AC Supportline (MV AC
Supportline/CHIND, mvac.supportline@ch.abb.com) after the
maintenance:
• Inspection record (xls)
• Field report (using the MV AC drives field report template)
• Parameter files (txt or dwp file formats)
• Software backups (bpg, pac or tar file formats)
• Fault logger data file (dwf or txt file formats)
• Test run recordings (DriveWindows or DriveDebug monitoring files
or attached to the field report)

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