ACS2000 4kV Service Manual

Medium Voltage Drives
Service Manual
ACS2000, 300 - 3000 HP, NEMA
Table of contents
Table of contents TOC-1
List of figures LOF-1
List of tables LOT-1
General information on manual and equipment GI-1
Copyright notice GI-1

Document identification GI-1
Contact information GI-1
Equipment covered by the manual GI-1
Target groups and required qualifications GI-2
Related documentation GI-2
Meaning of terms and abbreviations GI-3
Trademarks GI-6
Writing conventions GI-7
Meaning of icons GI-7
Text conventions GI-7
Illustration conventions GI-8
Tools tables GI-8
Personal equipment, tools GI-8
Personal safety GI-8
Personal computer GI-8
Measuring equipment GI-9
Antistatic equipment GI-10
Cleaning equipment GI-10
Grounding set GI-11
Tools for replacing phase modules GI-11
Tools for disassembling phase modules GI-12
Tools for removing, installing crowbars GI-12
ACS2000 Service manual 2UEB000096 Rev. - B TOC-1

Table of contents
Chapter 1 - Safety 1-1
1.1 Meaning of safety instructions 1-1

1.2 General safety information 1-2
Chapter 2 - General maintenance instructions 2-1
2.1 Before starting to work 2-1

2.2 Checks during maintenance 2-1
2.3 Instructions for faulty components 2-2
2.4 Spare parts 2-2
2.5 Documentation 2-2
2.6 Documentation and backup copies for MV Drives Supportline 2-2
2.7 DriveMonitor™ 2-3
Chapter 3 - Uploading data from the black box 3-1
Chapter 4 - Stopping, de-energizing, grounding the drive 4-1
4.1 Stopping and de-energizing the drive locally 4-1

4.2 Malfunctioning grounding switch 4-6
Chapter 5 - Opening the doors 5-1
5.1 Doors and door locks 5-1

5.2 Door opening procedure 5-2
Frames 1, 2 5-2
Frame 3 5-3
Chapter 6 - Visual checks and cleaning 6-1
6.1 Safety / general preparations 6-1

6.2 Visual check of the drive 6-1
6.3 Cleaning 6-2
TOC-2 2UEB000096 Rev. - B ACS2000 Service manual

Table of contents
Chapter 7 - Inspecting bolted connections 7-1
7.1 Tightening torques for bolted connections 7-1

7.3 Power cables 7-1
7.4 Busbars and other main connections 7-2
7.5 Control cables 7-2
Chapter 8 - Replacing filter mats 8-1
8.1 Maintenance intervals and replacement indications 8-1

8.3 Filter mat class and dimensions 8-2
8.4 Filter mat location 8-2
8.5 Filter mat replacement procedure 8-5
Chapter 9 - Replacing line-side fuses 9-1
9.1 Tools 9-1

9.2 Maintenance intervals 9-1
9.4 Fuse locations 9-2
9.5 Checking fuses 9-3
9.6 Fuse replacement 9-4
Chapter 10 - Inspecting optical fibers 10-1
10.1 Tools and accessories 10-1

10.4 Visual inspection 10-2
10.5 Measuring the attenuation 10-2

Table of contents
Chapter 11 - Inspecting power capacitors 11-1

11.2 Capacitor type 11-1
11.3 Location 11-2
11.6 Inspecting, measuring the capacitors 11-5
11.6.1 Visual inspection 11-5
11.6.2 DC-link capacitors 11-6
11.6.3 IFU capacitors 11-7
11.6.4 EMC and clamping capacitors 11-8
Chapter 12 - Testing the insulation of the drive 12-1

12.2 Safety 12-1
12.3 Testing the insulation of the drive (No integrated input contact disconnect) 12-2
12.3.1 Test procedure setup 12-2
12.3.2 Test procedures 12-3
12.3.3 Restore drive 12-4
12.4 Testing the insulation of the drive (With integrated input contact disconnect option) 12-5
12.4.1 Test procedure setup 12-5
12.4.2 Test procedures 12-6
12.4.3 Restore drive 12-7
Chapter 13 - Replacing the redundant fan 13-1

13.3 Checks 13-1
13.4 Redundant fan replacement preparation 13-2
13.5 Redundant fan removal procedure - Frame 1 13-3
13.5 Redundant fan removal procedure - Frames 2, 3 13-6
13.6 Redundant fan reinstallation procedure 13-8

Table of contents
Chapter 14 - Replacing a phase module 14-1
14.1 Overview 14-1

14.2 Dimensions and weight 14-2
14.3 Required tools and accessories 14-3
14.4 Phase module replacement procedure 14-3
14.4.1 De-energizing the drive 14-3
14.4.2 Removing the phase module 14.6
14.4.2.1 Frame 1 14-6
14.4.2.2 Frames 2, 3 14-8
14.4.3 Replacing the phase module 14.9
Chapter 15 - Inspecting phase modules 15-1
15.1 Checking a phase module for short-circuit 15-1

15.1.1 Visual check of the phase module 15-1
15.1.2 Measuring the voltage across phase module terminals 15-2
Chapter 16 - Checking and replacing the crowbar 16-1
16.1 Function 16-1

16.2 Location 16-2
16.3 Checking and replacement indications 16-3
16.4 Checking the crowbar thyristors 16-3
16.4.1 Tools 16-3
16.4.2 Safety / general preparations 16-3
16.4.3 Checks 16-4
16.5 Removing the crowbar 16-6
16.5.1 Tools and accessories 16-6
16.5.2 Safety / general preparations 16-7
16.5.3 Replacing crowbar procedure 16-7
Chapter 17 - Replacing circuit boards 17-1
17.1 Location 17-1

17.2 Handling instructions 17-4
17.2.1 Electrostatic precautions 17-4
17.2.2 Fiber-optic cables 17-4
17.4 Replacing the AMC circuit board 17-5
17.4.1 Changing the AMC software flash memory 17-5
17.5 Main INT circuit board 17-8

Table of contents
Chapter 18 - Meaning of
LEDs 18-1
18.1 AMC circuit board 18-1

18.2 Main INT circuit board 18-2
18.3 Phase INT circuit board 18-3
18.3.1 IOEC modules 18-4
18.3.2 Serial communication interfaces 18-5
Appendix A - Maintenance schedule MS-1

Table of contents

List of figures
Figure 3-1 AMC circuit board - Black box 3-1
Figure 4-1 Four-way grounding set 4-4
Figure 4-2 ACS2000 1MVA AFE - Connecting a grounding set 4-5
Figure 5-1 Door locks 5-1
Figure 5-2 AFE/INU door safety interlocking location 5-3
Figure 5-3 Frame 3 - AFE/inu door additional safety measure location 5-4
Figure 8-1 Frame 1 - Filter mat locations 8-2
Figure 9-1 Air-cooled fuse box 9-2
Figure 9-2 Checking power fuses 9-3
Figure 9-3 Integral input contactor disconnect fuse viewing wing 9-4
Figure 9-4 Separation panels 9-5
Figure 9-5 Integral input disconnect fuses 9-6
Figure 11-1 Frame 1 - Capacitors 11-2
Figure 11-2 DC-link capacitors 11-6
Figure 11-3 Frames 1, 2 IFU capacitor 11-7
Figure 11-3 Frame 3 IFU capacitor 11-7
Figure 12-1 Power electronics overview 12-3
Figure 13-1 Redundant fan 13-2
Figure 13-2 Fan installation 13-8
Figure 14-1 AFE and INU compartment 14-1
Figure 14-2 Phase module 14-2
Figure 15-1 Frame 1 - Measuring point locations 15-1
Figure 15-1 Frames 2, 3 - Measuring point locations 15-2
Figure 15-2 Measuring points diagram 15-4
Figure 16-1 Frames 2, 3 - MVA AFE - Crowbar assembly 16-1
Figure 16-2 Crowbar location 16-2
Figure 16-3 Grounding Switch 16-4
Figure 16-4 Frames 2, 3 - Crowbar connectors 16-5
Figure 17-1 Frame 1 - MVA AFE - Circuit boards 17-1
Figure 17-2 AMC flash memory 17-6
Figure 17-3 Main INT circuit board 17-8
Figure 18-1 AMC circuit board 18-1
Figure 18-2 Main INT circuit board 18-2
Figure 18-3 Phase INT circuit board 18-3
Figure 18-4 IOEC module 18-4
Figure 18-5 AF 100 interface 18-5
Figure 18-6 Ethernet interface 18-6
Figure 18-7 Modbus interface 18-7
Figure 18-8 Profibus interface 18-8
ACS2000 Service manual 2UEB000096 Rev. - B LOF-1

List of figures
LOF-2 2UEB000096 Rev. - B ACS2000 Service manual

List of tables
Table 8-1 Filter mat identification 8-2
Table 9-1 Power fuse ratings 9-7
Table 10-1 Optical meters - Settings 10-2
Table 10-2 Optical fibers - Limit values 10-3
Table 14-1 Phase module replacement information 14-2
Table 14-2 Phase module special tools 14-3
Table 15-1 Readings of a healthy phase module in diode mode 15-3
Table 16-1 Crowbar resistance measurement 16-5
Table 18-1 LEDs - AMC circuit board 18-1
Table 18-2 LEDs - Main INT circuit board 18-2
Table 18-3 LEDs - Phase INT circuit board 18-3
Table 18-4 LEDs - IOEC module 18-4
Table 18-5 LEDs - AF 100 interface 18-5
Table 18-6 LEDs - Ethernet interface 18-6
Table 18-7 LEDs - Modbus interface 18-7
Table 18-8 LEDs - Profibus interface 18-8
ACS2000 Service manual 2UEB000096 Rev. - B LOT-1

List of tables
LOT-2 2UEB000096 Rev. - B ACS2000 Service manual

General information on manual and equipment
Copyright notice
The information in this manual is subject to change without notice.
This manual and parts thereof must not be reproduced or copied, or
disclosed to third parties, nor used for any unauthorized purpose without
written permission from ABB Inc., Medium Voltage Drives.
The hardware described in this manual is provided under a license and may
be used, copied, or disclosed only in accordance with the terms of such
license.
Document identification
Ownership ABB Inc.
Document number 2UEB000096
Revision index B
Issue date 03.31.2015
Contact information
Address ABB Inc.
16250 W. Glendale Drive
New Berlin, WI 53151
Phone 800-752-0696
Fax 262-780-5150
Email mv.drives@us.abb.com
www.abb.us/drives
Equipment covered by the manual

The manual covers the preventive and corrective maintenance of the
ACS2000 with active front end.
The manual does not claim to cover all variations and details of the
equipment, nor to consider all eventualities that may arise during service of
the equipment.
If information is required beyond the instructions in this manual, refer the
matter to ABB. See section Contact information.
ACS2000 Service manual 2UEB000096 Rev. - B GI-1

Target groups and required qualifications

The equipment presented in this manual is part of an industrial environment
where voltages are present that contain a potential hazard of electric shock or
burn.
For this reason, maintenance on the equipment may only be carried out by
personnel who
• are qualified to carry out preventive and corrective maintenance on
equipment as described in this manual,
• are thoroughly familiar with the equipment,
• have a sound knowledge of the relevant electrical codes and
specifications covering low and medium voltage equipment,
• are able to assess the hazards associated with the energy sources of the
equipment and act correspondingly,
• know the safe shutdown and grounding procedures for the equipment.
Related documentation
Title Document number
ACS2000 4k User manual 2UEA001270
ACS2000 NEMA Spare parts manual 2UEB000131
Warranty directives 3BHS404420 ZAB E01
Wiring diagrams Refer to customer prints in Appendix E of the

ACS2000 4k User manual
GI-2 2UEB000096 Rev. - B ACS2000 Service manual

Meaning of terms and abbreviations

The following table lists terms and abbreviations you should be familiar with
when using the manual. Some of the terms and abbreviations used in the
manual are unique to ABB and might differ from the normal usage.
Term /
Meaning
Abbreviation
AFE Active Front End
The AFE, also referred to as ARU (Active Rectifier Unit), is the line-side
rectifier of the drive that enables optional four-quadrant operation and
reactive power compensation.
AMC circuit board Application and Motor Controller
The digital signal processor is the heart of the control system of the
drive. A separate AMC circuit board is assigned to the line-side rectifer
(AFE) and the motor inverter (INU) of the drive.
CDP Control/Display Panel
Removable controller of the drive located on the exterior of the terminal

entry unit door.
Converter Short form for ACS2000 frequency converter
Cluster A cluster is a synonym for a group of hardware modules of the drive

control system.
CT Current transducer
DC Direct current
DC link The DC link consists of the capacitor, the charging unit and the
grounding switch. Energy is absorbed and stored in the DC link
capacitor for distribution.
DDCS Distributed drive control system
DDCS is an acronym for a fieldbus communication protocol designed

for data transfer via fiber-optic cables
Drive Short form for ACS2000 frequency converter
Drive system The drive system includes all equipment used to convert electrical into
mechanical power to give motion to the machine.
DriveBus Communication link dedicated for ABB drives
DriveDebug DriveDebug is part of ABB’s DriveWare ® software tools for drives

using the DDCS communications protocol. DriveDebug runs on
computers with Windows ® operating systems. DriveDebug is a
specialist’s tool used to diagnose, tune and troubleshoot ABB drives.
DriveWindow DriveWindow is a DriveWare ® product. DriveWindow is a Windows ®

application for commissioning and maintaining ABB drives equipped
with fiber-optic communication.

Term /
Meaning
Abbreviation
DriveMonitor™ DriveMonitor is a monitoring and diagnostics system that allows

secure access to the drive via the internet from a remote location.
DriveMonitor provides long-term monitoring functions that allow
the user to read/display equipment status and improve equipment
performance.
EMC Electromagnetic compatibility
All measures to suppress electromagnetic disturbances caused

by different electrical equipment in the same electromagnetic
environment, and to strengthen the immunity of the equipment to such
disturbances.
Equipment ACS2000 and related equipment
Ground Earth
To ground The conducting path (e.g. conductor) between the electric equipment
(e.g. frequency converter) and the earth. The electric equipment is
connected to the earth, e.g. by a grounding set or a grounding switch.
HVD High voltage divider
IFU Input filter unit
The IFU is a tuned filter: inductors, resistors and capacitors that reduce
harmonic voltages injected to the supply network.
Inspection Part of preventive maintenance. Careful examination of an item in

order to assess its condition.
INT Interface
INU Inverter unit of the drive. The INU converts the DC voltage to the
required AC motor voltage and frequency.
IPS Isolated power supply
IOEC module Term of ABB’s I/O system. The I/O module is an active input or output
device for digital or analog signals.
LED Light emitting diode
Line voltage RMS voltage of the main power supply of the drive – line to line
MCB MV switchgear
MV switchgear Medium voltage switchgear isolation device
The MV switchgear is a mandatory inter-connection device of the drive

system and connects / disconnects the main power supply to the drive.
The MV switchgear must be controlled entirely by the drive.
NP Neutral point
OEI Optical electrical interface
PCB Printed circuit board

Term /
Meaning
Abbreviation
PCC Point of common coupling. The PCC is the point in the electrical power
supply system where the responsibility of the utility changes to the
industrial customer. The utility is responsible to provide clean voltage
and current with respect to harmonic distortion up to the PCC. The
industrial customer is responsible not to distort voltage and current by
its electrical systems.
PE Protective earth
Phase module The phase module is a compact assembly of wired components

including power semiconductors and circuit boards that serves as a
standardized building block for the AFE and INU of the drive.
PPCS Power plate communication system
PPCS is an acronym for a fieldbus communication protocol designed

for high speed data transfer via fiber-optic cables between the AMC
circuit board and phase INTerface circuit boards.
Preventive The maintenance carried out at predetermined intervals or according

maintenance to prescribed criteria and intended to reduce the probability of failure or
the degradation of the functioning of an item. 1
RTD Resistance temperature detector or device
The RTD is a temperature sensor where the change in electrical

resistance is used to measure the temperature.
Safeline ABB synonym for uninterruptible power supply
Service Preventive or corrective maintenance tasks that must be carried out

exclusively by ABB service personnel.
Supervisory signal Indicates the operating condition of a circuit or device.
SW Software
SYN circuit board Synchronization circuit board
TC Short form for terminal compartment of the drive
VLSCD Voltage level short circuit detection
Zero speed Used in the manual to indicate that the drive has reached the value
threshold “zero speed” that is set in a parameter. The value can be set in the
range from 0 to maximum speed (speed is measured in rpm).
1 IEC, International Electrotechnical Commission, Electropedia, http://www.electropedia.org/

Trademarks
Names that are believed to be trademarks of other companies and
organizations are designated as such. The absence or presence of such a
designation should however not be regarded as an offence of the legal status
of any trademark. The following registrations and trademarks are used in this
manual:
Term /
Meaning
Abbreviation
Windows® Registered trademark of Microsoft Corporation
Industrial IT™ Trademark of ABB
DriveWare® Registered trademark of ABB
DriveMonitor™ Trademark of ABB
Advant® Registered trademark of ABB
Advant Fieldbus™ Trademark of ABB
Ethernet® Registered trademark of Xerox Corporation
Fluke® Registered trademark of Fluke Corporation
Profibus® Registered trademark of Profibus International (P.I.)
Modbus® Registered trademark of the Modbus IDA organization
ControlNet® Registered trademark of ControlNet International, Ltd.
DeviceNet® Registered trademark of the Open DeviceNet Vendor Association, Inc.
Kirk® key Registered trademark of the Kirk Key Interlock Company
Anybus® Registered trademark of HMS Industrial Networks, Inc.
3M™ Registered trademark of 3M
3M Scotch-Brite™ Registered trademark of 3M

Writing conventions
Meaning of icons
Illustrates an illuminated pilot light or pushbutton.
Illustrates a button or key to be pressed.
Arrows indicate an alternating display message.
Refers to further information in a separate document.
Points to ESD handling precautions.
Text conventions
• Bulleted list
Used to list items or steps in a procedure, where the sequence does not
matter.
• Bulleted list of a subsection following a main paragraph
Used to list items for procedures, where the sequence does not
matter.
1 Steps of a procedure, to be followed in the specified order (for example,
1, 2, 3.....)
1 Figure legend, numbers identify the items referred to in the associated
illustration (for example, 1, 2, 3.....)
Bold is used to highlight switches to be operated, status messages shown in
a display and special terms.
UPPERCASE letters refer to a parameter.
Italic is used for references to illustrations, chapters and supplementary
documentation.
Gray-shaded areas highlight text.

Illustration conventions

Frame 1, ACS2000 4k V, is used for general layout and location photos
unless expressly stated. The electrical layout, the physical order, and the
topology are shared between all frames.
• Terminal Entry Unit (TEU) and LV COntrol Unit (COU) are shared with all
frames, left bay.
• The Input Filter Unit (IFU), filter bay, grows to accommodate the higher
current for each frame.
• The INverter Unit (INU) and power modules, right bay, grow to
accommodate the higher current for each frame.
Tools tables
10 M6x25 6 Nm 17 mm
Fastener
(Most likely used)
Numbers of fasteners used
Size of fastener
Tightening torque of fastener
Recommended tool(s)
Personal equipment, tools
Personal safety
• Safety shoes
• Safety goggles or spectacles
• Dust mask
• Hearing protection earmuffs
• Safety helmet
• Soft leather mechanic’s gloves
Personal computer
Personal computer with:
• NDPA-02 PCMCIA-card, NDPC-12 optical transmitter / receiver
(or RUSB-02)
• Optical fibers
• DriveWindow or DriveDebug

Measuring equipment
1 2 3
approximately 30 cm [11.8 in.]
• Multimeter (1), for example, Fluke® 87

• Capacitance meter (2)
• Test leads and test probes of sufficient length (3) and short uninsulated
tips (see circles).
• 5 kV insulation resistance tester, for example:
• MEGGER AVO BM11D (1) or MIT510 (2)
1 2

• Test leads for short-circuiting terminals

• Fiber-optic cable tester, for example:
• Tempo 253B LED source (set to 660 nm, no modulation), 10ZP
Adapter
• Tempo 557B power meter (set to 660 nm, dBm), 10ZP Adapter
• Photom 205A - optical power meter, Haktronics Co., Ltd
• LEONI optical power meter
• LEONI optical sender ZXXX-TS0
• Fiber-optic GmbH, 96524 Neuhaus-Schierschnitz, ZXXX-TM0
Antistatic equipment
1 2
Legend
1 Antistatic kit
2 Antistatic gloves
Cleaning equipment
• Antistatic vacuum cleaner (for example, SV-497 ABF - VACUUM 3M™
220 V from 3M) for cleaning sensitive electronic components (for
example, printed circuit boards)
• Antistatic brush for cleaning printed circuit boards
• Cloths and brushes for general cleaning

Grounding set
Tools for replacing phase modules
1 2
3
5
Legend
1 Hoisting gear for removing 2 MVA phase modules

2 Module tray
3 Socket wrench
4 Extension bars (150, 225 mm)
5 Drive socket (10 mm)

Tools for disassembling phase modules
1 3 4 5
2
6
Legend
1 Socket wrench
2 Extension bar
3 Torx bit or socket bit (TX 10)
4 Philips bit or socket bit
6 Allen key or hexagon bit socket
7 Ratchet ring spanner (10 mm)
Tools for removing, installing crowbars
1 3 4
Legend
1 Socket wrench with extension bar and 5.5 mm drive socket

3 Socket wrench with 8 mm hex-key socket
4 Small ladder


Chapter 1 - Safety
1.1 Meaning of safety instructions

Safety instructions are used to highlight a potential hazard when working on
the equipment. Safety instructions must be strictly followed! Noncompliance
can jeopardize the safety of personnel, the equipment and the environment.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result
in minor or moderate injury.
NOTICE
NOTICE is used to address practices not related to personal injury.
The safety instructions are derived from the following standards:

• ISO 3864-2:2004 (E)
Graphical symbols – Safety colors and safety signs – Part 2: Design
principles for product safety labels
• ANSI Z535.6
American National Standard for Product Safety Information in Product
Manuals, Instructions, and Other Collateral Materials
ACS2000 Service manual 2UEB000096 Rev. - B 1-1

Chapter 1 - Safety
1.2 General safety

information
To maintain safety and minimize hazards observe the following:
• Before the drive is energized, make sure that:
• all foreign objects are removed from the drive,
• all internal and external covers are securely fastened and all doors
are closed, locked and / or bolted.
• Before starting to work on the drive, refer to Chapter 4 - Stopping,
de-energizing, grounding the drive to make sure that:
• the main and auxiliary power supply to the drive is switched off,
locked out, and tagged out,
• the drive is de-energized and the DC bus is discharged,
• safety ground connections are in place,
• appropriate personal protective equipment is provided and used
when required,
• everyone involved is informed.
• When working near the running drive, protective earmuffs should be
worn.
• Before work is carried out simultaneously on the drive and on other drive
system equipment, make sure that
• the relevant safety codes and standards are observed,
• all energy sources of the equipment are turned off,
• lockout and tagout devices are in place,
• barriers and appropriate covers are used on equipment which is still
live,
• everyone involved is informed.
• In case of fire in the drive room:
• Observe the established rules and regulations for fire protection.
• Only firemen with appropriate protective equipment are permitted to
enter the drive room.
1-2 2UEB000096 Rev. - B ACS2000 Service manual

Chapter 2 - General maintenance instructions
To improve the efficiency of ABB’s service performance, to provide quality
service, and to improve and maintain the quality of the products, observe the
following when on site.
2.1 Before starting to work

Carry out the following steps each time you arrive on site:
• Upload the parameters including the parameter groups above 100.
• Back up the drive data.
• Drives with black box
Back up the contents (data and fault loggers) of the black box.
For further information, Chapter 3 - Uploading data from the black
box.
• Drives without black box
Upload the data and the fault logger.
Upload the data from the AMC circuit board of the AFE and INU
regardless of where the fault occurred in the drive.
If you need assistance, contact the MV Drives Supportline immediately.
When contacting the MV Drives Supportline, always include the following
information:
• Serial number of the drive
• Uploaded data of the drive
2.2 Checks during maintenance

• Visually check:
• The integrity of the input fuses
• The phase modules while the auxiliary power supply is ON
• Attach a label with the following information to each phase module which
is replaced:
• Location of the phase module
• Serial number of the drive
• Date of the maintenance work
Example: INU A / SN XXX / DD-MM-YY

Chapter 2 - General maintenance instructions
2.3 Instructions for faulty components

1 Order the replacement for a faulty component from ABB.
2 Package the faulty component and attach a label with the serial number
of the drive to the parcel.
3 Fill in the warranty report, add the serial number of the faulty component,
and send the report to the MV Drives Supportline.
2.4 Spare parts

• Check that the software version of all spare circuit boards corresponds to
the software version used in the drive.
• If necessary, update the spare circuit boards with the correct software
version and the parameters used in the drive.
• Check that all spare circuit boards are of the correct type.
2.5 Documentation
• Check that a complete set of documentation (paper or electronic media)
is on site.
2.6 Documentation and backup copies for MV Drives Supportline

After each site visit, send the following information to the MV Drives
Supportline:
• MV drives field report summarizing all actions, findings, summary of the
fault history and other relevant information
Use the MV drives field report template.
• Warranty and failure report if a faulty component has been replaced
Use only the infopath template.
Include:
• Serial number of the faulty component
• Mounting position of the faulty component
• Parameters including parameter groups above 100.
• DriveDebug: save all parameters in one file.

• DriveWindow: save the parameters in two files:
• File 1 includes parameter groups 112 and 190,
• File 2 includes all other parameter groups above 100.
• Software backup files

• Back up the drive fault data.

• Drives with black box
Back up the contents (data and fault loggers) of the black box.
For information, see Chapter 3 - Uploading data from the black box.
• Drives without black box
Upload the data and the fault logger.
Upload the data from the AMC circuit board of the AFE and INU
regardless of where the fault occurred in the drive.
2.7 DriveMonitor™
Depending on the operating time of DriveMonitor™, the following is
recommended to prevent data loss and to provide the necessary memory
space on the harddisk of the DriveMonitor™ computer:
• After 1 – 2 years of operation:
Back up the data on an external harddisk drive or a PC.
• After five years of operation:
Change the harddisk of the DriveMonitorTM computer.


Chapter 3 - Uploading data from the black box
The AMC34 circuit board is equipped with an additional flash memory circuit
board (box in Figure 3-1). The circuit board serves as a black box which
saves data and fault loggers of the drive for a longer time even if the auxiliary
power has been switched off. If a fault occurred in the drive, the black box
data should be sent to the MV Drives Supportline of ABB for assistance in
analyzing the fault.
Figure 3-1 AMC circuit board - Black box
The tools for uploading the content of the black box are part of the loading
package. The tools become only visible after the command l_acs has been
entered in a DOS window. Afterwards the folder black box is created in the
loading package. The folder contains one file blackbox_upload.exe
1 To upload any data from the black box, open a DOS window and open
folder black box. All files downloaded from the black box will be saved in
this folder.
2 After uploading move the files to another folder or rename them.
Otherwise they will be overwritten the next time a file is downloaded from
the black box.
The black box has two separate parts:
• data loggers
• fault / parameter loggers.

Chapter 3 - Uploading data from the black box
Uploading the fault To upload the fault logger, enter the command:
logger blackbox_upload 1 /bb_upload_data /mbaud=8
1 indicates the channel 3 node number of the circuit board.
To upload data from a circuit board with node number 2, enter the
command
blackbox_upload 2 /bb_upload_data /mbaud=8
Uploading the data To upload the dataloggers, enter the command:

logger blackbox_upload 1 /dl_upload_data /mbaud=8
1 indicates the channel 3 node number of the circuit board.
Each data logger is uploaded to a new file. Empty data loggers are not
uploaded.
If the black box is full, uploading the data can take up to 15 minutes. Once
started, do not interrupt the upload. If the upload is interrupted (for example
by closing the DOS window), some communication services will not be closed
properly, and it will not be possible to start the upload again. If this happens,
do the following:
Open DriveDebug and set any bit of parameter 103.01 to 1.
Uploading of data should work again.
NOTICE
mband = 8 is the maximum speed used for uploading. It is not
recommended to use this speed while the drive is running. In this case
mband = 4 should be used..

Chapter 4 - Stopping, de-energizing, grounding the drive
The following section describes how the drive is de-energized using the local
operator panel of the drive. If the drive is controlled from remote, follow the
established shutdown procedures.
4.1 Stopping and de-energizing the drive locally
Stopping 1 Set the CDP control panel to LOCAL mode.
For detailed instructions, see the User manual, Chapter 9 - CDP control
panel.
2 Press the stop key on the CDP control panel.
The motor stops according to the preset stop function. While the motor
stops, the status line of the display shows ReadyRef. The run status
indication blinks during the stop sequence.
1 L -> 600.0 rpm

StateINU ReadyRef
MOTOR SP 300.00 rpm
POWER 20.0 kW
Just before the motor comes to a standstill, the CDP control panel
displays shortly the message Stopping.
1 L -> 600.0 rpm 0

StateINU Stopping
MOTOR SP 0.00 rpm
POWER 0.0 kW

Chapter 4 - Stopping, de-energizing, grounding the drive
When the drive has stopped modulating, the CDP control panel displays
ReadyRun.
1 L -> 600.0 rpm 0

StateINU ReadyRun
MOTOR SP 0.00 rpm
POWER 0.0 kW
De-energizing 3 Press the SUPPLY OFF pushbutton to disconnect the drive from the
main power supply. The following takes place:
• The MV (Medium Voltage) switchgear opens.
• The DC link discharges.
While the DC link discharges, the display shows OffSeqOn.
1 L -> 600.0 rpm

StateINU OffSeqOn
MOTOR SP 0.00 rpm
POWER 0.0 kW
• The SUPPLY OFF pushbutton flashes and changes to a steady

light when the DC link has discharged completely.
When the DC link has discharged, the display shows ReadyOn.
1 L -> 600.0 rpm

StateINU ReadyOn
MOTOR SP 0.00 rpm
POWER 0.0 kW

Grounding 4 Rack out, lock out, ground and tag out the main power feeder.
5 Turn the grounding switch to the grounded position when the light
GROUNDING SWITCH RELEASED is on.
The lamp lights up after the fan has stopped. The fan runs continuously
for a preset time after the main power supply has been switched off to
dissipate the heat from the resistor assembly in the back of the cabinet.
If the pilot light does not light up and there is reason to believe that the
grounding circuit is malfunctioning, see 4.2 Malfunctioning grounding
switch for further information.
When the grounding switch is in the grounded position, the CDP
control panel shows the following.
1 L -> 600.0 rpm

StateINU DCGnd NOpen DCGnd NOpen
NotReadyOn
MOTOR SP 0.00 rpm
AFE NotRdy
POWER 0.0 kW
You can open the doors of the drive now.

6 Switch off and lockout all auxiliary voltages from external sources.
7 Verify that the drive system is de-energized.
Connecting a
grounding set WARNING
Hazardous voltages!
When maintenance on the drive is carried out that includes the removal of
phase modules, the connection of grounding equipment at the appropriate
locations is necessary. The grounding equipment ensures that hazardous
voltages cannot be fed into the drive from the main power supply or the
motor.

Legend
3
1 Telescopic insulating pole

2 Enclosure ground clamp
3 Busbar ground clamps
Figure 4-1 Four-way grounding set
8 Connect the clamps of the grounding set in the following sequence:

1 Connect the enclosure ground clamp (2 in Figure 4-1) to the ground
ball stud of the cabinet’s grounding bar (4 in Figure 4-2).
2 Use the telescopic insulating pole (1 in Figure 4-1) to connect the
busbar ground clamps (3 in Figure 4-1) to the ground ball studs of
the busbars, and to tighten each connection.
3 Connect the inner most busbar first (1 in Figure 4-2), then the
middle busbar (2 in Figure 4-2) and lastly the outer busbar (3 in
Figure 4-2).

1 2
Legend
3
1 Phase U busbar
2 Phase V busbar
3 Phase W busbar
4 Grounding bar
Figure 4-2 ACS2000 1MVA AFE - Connecting a grounding set
The drive is now de-energized, and safe access is possible.

4.2 Malfunctioning
grounding switch
CAUTION
If the control circuit of the grounding switch malfunctions, it is possible that
the grounding switch can be closed while the DC link is still charged.
Closing the switch will short-circuit the DC capacitors. The short-circuit
will manifest itself in a loud bang. To prevent temporary minor hearing
impairment, follow the instructions below.
When the DC link of the drive is de-energized, the light GROUNDING

SWITCH RELEASED comes on to indicate that the grounding switch
is released and can be turned to the grounded position. If the pilot light
does not light up or there is reason to assume that the grounding circuit is
malfunctioning, proceed as follows:
1 Do not try with force to turn the grounding switch in any direction. If
tried, the handle and / or the switch could be damaged.
2 Verify that the MV (Medium Voltage) switchgear is in the open position.
3 Check the drive status on the CDP control panel.
The message ReadyOn is displayed when the DC link of the drive has
been discharged.
1 L -> 0.0 rpm

StateINU ReadyOn
MOTOR SP 0.00 rpm
POWER 0.0 kW
4 Verify that the DC link has been discharged.

The discharging level can be viewed in parameter 2.01 DC VOLTAGE.
The value should be below 50 V.
5 Check if there are any alarm and fault messages on the display.
6 Try to rectify the reason for the alarms and faults, and then press the
RESET key on the CDP control panel.

Chapter 5 - Opening the doors
5.1 Doors and door locks

To ensure safety and to prevent the doors from being opened unintentionally,
both doors are lockable, and the AFE/INU compartment door where medium
voltage is present during operation is mechanically interlocked. The door
locks also have inserts to ensure that these doors can only be opened by
personnel authorized to do so.
WARNING
Dangerous voltage is present. Grounding the drive does not switch off
control voltage from a separate source. Auxiliary power supply will remain
live.
Round key Triangular key

PN: 2UEA002174 PN: 2UEA002175
1 2 3
Legend
1 Door of control compartment with swing 3 Door of AFE/INU compartment:

frame: lockable Mechanically interlocked and lockable
The door of the control compartment Door cannot be opened when the main
is not integrated into the interlocking power has been applied.
system and can always be opened.
Door cannot be opened when the drive
2 Cover of input filter compartment: is ungrounded.
bolted
Figure 5-1 Door locks

Chapter 5 - Opening the doors
5.2 Door opening

procedure
The door of the AFE/INU compartment (see 3 in Figure 5-2) is secured by
two safety measures. Frame 3 drives also include a third safety measure, the
door interlocking mechanism. The door will not open unless these steps are
completed.
DANGER
Hazardous voltage! Dangerous voltage is present when
input power is connected.
Verify that the main power supply is switched off, locked out
and tagged out.
1 Disconnect upstream power
using the Kirk® key and perform WARNING
generally accepted Lockout-Tagout
WARNING! Dangerous voltage is present when input
Procedures.
power is connected. After disconnecting the supply, wait
until the ground RELEASED indicator lights up (to let the
intermediate circuit capacitors discharge) before attempting
to ground and open the AFE/INU compartment door.
2 Turn the grounding switch to the See User manual, Appendix P - Integral input
grounded position, which can contactor disconnect, located on the CD, for Kirk key
only be done after the DC link location on drives with this option.
capacitors have been discharged.
Open incoming cabinet and
perform Live-Dead-Live check
on incoming terminals. See User Grounding
manual, Chapter 1 - Safety, switch
Chapter 4 - Stopping, de- (shown in
energizing, grounding the drive grounded
and User manual, Chapter 6 - position)
Electrical installation, if you need
further information.

Frame 1 The Kirk key mechanical interlock allows access to the AFE/INU door
only after the main power has been switched off and the ground switch is
moved to the grounded position.
Frame 2 The Kirk key mechanical interlock allows access to the filter compartment
door only after the main power has been switched off and the ground
switch is moved to the grounded position. Once this door has been
opened, the AFE/INU door can be opened by releasing the top and bottom
draw latches located inside the door.
See User manual, Appendix I - Kirk Key Specifications, located on the CD, for
detailed information.
2 1
Legend
1 Grounding switch
(grounded position)
PN: 2UEA000463
2 Kirk key
3 AFE/INU compartment door
Figure 5-2 AFE/INU door safety interlocking location

Frame 3 The Kirk key mechanical interlock allows access to the filter compartment
door only after the main power has been switched off and the ground
switch is moved to the grounded position. Once this door has been
opened, the AFE/INU door can be opened by releasing the top and bottom
draw latches located inside the door.
See User manual, Appendix I - Kirk Key Specifications, located on the CD

for detailed information.
Legend
1 Access doors
2 Rotating bar
3 Spring-loaded
mechanism
2 3
Figure 5-3 Frame 3 - AFE/INU door additional safety measure location

Chapter 6 - Visual checks and cleaning
6.1 Safety / general preparations
DANGER
Hazardous voltage!
Make sure the drive is de-energized according to Chapter 4 - Stopping,
de-energizing, grounding the drive.
6.2 Visual check of the drive

Check the drive and its immediate vicinity visually at the intervals stated on
the maintenance schedule and pay attention to the following items:
• Humidity inside the cabinet
• Permitted range of ambient temperature and humidity of the drive
• Dust built-up inside the cabinet
• Appropriate fastening of cables and wires and connections of cable
shields and screens
• Integrity of the cable insulation
• Correct type of signal and power cables
The outer cable sheath must not be damaged.
• Signs for overheated components, wires, cables or busbars
• Corrosion on circuit boards, connectors or busbars
For reference, see applicable cable specifications.

Chapter 6 - Visual checks and cleaning
6.3 Cleaning
NOTICE
Equipment failure
• Dust on electrical components and wiring causes failure and damages

the components. Dust and moisture can build up in loose connections
and cause loss of low-level signals.
For these reasons, check the cabinet regularly and clean the cabinet if
necessary.
• Alcohol and solvents can damage the components. Use appropriate
and recommended cleansing agents.
When cleaning the drive cabinet, mind the following:

• Cover equipment or assemblies to prevent dirt from falling into them.
• The drive contains components which are sensitive to electrostatic
discharge. Therefore, take electrostatic-sensitive precautions and use
suitable tools when cleaning circuit boards and assemblies that are
sensitive to electrostatic discharge.
Clean circuit boards with special care using antistatic brushes and a
vacuum cleaner with a soft nozzle to prevent damaging the component.
• Remove dust on assemblies and busbars inside the cabinet with a
vacuum cleaner and lint-free cleaning cloths.
• Remove water, oily or greasy deposits on assemblies, components and
busbars with water- and oil-absorbing microfibers such as 3M Scotch
Brite™.
• Use a nylon brush or a vacuum cleaner for removing dust or deposits
from holes.
• Clean the outside of the cabinet with a vacuum cleaner and cleaning
cloths.

Chapter 7 - Inspecting bolted connections
7.1 Tightening torques for bolted connections
Fastener Tightening torque Nm [ft-lbs]
M6 10 [7.4]
M8 20 [14.8]
M10 40 [29.5]
M12 80 [59]
DANGER
Hazardous voltage!
7.3 Power cables

• Check that bolted connections with bolts of sizes M10 and greater are
tightened with the recommended nominal torque for the bolt size used.
• Check that stainless steel bolts and nuts with the appropriate steel grade
and property class for the connection are used.
Recommended: A2-70 (according to ISO 3506)

Nuts with bonded coating can be used as an alternative to uncoated
stainless steel nuts.

Chapter 7 - Inspecting bolted connections
The following connection type is recommended for the connection of a cable

lug (4) to a busbar:
• Belleville (1) and flat washer (2) on each side of the busbar (3).
1 2 2 1
Other washers may be used, provided they maintain the required contact
pressure.
If stainless steel bolts and nuts are used, check that thread and head contact
surface of the bolt are lubricated with a recommended paste, for example,
Molykote D paste.
If a coated nut (for example, with bonded molybdenum-disulfide [MoS2]

coating) is used, the connection does not have to be lubricated.
7.4 Busbars and other main connections

• Check that bolted connections are tightened with the recommended
nominal torque for the bolt size used.
7.5 Control cables

• Check the terminal connections of control cables and relays by pulling at
them one by one.
• Tighten them if necessary.

Chapter 8 - Replacing filter mats
8.1 Maintenance intervals and replacement indications

The expected lifetime of filter mats depends mainly on the cleanliness of the
cooling air. Check the filter mats regularly and according to the recommended
maintenance intervals in the maintenance schedule.
The filter mats are monitored by a pressure sensor. When the mats are
clogging and the pressure drop reaches the specified final pressure loss, the
message Conv1CoolAirFilter comes up on the CDP control panel and the
alarm/fault lamp lights up on the control compartment door.

Filter mats can be replaced while the drive is running, as they are accessible
from the outside, although it is easier to do when the drive is shut down.
When replacing a filter mat while the drive is running, work carefully to
prevent foreign matter from entering the drive. Also, pay attention that dust
accumulated on the filter mat is not sucked into the cabinet.
De-energize the drive. For instructions, see Chapter 4 - Stopping,
NOTICE
Risk of damage to the drive.
To prevent foreign matter from entering the drive while you remove or
replace a filter mat, do not discontinue work for an extended period of time.
CAUTION
While filter grills are finger safe, be aware that components on the inside
may be electrically live and action should be taken to avoid contact with
tools or fingers.

Chapter 8 - Replacing filter mats
8.3 Filter mat class

and dimensions
Use only replacement filter mats of the same filter class, thickness, and size
as the original filter mat:
• Filter class: G3 (EN779)
• Thickness: approximately 10 mm [0.4 in]
• ABB supplies replacement filter mats as specified in Table 8-1.
Table 8-1 Filter mat identification
INU and AFE

ABB
Filter mat replacement Qty Width mm [in] Height mm [in]
part number
Frame 1 2UEA001026 2 445 [17.5] 740 [29.0]
Frame 2 2UEA001704 2 830 [32.7] 795 [31.3]
Frame 3 2UEA002487 4 550 [21.7] 795 [31.3]
Input Filter Unit (IFU)
ABB
Filter mat replacement Qty Width mm [in] Height mm [in]
part number
Frame 1 2UEA001042* 1 600 [23.5] 1120 [44.0]
Frame 2 2UEA001694 1 646 [25.4] 610 [24.0]
Frame 3 2UEA001694 1 646 [25.4] 610 [24.0]
* Frame 1 (SN≥ 2124903744) = PN 2UEA001026
8.4 Filter mat location

The filter mats are located behind the ventilation grills of the INU (1), AFE (2),
and Input filter (3) sections.
1
Legend
1 INU
2 AFE
3 Input Filter Unit
(IFU)
2
Figure 8-1 Frame 1 - Filter mat locations

3 1
Legend
1 INU 2
2 AFE
3 Input Filter Unit (IFU)

3 1
Legend
1 INU
2 AFE 2
3 Input Filter Unit (IFU)

8.5 Filter mat replacement procedure
1 Remove the ventilation grill of the

corresponding section.
Ventilation grill
The ventilation grills are secured to the cabinet by a

channel.
Lift the grill to the slot position and remove.

2 Visually check the filter mat. If the filter mat needs replacement, go on to Step 3. If the
mat is clean, replace the grill as in Step 5.
3 Remove the filter mat. Remove the filter mat, being careful not to disturb
accumulated dust, by rolling the mat down from the top to
the bottom.
4 Install a new filter mat. Place the new filter mat against the opening. Tuck the
edges into the metal frame.

5 grill.
Replace the ventilation Clean the grill, removing any dust or accumulated dirt.
Position the grill over the door slot and slide into the
channel. Lower the grill into place.
Ventilation grill
Slot
6 Installation is complete.

Chapter 9 - Replacing line-side fuses
9.1 Tools
1 2
Legend
1 Socket wrench
3 Spanner (17 mm)
9.2 Maintenance intervals

For recommended maintenance intervals, see Appendix A - Maintenance
schedule.
DANGER
Hazardous voltage!

Chapter 9 - Replacing line-side fuses
9.4 Fuse locations

Even if only one fuse is blown, always replace all three.

All fuses are accessible through the front of the cabinet.
Fuses are located in either the TEU (Terminal Entry Unit) or in the integral
input contactor disconnect option if installed.
• For standard drives the fuses are located in the air-cooled fuse box in
the TEU behind the separation panels. See Figure 9-1.
Legend
1 Air-cooled
fuse box
Figure 9-1 Air-cooled fuse box
• If the VFD has the integral input contactor disconnect option, the fuses
will be inside the integral input contactor disconnect enclosure.

9.5 Checking fuses
Flush Raised
1
2
Good Blown
Fuse condition
Legend
1 Red indicator pin

2 Fuse
Site window detail
(Behind swing frame)
Figure 9-2 Checking power fuses
Check that the power fuses are securely bolted and torqued in place. Torque
value is 20 Nm [15 ft-lbs]. Check that the electrical wires are attached to both
ends of the fuses. Make sure the fuses are not blown. The red indicator pin
should be flush with the top of the fuse. See Figure 9-2.
If one fuse has blown, the other fuses may be degraded. ABB recommends
that all fuses be replaced.
NOTICE
In case of a failure, it is always good practice to check the fuses with a
meter.

If the drive is equipped with an integral input contactor disconnect package,
the fuse can be seen from the viewing wing shown in Figure 9-3.
Legend
1 Viewing
wing
Figure 9-3 Integral input contactor disconnect fuse viewing wing
9.6 Fuse replacement
Standard drive 1 Lock out and tag out the drive including the upstream breaker in
accordance with Chapter 9 - Replacing line-side fuses.
2 Open COU door and open the swing frame.
3 Remove the separation panels between the COU and TEU. See
Figure 9-4.

Legend
1 Separation panels
Figure 9-4 Separation panels
4 Install the four-way grounding cable in accordance with Chapter 4 -

Stopping, de-energizing, grounding the drive.
5 Remove the fuse box cover using a T30 bit.
6 Remove the opened fuses with the 17 mm socket and/or wrench.
7 Replace fuses and torque connections to 20 Nm [15 ft-lbs].
8 Reinstall fuse box cover.

Drive with integral 1 Lock out and tag out the upstream breaker in accordance with
input disconnect fuse Chapter 4 - Stopping, de-energizing, grounding the drive.
package
2 Open the integral input disconnect door.
3 Remove the opened fuses with the 17 mm socket and/or wrench. See
Figure 9-5.
Legend
1 Remove fuses with 17 mm tools
Figure 9-5 Integral input disconnect fuses

4 Replace fuses and torque connections to 20 Nm [15 ft-lbs].
Fuse specifications The power fuses are specified in Table 9-1.

Table 9-1 Power fuse ratings
Drive rating Current rating ABB Quantity

kW [hp] (A) part number per phase
Frame 1
224-298 [300-400] 80 2UEA001267 1
336-522 [450-700] 140 2UEA001268 1
597-746 [800-1000] 200 2UEA000093 1
Frame 2
933 [1250] 140 2UEA001268 2
1119-1492 [1500-2000] 160 2UEA002203 2
Frame 3
1679-2238 [2250-3000] 230 2UEA001947 2


Chapter 10 - Inspecting optical fibers
10.1 Tools and accessories

• Fiber-optic cable tester, for example:
• Tempo 253B LED source (set to 660 nm, no modulation), 10ZP
Adapter
• Tempo 557B power meter (set to 660 nm, dBm), 10ZP Adapter
• Photom 205A - optical power meter, Haktronics Co., Ltd
• LEONI optical power meter
• LEONI optical sender ZXXX-TS0
• Fiber-optic GmbH, 96524 Neuhaus-Schierschnitz, ZXXX-TM0
1 2
• Reference cable corresponding to the optical fibers to be tested.
DANGER
Hazardous voltage!

Chapter 10 - Inspecting optical fibers
For recommended maintenance intervals, see the Maintenance schedule.
10.4 Visual inspection

Pay special attention to the following:
• Cracks in the core or the coating
• Minimum bend radius (25 mm)
• Condition of male and female connectors
• Installation across sharp edges
• Tightness of cable ties
Cable ties must not deform the optical fibers.
10.5 Measuring the attenuation

1 Check the ends of the optical fiber.
2 Clean the fiber ends if necessary.
3 Connect the light source to one end and the power meter to the other
end of the optical fiber.
4 Set the light source and the power meter to the appropriate wavelength
and attenuation in dB.
Table 10-1 Optical meters - Settings
Setting
Light source 660 nm, dBm No modulation
Power meter 630 nm, dBm
5 Turn on the light source.

6 Gently jiggle the optical fiber.
If the reading on the power meter changes, the optical fiber is most
probably cracked.
7 Continue with
• Tempo meters
or
• Other meters

Tempo meters 1 Measure the attenuation of the optical fiber.

2 Compare the measured values with the values in Table 10-2.
Table 10-2 Optical fibers - Limit values
Value Assessment
Less than -9 dBm Perfect
Less than -12 dBm Acceptable
Higher than -12 dBm Not acceptable
Other meters 1 Measure the attenuation of each optical fiber.
2 Determine the average value.

3 Compare the measured attenuation of each optical fiber with
• the average value,
or
• the attenuation of the reference cable.
If several optical fibers have an unacceptable attenuation,

• replace the optical fiber, and
• check all optical fibers.


Chapter 11 - Inspecting power capacitors

The expected lifetime of the capacitors depends mainly on the ambient
conditions. The recommended intervals for visual checks, measurement
and replacements are based on operation with rated current and maximum
permitted temperature.
For recommended maintenance intervals, see the Maintenance schedule.
11.2 Capacitor type

The following capacitors are installed in the drive:
• Self-healing capacitors (DC-link capacitors, clamp capacitors)
The capacitance decreases gradually due to the design and aging of the
capacitor. The main two factors that affect the lifetime of the capacitor
are temperature and voltage.
Therefore, carry out regular checks and measurements in order to
observe and respond to aging effects.
To identify the capacitors, see the Wiring diagram.

Chapter 11 - Inspecting power capacitors
11.3 Location
All capacitors are replaceable from the front of the drive. The pictures
showing the back of the drive are used for location purposes only. Some
capacitors are easier to replace from the back if access is available.
Front view
2
3
Legend
1 DC link capacitor
2 IFU capacitor
Rear view 3 EMC capacitor
4 4 Upper and lower

clamping capacitors
Figure 11-1 Frame 1 - Capacitors

Front view
2 3 1
Rear view
4 Legend
1 DC link capacitor
2 IFU capacitor
3 EMC capacitor
4 Upper and lower
clamping capacitors
4 1 2 3


Front view
Legend
1 DC link capacitor
2 IFU capacitor
3 EMC capacitor
3 1
4 Upper and lower
clamping capacitors
Rear view
3 2
1 4


• Multimeter with capacitance mode (1), for example, Fluke® 87
or
• Capacitance meter (2)
1 2
• Test leads
DANGER
Hazardous voltage!
11.6 Inspecting, measuring the capacitors
11.6.1 Visual inspection

Check that:
• The capacitor connections are tightened to the specified torque.
• The bushings (if present) are not discolored or cracked.
• The capacitors are not discolored, deformed or cracked.

11.6.2 DC-link capacitors

Legend
1 Locking solenoid
1 2 Grounding switch
blades
3 Grounding switches
Figure 11-2 DC-link capacitors
1 Open the grounding switch circuit by pulling out the locking solenoid on
the grounding switch shown in Figure 11-2 (1) and manually opening the
grounding switch blades (2).
2 With the multimeter in capacitance mode, measure the capacitance
between the +DC Bus (W10607) and the NP (W10608) power wires on
the grounding switches (3).
3 Measure the capacitance between the -DC Bus (W10609) and the NP
(W10608).
4 Compare the measured values to the capacitor nameplate which can be
found on the capacitor or in the schematic drawings located on the User
manual CD, Appendix D.
5 Replace DC-link capacitors if capacitance deviation is 10% or more.

11.6.3 IFU capacitors

1 Isolate the IFU capacitor.
Legend
1 Wire connections
Figure 11-3 Frames 1, 2 IFU capacitor
• Frames 1, 2: Remove the three wire connections (W10116, W10117,

and W10118) for each input phase on the capacitor shown in
Figure 11-3 Frames 1, 2 (1).
1 2
Legend
1 Wire connections
W10116, W10117,
W10118
2 Wire connections
W10110, W10113,
W10114
Figure 11-3 Frame 3 IFU capacitor
• Frame 3: There are separate capacitors for each phase. Remove either
the three wire connections (W10116, W10117, and W10118) or (W10110,

W10113, and W10114) for each input phase on the individual capacitors
shown in Figure 11-3 Frame 3 (1) and (2). Access the capacitor
terminals by removing the metal panel at front of the capacitor stack or
by removing the grounding switch if back access is not available.
between each phase terminal and the ground terminal on the IFU
capacitor.
3 Compare the measured value to the capacitor nameplate which can be
4 Replace the IFU capacitors if capacitance deviation is 10% or more.
5 Reconnect the three wire connections that were removed in Step 1 and
reinstall the panels.
11.6.4 EMC and clamping capacitors

1 Isolate one terminal of the capacitor being measured.
between each phase terminal and the ground terminal on the IFU
capacitor.
3 Compare the measured value to the capacitor nameplate which can be
4 Reconnect the capacitor.

Chapter 12 - Testing the insulation of the drive
The insulation test must only be carried out if recommended by the MV

Drives Supportline.
The test is not carried out when the drive is commissioned for the first
time.

• 5 kV insulation resistance tester, for example, MEGGER AVO BM11D (1)
or MIT510 (2)
1 2
• Leads for short-circuiting the terminals
12.2 Safety
DANGER
Hazardous voltage!
• All cabling to the drive *MUST* be disconnected with the exception of

earth ground.
• Testing may cause damage to the drive if performed incorrectly.
• Leave the ground switch in the grounded position unless otherwise
indicated.

Chapter 12 - Testing the insulation of the drive
12.3 Testing the insulation

of the drive (No integrated input contact
disconnect)
12.3.1 Test procedure setup

Connect the short-circuit leads in the following steps:
The following step numbers correspond to the numbers in figure

12-1 power electronics overview on page 12-3
1 Short-circuit the medium voltage input and output terminals

2 Remove the surge arrestors from the input bus (not shown)
3 Short-circuit the IFU capacitors (C1011) and connect them to NP
4 Short-circuit the EMC capacitors (C1112, C1113, C1114)
5 Disconnect the NP-to-ground-capacitor (C1111)
6 Short-circuit the terminals of the grounding switch
7 Put the grounding switch to the position not grounded
12.3.2 Testing the insulation

1 Connect the insulation tester between the main terminals (U1, V1, W1,
U2, V2, W2) and ground.
2 Apply the test voltage of 5 kV for 60 s
The insulation test is passed if the measured insulation resistance is

100 MΩ or higher
12.3.3 Final steps

Remove the short-circuit leads.
NOTICE
Short-circuit!
A short-circuit in any part of the drive will lead to severe damage.

Therefore, check that all short-circuit leads have been removed before the
drive is energized.

4
1
7
6
6
5
3
Figure 12-1 Power electronics overview


Chapter 13 - Replacing the redundant fan

For recommended maintenance intervals, see Appendix A - Maintenance
schedule.
DANGER
Hazardous voltage!
13.3 Checks
1 Check the general condition of the cooling fans.
2 Manually check that the cooling fans rotate smoothly.
Hints The cooling fans should sound healthy and should show little or no
vibration.
A grinding noise is a sign of worn bearings.

Chapter 13 - Replacing the redundant fan
13.4 Redundant fan

replacement preparation
2
1
3
Legend
1 Fan
2 Fan wires
3 Terminal block
Figure 13-1 Redundant fan
Dimensions (L x W x H) Approximately 760 x 760 x 305 mm [30 x 30 x 12 in]
Weight Approximately 34 kg [75 lbs]
Tools • Torx screwdriver for removing/installing the side panels of the fan or
10 mm hex wrench to install the hexagon fastening hardware.
• See User manual, Appendix D - Mechanical drawings, located on
the CD, for specific information on the dimensions and weight of the
redundant fan.
WARNING
Wiring connections will need to be made. Make sure no power is connected
to the drive before proceeding with redundant fan installation.
Consider the size and weight of the components when planning to lift them
onto the top of drive.
The fan components can be lifted by means of a forklift or a crane.

13.5 Redundant fan removal procedure - Frame 1

1 Remove fan box cover by removing (13) M6 thread-forming screws with
a T30 Torx screwdriver.
M6 thread-
forming screws
2 Remove the redundant fan box front panel by removing (14) M6 thread
forming screws.
M6 thread-
forming screws

3
Disconnect the fan wires from the terminal block.
Fan wire
4 Remove (8) M6 thread forming screws from the fan mount with T30 Torx
screwdriver.
Fan mounting
screws

5 Lift the fan out with a strap by strapping (2) of legs of the fan mount.
Strap
location
6 Once the fan is off and on the floor. Remove (8) M10 bolts with a 17 mm
socket and install the fan mount on the new fan. Torque bolts to 40 Nm in
a star pattern.
Fan mounting
bolts

13.5 Redundant fan

removal procedure - Frames 2, 3
1 Remove fan box roof panel by removing (10) M6 thread-forming screws
with T30 Torx screwdriver.
M6 thread-forming
screws
2 Disconnect the fan wires from the terminal block.
Fan wire

3 Remove (8) M6 thread-forming screws from the fan mount.
Fan mounting
screws
4 Lift the fan out with a trap by strapping (2) of the legs of the fan mount.
Strap location


5 Once the fan is off and on the floor, remove (8) M10 bolts with a 17 mm
socket and install the fan mount on the new fan. Torque bolts to 40 Nm in
a star pattern.
Fan mounting
bolts
13.6 Redundant fan reinstallation procedure

1 Install the fan in the fan box.
2
1
3
Legend
1 Fan
2 Fan wires
3 Terminal block
Figure 13-2 Fan installation
2 Route the fan wires (see Figure 13-2) and connect to the terminal block.
3 Check that the flapper is moving freely.
4 Reattach the front panel and the cover of the fan unit using M6 thread-
forming screws and a T30 Torx screwdriver. Torque to 5 Nm.

Chapter 14 - Replacing a phase module
14.1 Overview
2
2 2
3 1
3 1 3 1
4
4 4
6
6
6
7 5
7 5
7 5
8
8
8
Frame 1 Frame 2 Frame 3
Legend
1 INverter Unit (INU) 5 Active Front End (AFE)

2 U2 phase module of INU 6 L1 phase module of AFE
3 V2 phase module of INU 7 L2 phase module of AFE
4 W2 phase module of INU 8 L3 phase module of AFE
Figure 14-1 AFE and INU compartment
Replacement phase module kits are per frame, not subframe rating and can
be used in any one of the six phase module locations shown above. See
Table 14-1 for replacement part number by frame.
WARNING
Original phase modules shipped with drive should not be interchanged with
another unit without contacting ABB for guidance, as they are designed to
meet the current requirements of the specific type code listed on the unit.

Chapter 14 - Replacing a phase module
14.2 Dimensions and weight
2
Frame 1
Frames 2, 3 (Frame 2 pictured)
Legend
1 Phase module 2 Phase module tool tray
Figure 14-2 Phase module
Table 14-1 Phase module replacement information

Length Width Height Weight
Phase Module*
mm [in] mm [in] mm [in] kg [lbs]
Frame 1 628 [24.7] 495 [19.5] 242 [9.5] 35 [77.0]
Frame 2 638 [25.1] 905 [35.6] 256 [10.1] 64 [140]
Frame 3 638 [25.1] 1240 [48.8] 256 [10.1] 210 [463]
*Contact your customer service representative for replacement part numbers.

Table 14-2 Phase module special tools

Frame Special tools ABB part number Comments
1 Tool tray 2UEA001362 Suggest two people
2, 3 Rails (Qty. 2) 2UEA002274 Requires lifting hoist and

bracket
2, 3 Hoist lift kit 2UEA002561 Not required for Frame 1

phase module replacement
14.3 Required tools and accessories

• Phase module tray tool - The phase module tray tool is shipped with the
new replacement phase module.
• Reversible ratchet with extension
• Phillips, Torx and slotted screwdrivers
• Cable tie
• 10 mm and 13 mm sockets
14.4 Phase module replacement procedure
14.4.1 De-energizing the drive
DANGER
Hazardous voltage! Dangerous voltage is present when
input power is connected.
Verify that the main power supply is switched off, locked
out and tagged out.
1 Disconnect upstream power using
the Kirk® key and perform generally WARNING
accepted Lockout-Tagout Procedures.
WARNING! Dangerous voltage is present when input
power is connected. After disconnecting the supply,
wait until the ground RELEASED indicator lights up (to
let the intermediate circuit capacitors discharge) before
attempting to ground and open the AFE/INU compartment
door.
2 Turn the grounding switch to the See User manual, Appendix P - Integral input
grounded position. contactor disconnect, located on the CD, for Kirk
key location on drives with this option.

Open incoming cabinet and perform

Live-Dead-Live check on incoming
terminals. See User manual, Grounding
Chapter 1 - Safety, Chapter 4 - switch
Stopping, de-energizing, grounding the (shown in
drive and User manual, Chapter 6 - grounded
Electrical installation, if you need further position)
information.
3 Identify defective phase module.
INU
U2 phase module
V2 phase module
W2 phase module
AFE
L1 phase module
L2 phase module
L3 phase module
Frame 1 Frame 2
INU
U2 phase module
V2 phase module
W2 phase module
AFE
L1 phase module
L2 phase module
L3 phase module
Frame 3

4 Turn off auxiliary power supply to the

phase modules. (Q1351) CAUTION
After the circuit breakers have been switched off, the
See User manual, Appendix E - charging transformer and the fan unit are still connected to
Wiring diagrams, located on the CD, their power supplies.
to identify the circuit breakers that
remove auxiliary power from the drive.
5 Remove the plexiglas air plenum by

removing the six screws. Air pressure tube
• Screw type: M6 socket-head

screw
• Required tool: 10 mm socket
When working on the AFE, first pull out
the air pressure tube at the bottom of
the panel.
Remove 6 screws
6 Unplug fiber optic cables and control

wiring connector from the front of
the phase module. Carefully position
cables to prevent damaging them
when changing the phase module.
7 Remove the screws on the left/right

side of the phase module.
• Screw type: M10 socket-head
screw
• Required tool: 10 mm socket Phase module
screws

14.4.2 Removing the phase module
14.4.2.1 Frame 1
1 Frame 1 - Insert the module tray into
the cabinet along the lower sides of
the phase module.
• Slide the phase module tray tool
in, until it makes contact with the
metal flange on both sides of the
NP frame.
• Open the securing hinges of the

tray tool to firmly attach the tray CAUTION
tool to the drive frame. (This
Make sure to open the hinges to prevent dropping the
prevents any movement of the
phase module and the tray tool.
tray tool while pulling out the
phase module.)

2 Hold the phase module by the handle

and pull it out slowly until it is flush with
the leading edge of the tray.
Note: Verify that the module tray tool
is firmly in place during this step.
3 Lift the phase module off the module

tray. CAUTION
Hold the phase module at the positions Due to weight of phase module, it is recommended that two
indicated by the arrows. people are involved in removal and in the case for Frame 2,
the hoist is used. Refer to 14.2 Dimensions and weight for
details on weights, replacement part numbers and special
tools.

14.4.2.2 Frames 2, 3
1 Frames 2, 3 Insert the module tray
into the cabinet along the lower sides
of the phase module.
• Slide the phase module tray tool
in, until it makes contact with the
metal flange on both sides of
the NP frame and the spring.clip
engages
2 Mount the lifting hoist to the drive per

hoist instructions. Hook up the lifting
harness at locations shown.
Using the hoist, lift the phase module
off the module tray.

14.4.3 Replacing the phase module

1 Place the new module on the tray.
2 Gently push the phase module back
into the rack, ensuring cables are not
pinched against the cabinet, as far as
it goes.
Tighten the fastening bolts that secure
module to cabinet on each side.
3 Reconnect fiber optic cables and

control wires to the phase module.
Be sure to connect the gray fiber optic
connector to the gray socket and the
blue fiber optic connector to the blue
socket.
4 Remove the phase module tray tool.
5 Reinstall the plexiglass air plenum Air pressure tube

with the six socket-head screws. If an
AFE module was replaced, be sure to
reinstall air pressure tube in plenum.
Failure to do so will result in pressure
fault.
6 Switch on all miniature circuit breakers

in the control compartment.
7 Close the compartment door, follow Replace 6 screws

lockout-tagout removal procedures,
un-ground, and start the drive
.
See User manual, Chapter 8 - Local
operation, 8.5.3 Starting the drive
system locally if you need information NOTICE
on the start-up procedure. If you need further assistance, please contact ABB
Medium Voltage Drives Technical Support at 1-800-
752-0696 Option 1. Please have the serial number of
the ACS2000 unit ready for reference.
Questions can also be emailed to
MV.Drives.SupportLine@us.abb.com

8 The failed phase module needs to be

returned to ABB after the replacement NOTICE
is complete. See Notice for address. Parts sent as warranty replacements need to be
returned to the address listed below within 30 days
from the date of shipment to avoid being charged.
Please place the RMA number on the outside of the
box.
ABB Inc.
2500 S. Commerce Dr.

Chapter 15 - Inspecting phase modules
15.1 Checking a phase module for short-circuit

A faulty phase module can be detected by one of two methods:
• Visually checking the phase module
• Measuring the voltage across the phase module terminals
15.1.1 Visual check of the phase module

Note: For the visual check, the phase module needs to be pulled half way out
of the cabinet. To do this, follow the instructions De-energizing the drive and
Removing the phase module in Chapter 14 - Replacing a phase module, 14.4
Phase module replacement procedure.
Each phase module contains one phase INT (interface) circuit board (2)
which interfaces with the six gate drives (1). Each gate drive controls two
IGBTs.
MEAS PH DC- NP DC+ MEASURING POINTS
1
1
2
C E
Legend
1 Six gate drives

2 INT circuit board
Figure 15-1 Frame 1 - Measuring point locations

Chapter 15 - Inspecting phase modules

MEAS PH DC- NP DC+ MEASURING POINTS
2
E C
Legend
1 Six gate drives

2 INT circuit board
Figure 15-1 Frames 2, 3 - Measuring point locations
Visually check the six gate drives of the phase module. Possible findings:
Supply +24 VDC to phase module by separate power supply or creating an
extension and using the drives main supply.
• All LEDs on the gate drives are on.
This means that the phase module could be healthy or faulty. For further
investigation, proceed with section 15.1.2 Measuring the voltage across
phase module terminals.
• The LEDs on one or several gate drives are off.
This means that these gate drives are short-circuited at the output. Either
the gate drive or one of the associated IGBTs caused the problem. In
this case, the phase module has to be replaced to get the drive running
again. Check the faulty phase module according to section 15.1.2
Measuring the voltage across phase module terminals.
15.1.2 Measuring the voltage across phase module terminals

Note: The phase module needs to be completely pulled out of the cabinet.
To do this, follow the instructions De-energizing the drive and Removing
the phase module in Chapter 14 - Replacing a phase module, 14.4 Phase
module replacement procedure.
With the multimeter in diode test mode, measure the voltages at the
measuring points shown in Figure 15-1. The reading should be as stated
in Table 15-1. If the measured values are different, contact the MV Drives
Supportline for more information.
Note: The threshold voltage for each IGBT is approximately 0.35 V; the
measurement includes two IGBTs.

Table 15-1 Readings of a healthy phase module in diode mode
Plus probe Minus probe Reading
PH C ~0.7 V
C DC+ ~0.7 V
NP C ~0.7 V
DC- E ~0.7 V
E PH ~0.7 V
E NP ~0.7 V

Figure 15-2 Measuring points diagram

Chapter 16 - Checking and replacing the crowbar
16.1 Function
The crowbar is a main protection device of the drive. If the crowbar is
malfunctioning, all phase modules of the drive can be damaged when a
firing‑through command is applied.
The crowbar assembly consists of the following components:
• Thyristor stack (1)
• Crowbar detection circuit board (2)
• Inrestors (3)
Figure 16-1 Frames 2, 3 - MVA AFE - Crowbar assembly

Chapter 16 - Checking and replacing the crowbar
16.2 Location
Frames - 2, 3
Legend
1 Frame - 1 Crowbar
Frame - 1
detection circuit board and
1 thyristor stack
2 Frames 2, 3 - Crowbar
detection circuit board,
inrestors and thyristor stack
Figure 16-2 Crowbar location
Frame 1 - The crowbar detection circuit board and thyristor stack are located
behind the AFE phase modules as shown in Figure 16-2. The inrestor is
located behind the IFU inductor stack. Replacement from front of drive
involves removal of the IFU stack.
Frames 2, 3 - The crowbar detection circuit board, inrestors, and thyristor
stack are all together and located behind the IPS power supply module as
shown in Figure 16-2.

16.3 Checking and replacement indications

The crowbar must be checked if
• a failure occurred that damaged more than one phase module,
• the MV (Medium Voltage) switchgear was operated incorrectly (for
example, MV switchgear was closed manually).
It is recommended to check the crowbar when a failure occurred that
damaged the power electronics hardware.
16.4 Checking the crowbar thyristors
16.4.1 Tools
~30 cm [11.8 in]
16.4.2 Safety / general preparations
DANGER
Hazardous voltage!

16.4.3 Checks
1 Open the door of the medium voltage compartment.
2 Switch off the auxiliary power supply.
Legend
1 Locking
solenoid
2 Grounding
switch
blades
Figure 16-3 Grounding Switch
3 Open grounding switch circuit by pulling out the locking solenoid on the
grounding switch shown in Figure 16-3 (1) and manually opening the
grounding switch blades (2).
4 Check the crowbar detection circuit board for overheated and damaged
components.
5 Unplug the gate cables at the crowbar detection circuit board shown in
Figure 16-4 (1).
Do not disconnect the cables at the thyristor as the pins break easily.
Note the position of the cables for assembly.

Legend
1 Gate
cables
Figure 16-4 Frames 2, 3 - Crowbar connectors
6 Measure the resistance of each of the four thyristors.

7 Compare the measured values with the values in Table 16-1.
Table 16-1 Crowbar resistance measurement
Measure between:
Pass Fail Remarks
Plus Minus
Anode Cathode >100 kΩ <100 kΩ - Very low value indicates short-circuit

- Value <100 kΩ indicates broken thyristor
Gate Cathode <100 Ω >100 Ω - Gate forward polarity measurement

- Value >100 Ω indicates broken gate contact (very seldom)
Cathode Gate <100 Ω >100 Ω - Gate reverse polarity measurement

(<1 MΩ) (>1 MΩ) - Value depends on thyristor type
- Value >100 Ω (>1 MΩ) indicates broken thyristor
8 Even if only one thyristor is broken, replace all four.

If a thyristor must be replaced, see 16.5.3 Replacing crowbar procedure
for information.
9 Reconnect the gate cables to the crowbar detection circuit board.

16.5 Removing the

crowbar
16.5.1 Tools and accessories
4 3
Legend
1 Socket wrench with extension bar and 5.5 mm socket for M3 nuts of the
crowbar detection circuit board
2 Socket wrench with T25 and T30 Torx bits
4 Small ladder
5 Antistatic gloves

16.5.2 Safety / general preparations
DANGER
Hazardous voltage!
16.5.3 Replacing crowbar procedure

The crowbar can be removed if only front access to the cabinet is possible.
However, additional rear access makes it easier.
Frame 1:
1 Remove all three INU phase modules. See Chapter 14 - Replacing a

phase module for removal of phase modules.

2 Unplug the two thyristor gate connections from the crowbar board.
3 Remove the three power cables (W10611, W10613, and W10616) from
the crowbar busbars using a T25 Torx driver.
4 Remove the four T30 Torx screws securing the crowbar assembly to the
drive chassis.
5 Reinstall replacement crowbar in reverse order.

Frames 2, 3:
1 Gain access to drive from the rear panel if accessible. If there is no rear
access you may have to remove the ground switch to gain access to the
crowbar assembly.
2 Unplug the two thyristor gate connections from the crowbar board.
3 Remove the three power cables (W10611, W10613, and W10616) from
the crowbar busbars using a T25 Torx driver.
4 Remove the four T30 Torx screws securing the crowbar assembly to
drive chassis.
5 Reinstall replacement crowbar in reverse order.


Chapter 17 - Replacing circuit boards
17.1 Location
4 3 5
3-6
6
7, 8
Legend
1 AMC and main INT circuit board of INU (AMC at the front)
2 AMC and main INT circuit board of AFE (AMC at the front)
3 OEI board
4 Voltage regulator for SYN circuit board
5 HVD circuit board
6 SYN circuit board
7 Crowbar detection circuit board
8 VLSCD circuit boards
Figure 17-1 Frame 1 - MVA AFE - Circuit boards

Chapter 17 - Replacing circuit boards
7
1
3-6
4 3 5
8 8
Legend
3 OEI board
5 HVD circuit board
6 SYN circuit board

7
1
3-6
(Behind)
4 3 5
8 8
Legend
3 OEI board
5 HVD circuit board
6 SYN circuit board

17.2 Handling instructions

17.2.1 Electrostatic precautions
NOTICE
Electrostatic discharge (ESD)!
Printed circuit boards are sensitive to ESD. ESD can damage these
devices.
Apply ESD precautions before handling these devices.

• Set up a static-safe working environment.
• Cover the table with a grounded conductive cover.
• Use the antistatic service kit.
• Remove all nonconductive materials from the working area.
• Put the static-sensitive device on the grounded working surface, or on
the antistatic service kit.
• Ground yourself properly with a wrist strap before touching a static-

sensitive device.
17.2.2 Fiber-optic cables

• Handle fiber-optic cables with care.
• Do not touch the ends of the fiber-optic cables. They are extremely
sensitive to dirt.
• To unplug a fiber-optic cable, hold it at the connector.
• Observe the minimum bend radius of 25 mm for fiber-optic cables.
Optical fibers can be damaged if bent sharply.

DANGER
Hazardous voltage!

17.4 Replacing the AMC circuit board

Before replacing the AMC circuit board, check that the installed software
version and the parameter settings of the new circuit board correspond to
those in the drive.
For information on loading software and firmware to the new AMC circuit
board, see the Commissioning manual.
1 Unplug the fiber-optic cables, the power supply connector and the
control panel connector.
2 Remove the seven fastening screws and the AMC circuit board.
3 Attach the new AMC circuit board.
Use all fastening screws to ensure proper grounding of the circuit board.
4 Reconnect the fiber-optic cables, the power supply connector and the
control panel connector.
5 Verify the connections with the corresponding Wiring diagram.
6 Put the defective circuit board into an antistatic bag.
7 Power up the drive and check if it is functioning properly.
If a defective circuit board has to be returned to ABB, follow the
procedures as stated in the MV Warranty Directive, particularly if the
circuit board is still under warranty. This procedure is also recommended
even if the warranty period has already expired.
17.4.1 Changing the AMC software flash memory

The application control software and the parameter settings are saved in the
flash memory which is on a separate flash memory circuit board (rectangle).


Figure 17-2 AMC flash memory
When the AMC circuit board is replaced, the old flash memory can still be
used if the software has not been upgraded.
If only the flash memory has to be replaced, the AMC circuit board can
remain in the cabinet. It is also not necessary to disconnect the fiber-optic
cables.
1 To remove the flash memory, hold it with both hands and pull it at a 90°
angle away from the AMC circuit board.

2 When attaching the new flash memory, make sure that the dot on the
flash memory (1) is on top of that on the AMC circuit board (2).
2
1
NOTICE
Flash memory orientation!
The correct orientation of the new flash memory is important. If attached
wrongly, the new flash memory will be damaged immediately when the
auxiliary power is switched on.
3 Push the flash memory down firmly, making sure that all pins are
inserted properly.
4 Install the AMC circuit board.
6 Energize the drive and check if it is functioning properly.
Follow the procedures in the MV Warranty Directive if a defective circuit
board has to be returned to ABB, particularly if it is still under warranty. This
procedure is also recommended even if the warranty period has already
expired.

17.5 Main INT circuit board

The main INT circuit board (1) is located behind the AMC circuit board (2).
Figure 17-3 Main INT circuit board
1 Remove the AMC circuit board according to 17.4 Replacing the AMC
circuit board.
2 Unplug the fiber-optic cable and the power supply connector.
3 Remove the 13 fastening screws.
Take all necessary precautions to prevent screws and washers from
falling into other components.
4 Remove the main INT circuit board and place it on a grounded working
surface.
5 Install the new main INT circuit board.
6 Reconnect the fiber-optic cable and the power supply connector.
Verify the connections with the corresponding Wiring diagram.
8 Power up the drive and check if it is functioning properly.

Follow the procedures as stated in the MV Warranty Directive if a

defective circuit board has to be returned to ABB, particularly if it is
still under warranty. This procedure is also recommended even if the
warranty period has already expired.


Chapter 18 - Meaning of LEDs
18.1 AMC circuit board
Fault Run
M P
T1 T2
S3 S1
S2 S0
Figure 18-1 AMC circuit board
Table 18-1 LEDs - AMC circuit board
LED LED color Function
R green Run indication
F red Fault indication
P green supply OK
M green not used (ON when booting)
T1 yellow ON = receiving data on DDCS channel 0
T2 yellow ON = receiving data on DDCS channel 3
S0 yellow always OFF

Chapter 18 - Meaning of LEDs
18.2 Main INT circuit

board
LED_9
LED_8
LED_7
LED_6
LED_5
LED_4
LED_3
LED_2
LED_1
Power
Figure 18-2 Main INT circuit board
Table 18-2 LEDs - Main INT circuit board
1 yellow all configured PPCS phase INT links enabled
2 yellow any latched fault (fc1/fc2)
3 yellow supply OK
4 yellow reserved for future use
5 yellow internal use
6 yellow firing-through-link faulty
7 yellow PFF link to / from AFE faulty
8 yellow PFF link to / from INU faulty
9 yellow yellow, green, FPGA successfully configured
Power green Internal 4V supply OK

18.3 Phase INT circuit board
Figure 18-3 Phase INT circuit board
Table 18-3 LEDs - Phase INT circuit board
Dome green board ready
R_OK green reset released
GDerr red any shutdown of the gate drive link (short-circuit detected)
Alarm red alarm pending
Fault red fault pending
LED1 red not used
LED2 red not used
+5V green power supply on
+3.3 V green power supply on
- 15 V green power supply on

18.3.1 IOEC modules

For information on IOEC switch settings, see the Wiring diagrams.
1 2 3 4 5
LEDs
Figure 18-4 IOEC module
Table 18-4 LEDs - IOEC module
LED Meaning
1 in Figure 18-4 Status LEDs of digital outputs On when output is energized
2 in Figure 18-4 Link error light LED is either on or off. LED is on only

when there is a problem with the optical
fibers.
4 in Figure 18-4 Status LEDs of digital inputs On when input is energized
5 in Figure 18-4 Status LED of the 24 V On when energized

internal voltage supply
Cluster address Each IOEC module has a unique cluster address that identifies the
module in the software and links it to a parameter.
The address is set with the rotary switch on the module (3 in Figure 18-4).
The factory set value must not be changed.

18.3.2 Options - Serial communication interfaces

To identify the serial communication interface in the drive, see the Wiring
diagrams or the Parts list.
For further information, select the appropriate manual from the following list:
• AF 100 fieldbus - NAFA-01 installation and start-up guide
• Ethernet - user’s manual ethernet adapter module NETA-01
• Modbus - NMBA-01 installation and start-up guide
• Profibus - NPBA-12 installation and start-up guide
18.3.2.1 AF 100 interface
Legend
1 Status LEDs
4
2 Service connector
3 AF 100 station address selectors
5
4 Power supply terminals
5 AF 100 terminals
Figure 18-5 AF 100 interface
Table 18-5 LEDs - AF 100 interface
LED Meaning
F (Fault) Red Module fault. The LED also lights up during module start-up. It turns off when the
self-test is successful
R (Run) Green In operation
P (Power OK) Green Internal power OK
T1 (Traffic 1) Yellow Data traffic on AF 100 cable 1
T2 (Traffic 2) Yellow Data traffic on AF 100 cable 2

18.3.2.2 Ethernet interface

2
Legend
1 RJ-45 connector for Ethernet cable

2 DIP switches for IP address selection
3 Fiber-optic connectors for communication cable to the drive
3 • TXD = transmitter
• RXD = receiver
4 Status LEDs
4
5 Power supply connection on underside
5
Figure 18-6 Ethernet interface
Table 18-6 LEDs - Ethernet interface
LED Meaning
ACTIVE Off Not on-line, not energized
Flashing green A data packet is received or transmitted through the Ethernet module
LINKED Off Not on-line, not energized
Steady green Module connected to Ethernet network
MB/TCP Off Not on-line, not energized
Flashing green The number of established Modbus/TCP connections to the module equals
the number of flashes
STAT Off Not energized
Steady green OK
Flashing green DIP switch setting does not correspond to the IP address
Flashing red, 1Hz Ethernet configuration failed
Flashing red, 2Hz Failed to load Ethernet configuration from memory
Flashing red, 4Hz Internal fatal error

18.3.2.3 Modbus interface
3
Legend
4 1 Bus-cable terminals
2 Fiber-optic connectors for communication cable to the drive
• TXD = transmitter
• RXD = receiver
3 Status LEDs
4 Switch for bus termination
Figure 18-7 Modbus interface
Table 18-7 LEDs - Modbus interface
LED Meaning
XMIT Flashing Interface transmits a response or an exception
REC Flashing Interface receives a command from the Modbus network
ERROR Flashing If the received command has a parity error, or

if the received command has a CRC error, or
if the received command is not supported by the interface, or
if the interface has detected an error
LED Error indication Meaning
XMIT, REC, ERROR On ROM checksum test failed
REC, ERROR On RAM test failed
ERROR On DDCS-ASIC-register-access test failed

18.3.2.4 Profibus interface
1
Legend
2 1 Fiber-optic connectors for communication cable to the drive

• TXD = transmitter
3 • RXD = receiver
2 Reset button for initialization of module
3 Status LEDs
4
4 Bus-cable terminals
Figure 18-8 Profibus interface
Table 18-8 LEDs - Profibus interface
LED
During start-up
Master MSG DDCS
Power-on Off Off Green then red then off
Off Green then red then off Off
Green then red then off Off Off
DDCS link initialization Off Off Flashing green then green
Transfer-rate detection Flashing green then green Off Green
Communication established Green Flashing green then green Green
Operation Green Green Green
LED
Cause
Master MSG DDCS
Red Red Off RAM test failure
Off Red Red ROM test failure
Last valid state Last valid state Red DDCS link failure
Green Flashing red Flashing green Communication failure
Flashing red Red Flashing green Link failure


Appendix A - Maintenance schedule
The maintenance schedule applies to all air-cooled and water-cooled medium
voltage drives. Please note the maintenance items in the schedule which only
apply to particular drives.
The recommended intervals for maintenance and component replacement
are based on the normal operating conditions of the drive. The drive
should be checked at least every two years by qualified personnel whose
recommendations should be followed. Depending on the actual condition
of the drive, the maintenance work can be carried out before or after the
recommended interval.
Years from start-up

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Air cooling
- Air filters 1 I R R R R R R R R R R R R R R R R R R R
- Cooling fan (continuous operation) A, 2 I I P I R I P I R I P I R I P I R I P I
- Cooling fan (redundant) B, 2
I I P I P I P I R I P I P I P I R I P I
Water cooling C
- Deionizer, microfilter and strainer 3 R I R I R I R I R I R I R I R I R I R I

- Cooling pump gasket - - - - R - - - R - - - R - - - R - - -
- Cooling pump (continuous operation) 2 I I P I R I P I R I P I R I P I R I P I
- Cooling pump (redundant) 2
I I P I P I P I R I P I P I P I R I P I
- Hoses I I I I I I I I R I I I I I I I R I I I
- Plastic tubes and connectors I I I I I I I I I I I I I I I I I I I I
Aging
- DC capacitors 4 I I I I I I I I P I P I P I P I P I P I
- AC capacitors D, 5 I I I I I I I I I I R I I I I I I I I I
- Printed circuit boards, power supplies - - - - - - - - - - R - - - - - - - - -
- Batteries (internal to the drive)
E
I I R I R I R I R I R I R I R I R I R I
- UPS batteries (external to the drive) I I R I R I R I R I R I R I R I R I R I
Fuses
- Line-side fuses F I I I I I I I I R I I I I I I I R I I I
Connections and operating conditions
- Optical fibers 6 - - - - - - P - P - P - P - P - P - P -
- Cable connections, bolted connections I I I I I I I I I I I I I I I I I I I I
- Dustiness, corrosion, temperature I I I I I I I I I I I I I I I I I I I I
Improvements and spare parts
- Software, hardware upgrades 7 I - I - I - I - I - P - I - I - I - I -
- Spare parts I - I - P - I - P - I - P - I - P - I -
Measurements and tests
- Measurements with auxiliary voltage I I P I P I P I P I P I P I P I P I P I
- Insulation - - - - P - - - P - - - P - - - P - - -
- Safety circuits P P P P P P P P P P P P P P P P P P P P
ACS2000 Service manual 2UEB000096 Rev. - B MS-1

Appendix A - Maintenance schedule
R
Replacement of the component
I Inspection (visual inspection; corrective measures, repair and/or replacement of component if needed)
P Performance of on-site work (for example, commissioning, tests, measurements)
- No action
A Applies to ACS1000i, ACS1000A, ACS1000W, ACS2000, ACS5000A, ACS5000W, ACS6000, MEGADRIVE-LCI

B Applies to ACS1000i, ACS1000A, ACS1000W, ACS2000, ACS5000A, ACS5000W
C Applies to all water-cooled drives
D Applies to ACS1000i, ACS1000A, ACS1000W, ACS2000 and ACS6000
E Applies to ACS1000i, ACS1000A, ACS1000W
F Applies to ACS2000
1 Air filters can be replaced or cleaned. The decision to replace or clean a filter depends on the condition of the filter.
2 It is recommended to replace the device after four years of operation.
3 The average lifetime of the deionizer is 2-4 years, depending mainly on the water quality. At the same time the
deionizer is changed, the microfilter should also be replaced and the strainer should be cleaned.
4 The expected lifetime of DC capacitors (self-healing) depends mainly on the ambient conditions. The recommended
intervals are based on operation with rated current and maximum permitted temperature. A capacitor should be
replaced when regularly taken measurements show a significant deviation from the rated capacitance.
5 AC capacitors (not self-healing) are used in input and output filters. Unlike DC capacitors, AC capacitors do not show
signs of reduced capacitance over the lifetime. Measurements of the capacitance also do not allow predicting the
lifetime, which depends mainly on the ambient conditions.
6 The expected lifetime of the optical fibers depends mainly on the ambient conditions. The recommended intervals are
based on operation with rated current and maximum permitted temperature. An optical fiber should be replaced when
regularly taken measurements show significant deterioration of the fiber.
7 Improvements based on further development, software modifications, and so on. When printed circuit boards must be
replaced, an upgrade of the control system should be considered as well.
MS-2 2UEB000096 Rev. - B ACS2000 Service manual

Contact us
ABB Inc
16250 W. Glendale Drive
© Copyright 2015 ABB. All rights reserved. Specifications subject to change without notice. 2UEB000096 Rev. - B.
Phone: 800-752-0696
Fax: 262-780-5150
E-Mail: mv.drives@us.abb.com
www.abb.com/drives

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Medium Voltage Drives

Table of contents TOC-1

List of figures LOF-1

List of tables LOT-1

General information on manual and equipment GI-1

Copyright notice GI-1

ACS2000 Service manual 2UEB000096 Rev. - B TOC-1

1.1 Meaning of safety instructions 1-1

Chapter 2 - General maintenance instructions 2-1

2.1 Before starting to work 2-1

Chapter 3 - Uploading data from the black box 3-1

Chapter 4 - Stopping, de-energizing, grounding the drive 4-1

4.1 Stopping and de-energizing the drive locally 4-1

Chapter 5 - Opening the doors 5-1

5.1 Doors and door locks 5-1

Chapter 6 - Visual checks and cleaning 6-1

6.1 Safety / general preparations 6-1

TOC-2 2UEB000096 Rev. - B ACS2000 Service manual

Chapter 7 - Inspecting bolted connections 7-1

7.1 Tightening torques for bolted connections 7-1

Chapter 8 - Replacing filter mats 8-1

8.1 Maintenance intervals and replacement indications 8-1

Chapter 9 - Replacing line-side fuses 9-1

9.1 Tools 9-1

Chapter 10 - Inspecting optical fibers 10-1

10.1 Tools and accessories 10-1

ACS2000 Service manual 2UEB000096 Rev. - B TOC-3

Chapter 11 - Inspecting power capacitors 11-1

11.1 Maintenance intervals 11-1

Chapter 12 - Testing the insulation of the drive 12-1

12.1 Tools and accessories 12-1

Chapter 13 - Replacing the redundant fan 13-1

13.1 Maintenance intervals 13-1

TOC-4 2UEB000096 Rev. - B ACS2000 Service manual

Chapter 14 - Replacing a phase module 14-1

14.1 Overview 14-1

Chapter 15 - Inspecting phase modules 15-1

15.1 Checking a phase module for short-circuit 15-1

Chapter 16 - Checking and replacing the crowbar 16-1

16.1 Function 16-1

Chapter 17 - Replacing circuit boards 17-1

17.1 Location 17-1

ACS2000 Service manual 2UEB000096 Rev. - B TOC-5

18.1 AMC circuit board 18-1

Appendix A - Maintenance schedule MS-1

TOC-6 2UEB000096 Rev. - B ACS2000 Service manual

ACS2000 Service manual 2UEB000096 Rev. - B TOC-7

ACS2000 Service manual 2UEB000096 Rev. - B LOF-1

LOF-2 2UEB000096 Rev. - B ACS2000 Service manual

ACS2000 Service manual 2UEB000096 Rev. - B LOT-1

LOT-2 2UEB000096 Rev. - B ACS2000 Service manual

Equipment covered by the manual

ACS2000 Service manual 2UEB000096 Rev. - B GI-1

Target groups and required qualifications

Title Document number

ACS2000 4k User manual 2UEA001270

ACS2000 NEMA Spare parts manual 2UEB000131

Warranty directives 3BHS404420 ZAB E01

Wiring diagrams Refer to customer prints in Appendix E of the

GI-2 2UEB000096 Rev. - B ACS2000 Service manual

Meaning of terms and abbreviations

AFE Active Front End

AMC circuit board Application and Motor Controller

CDP Control/Display Panel

Chapter 2 - General maintenance instructions 2-1

Chapter 3 - Uploading data from the black box 3-1

Chapter 4 - Stopping, de-energizing, grounding the drive 4-1

Chapter 5 - Opening the doors 5-1

Chapter 6 - Visual checks and cleaning 6-1

Chapter 7 - Inspecting bolted connections 7-1

Chapter 8 - Replacing filter mats 8-1

Chapter 9 - Replacing line-side fuses 9-1

Chapter 10 - Inspecting optical fibers 10-1

Chapter 11 - Inspecting power capacitors 11-1

Chapter 12 - Testing the insulation of the drive 12-1

Chapter 13 - Replacing the redundant fan 13-1

Chapter 14 - Replacing a phase module 14-1

Chapter 15 - Inspecting phase modules 15-1

Chapter 16 - Checking and replacing the crowbar 16-1

Chapter 17 - Replacing circuit boards 17-1