ABB

ACS 1000
Medium Voltage Drives

315 to 5000 kW
400 to 6700 hp

User’s Manual
Frequency Converter
12-pulse and 24-pulse Air-Cooled Version

Document No.: 3BHS213401 ZAB E01 Rev. -

Issued: 25-10-2005

 ABB Switzerland Ltd. All Rights Reserved.

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

3BHS213401 ZAB E01 Rev. - ACS 1000 User’s Manual

ABB
Table of Contents

General Information

Contact Information
Related Documentation
Quality Certificates and Applicable Standards

Chapter 1 - Safety 1-1

1.1 Intended Audience and Required Qualifications 1-1

1.2 Owner’s Responsibilities 1-1
1.3 Safety Instructions 1-2
1.4 Safety Labels and Signs 1-3
1.5 Danger Zones 1-4

Chapter 2 - Transportation, Storage and Disposal 2-1

2.1 Transportation 2-1

2.1.1 Transport Conditions 2-1
2.1.2 Unpacking and Inspection 2-1
2.1.3 Loading and Unloading 2-2
2.2 Storage 2-3
2.2.1 Storage Conditions 2-3
2.2.2 Storage 2-3
2.3 Storage and Handling Instructions for Spare Parts 2-4
2.4 Disposal of Packaging Materials 2-5
2.5 Disposal of Components 2-5

Chapter 3 - Mechanical Installation 3-1

3.1 Overview of Mechanical Installation 3-1

3.2 Installation Site 3-1
3.2.1 Ambient Conditions 3-1
3.2.2 Dimensions and Clearances 3-1
3.2.3 Foundation, Floor Levelling and Cable Ducts 3-1
3.3 Installing the Converter 3-2
3.3.1 Mechanical Door Interlock 3-2
3.3.2 Installation Procedure 3-2
3.3.3 Redundant Fan Unit 3-4

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 ABB
Chapter 4 - Electrical Installation 4-1

4.1 Overview 4-1

4.2 Cables 4-2
4.3 Ground Connections 4-3
4.4 Power Cables 4-3
4.4.1 Cable Entry 4-3
4.4.2 Connecting Incoming Feeder and Motor Cables 4-6
4.5 Connecting Auxiliary Power and Control Cables 4-8

Chapter 5 - Information on Commissioning 5-1

5.1 Customer Assistance and Acceptance 5-1

Chapter 6 - Operation 6-1

6.1 Control Panel 6-2

6.2 Starting 6-3
6.2.1 Checks before Switching on 6-3
6.2.2 Starting-up the Converter 6-4
6.3 Stopping 6-6
6.4 De-energizing the Converter 6-7
6.5 Emergency Off 6-8
6.6 Alarms and Faults 6-9

Chapter 7 - CDP Control Panel 7-1

7.1 Overview 7-1

7.2 Identification Mode 7-2
7.3 Actual Signal Display Mode 7-3
7.4 Parameter Mode 7-6
7.4.1 Parameter Lock 7-8
7.5 Function Mode 7-8
7.6 Operational Commands 7-9
7.6.1 Selecting Local/Remote 7-9
7.6.2 Setting the Direction of Rotation 7-10
7.6.3 Entering a Setpoint 7-11

Chapter 8 - Maintenance and Troubleshooting 8-1

8.1 Safety Instructions 8-2

8.2 Specific Maintenance Tasks 8-3
8.2.1 Cleaning 8-3

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8.2.2 Checking Wire and Cable Connections 8-3
8.3 Standard Procedure for Troubleshooting 8-3

Appendix A - Additional Manuals

Appendix B - Technical Data

Appendix C - Mechanical Drawings

Appendix D - Electrical Diagrams

Appendix E - Part List and Spare Parts

Appendix F - Test Reports

Appendix G - Signal and Parameter Table

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General Information

Contact Information

If information is required beyond the instructions in this manual, ABB can

be contacted as follows:
ABB Switzerland Ltd
Medium Voltage Drives
CH-5300 Turgi, Switzerland

Phone: +41 844 845 845

Fax: +41 58 589 2984
E-mail mvdrives@ch.abb.com

Related Documentation

The following documents can be optained from ABB for supplementary

information.

Document
Title
Number

Power Cable Specification 3BHS189994

Main Circuit Breaker Specification 3BHS197846

Asynchronous Motor Specification 3BHS103892

Tripping Loop 3BHS104786

Troubleshooting Manual

Quality Certificates and Applicable Standards

The following certificates and conformity declarations are available with

ABB:
• ISO 9001 / ISO 14001 certificates stating that ABB Switzerland Ltd has
implemented and maintains a management system which fulfills the re-
quirements of the normative standards
• EC Conformity Declaration
• List of standards the converter complies with

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Chapter 1 - Safety

1.1 Intended Audience and Required Qualifications

The user’s manual addresses personnel who are responsible for the
installation, operation and maintenance of the converter. The personnel
must be qualified and fully acquainted with medium voltage equipment.

Installation Personnel The installation personnel are mainly responsible for:

• Preparing the mounting site
• Transporting the converter
• Performing the mechanical and electrical installation
• Preparing the water cooling unit for operation (if present in the
converter)

Operating Personnel The operating personnel include all persons who operate the converter as
required for the application using the control panel(s) of the converter or a
supervisory control system. Operating the converter does not require
special knowledge of converter technology. However, the operator must
know the functions of the control panel.

Maintenance The maintenance personnel are mainly responsible for:

Personnel
• Periodical checks of the converter
• Maintenance tasks

1.2 Owner’s Responsibilities

It is the owners responsibility to ensure that each person involved in the

installation, operation or maintenance of the converter has received the
appropriate training and has thoroughly read and clearly understood the
relevant safety instructions.
The technical specifications and the approved purpose of the converter
must be strictly adhered to.
The owner must ensure that the converter is operated under proper
conditions and in a fully serviceable state. The specified service intervalls
and ambient conditions for the converter must be followed.
Unauthorized modifications and constructional changes of the converter
are not permitted.

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Chapter 1 - Safety ABB

1.3 Safety Instructions

Safety instructions are used to highlight a potentially dangerous situation

when working on the converter. Safety instructions must be strictly
followed! Non-compliance can jeopardise the safety of personnel, the
machine and the environment.

DANGER!
Indicates an imminent hazardous situation. If not observed, it will lead to
death or life-threatening injury.

WARNING!
Indicates a potentially dangerous situation. If not observed, it could result
in death or life-threatening injury.

CAUTION!

! Indicates a potentially dangerous situation. If not observed, it could lead to

minor or moderate injury or property damage.

NOTICE!
Indicates important information related to personal safety and protection
of property.

IMPORTANT!

! Emphazises hints and highlights information.

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1.4 Safety Labels and Signs

Safety labels are attached to the converter enclosure to alert personnel of

potential hazards when working on the converter. The safety labels must
always be followed and kept in perfectly legible condition.
Depending on the scope of supply, the following additional safety signs are
provided:
Fire fighting:
The sign explains the procedure when fighting fire in electrical equipment.
The sign should be installed well visible near the converter.
Heart pacemaker:
The magnetic field of the converter can influence the functioning of heart
pacemakers. The sign should be installed at the entrance to the drive
room or at a minimum distance of 6 meters (20 ft) from the converter!
High voltage:
The sign should be installed well visible at the main circuit breaker in the
switchgear room. The sign alerts personnel to the high voltage which can
be present on the secondary side of the converter transformer until the
main circuit breaker has been opened and secured and the converter has
been de-energized and grounded.

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Chapter 1 - Safety ABB

1.5 Danger Zones

Figure 1-1 indicates the danger zones of the converter.

High voltage!
Do not remove any bolted walls or plates
when converter is energized or before
converter is grounded. Hot equipment inside the converter

Rectifier and filter Inverter unit

Control unit
components unit

Danger from auxiliary and control voltages in High voltage!

control unit when front door is open!
Do not attempt to open doors of medium
voltage units by force when converter is
energized.
The doors are electromechanically inter-
locked. When the light GROUNDING
SWITCH UNLOCKED is on, the converter
can be grounded and then the doors can
be opened.

Figure 1-1 Danger Zones

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Chapter 2 - Transportation, Storage and Disposal

2.1 Transportation

2.1.1 Transport Conditions

The transport conditions are based on IEC 721-3-2 'Classification of
environmental conditions: Classification of groups of environmental
parameters and their severities; Transportation'.
Classification: 2K3 / 2B1 / 2M1
See also to Appendix B - Technical Data.

2.1.2 Unpacking and Inspection

When unpacking the converter proceed as follows:
1 Remove all packaging material carefully. Do not use sharp or pointed
tools. Proceed as follows if the converter is delivered in a wooden
box.
1 Remove the top of the box.
2 Remove the end and the side walls.
3 Remove the bottom of the box.

Top of the box End wall

1000
ACS

End wall Bottom of the box Side wall

Figure 2-1 Unpacking the Converter

2 Check the converter and accompanying equipment for damage.

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3 Compare the complete delivery with the purchase order and the
packing list.
4 If parts are missing or damaged, immediately inform the shipping
company and the ABB service organization.
It is recommended to photograph the damages.

2.1.3 Loading and Unloading

Observe the following points when transporting the converter:

CAUTION!

! Do not lift and move the converter or a transport unit using a forklift. The
frame of the cabinets could be damaged. If a crane is not available contact
ABB for instructions on other means of moving. See section General
Information for contact address.

CAUTION!

! Converter components can be damaged during transportation. Therefore,

the converter must be transported in upright position.

CAUTION!

! When transporting the converter ensure that no dirt enters. Keep doors
closed. Metallic dust in particular may cause damage and lead to
malfunction when the converter is powered up.

• See Appendix C - Mechanical Drawings for dimensions and center of

gravity and Appendix B - Technical Data for weight details.
• Material and diameter of the lifting cables must correspond to the
weight of the converter.
• When lifting the converter always use the lifting rails on the roof of the
converter. The rails can be removed after the converter has been
installed at its final location.
• Do not pass a lifting cable through the fastening hole of a rail. Use a
safety hook to attach a cable to a rail.
• The lifting cables should be approximately at an angle as indicated in
Figure 2-2.
• Select the appropriate fastening holes to balance the weight.
• Lift the converter slowly and steadily to the required clearance height
maintaining the converter in upright position.
• Check the horizontal position of the converter. Reposition the cables
if necessary.

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ABB Chapter 2 - Transportation, Storage and Disposal

min. 45° min. 45°

Figure 2-2 Lifting Angle

2.2 Storage

2.2.1 Storage Conditions

The minimum requirements for storage are based on IEC 721-3-1
'Classification of environmental conditions: Classification of groups of
environmental parameters and their severities; Storage'.
Classification: 1K4 / 1Z5 / 1B1 / 1M1
See also Appendix B - Technical Data.
The converter can be stored for up to 1 year in the original packaging as
long as it is not damaged or opened. For information on longer storage
periods contact the ABB service organization.

2.2.2 Storage
If the converter is taken out of service for a longer time proceed as follows:
1 Water cooled converters: drain the cooling circuit completely
(contact the ABB service organization for information) or add the
appropriate amount of glycol for frostproofing, if the converter is to be
stored in ambient temperatures below 0 °C (32 °F).
See Appendix A - Additional Manuals for information on frostproofing.
2 Remove the batteries (if applicable).

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3 Cover all cable inlets and ventilation slots with an impermeable plastic
or aluminum foil and a wooden panel.
4 Add the desiccant of the appropriate quality: 1 unit desiccant (30g)
absorbs 6g water vapor. The following quantity is needed when using
a polyethylene foil:
• 10 units/sqm foil
5 Close and lock the doors of the converter.
6 Use polyethylene or equivalent for packaging:
• 0,3 g/sqm/24h water vapor diffusion
7 Attach humidity indicators to the packaging.
The storage conditions and the packaging should be checked regularly.
Any damages which occur during the storage period should be repaired
immediately.

2.3 Storage and Handling Instructions for Spare Parts

Inspect the spare parts immediately after receipt for damages. Report any
damage to the shipping company and the ABB service organization.
Observe the following to maintain spare parts in good condition and to
keep the warranty valid during the warranty period:
• Keep spare parts in their original packaging.
• Store printed circuit boards in antistatic bags or boxes.
• Storage temperature range: -5 °C to + 55 °C (23 °F to 131 °F)
• Storage place requirements:
• Free of vibration and shock.
• Protected against dust, sand, vermin and insects.
• Free of corrosive gases, salt or other impurities that
could damage electronic equipment.
• Dry; no condensation
Relative air humidity: 5 to 85 %
If in doubt if the maximum allowed humidity is
exceeded, protect spare parts by an external heater.
• Apply static-sensitive precautions when handling printed circuit
boards. Static electricity can damage these components.
• Do not touch a component without wearing a wrist
grounding strap.
• Put the component on a grounded working surface
protected against electrostatic discharges.
• Hold the component only at the edge.

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2.4 Disposal of Packaging Materials

Dispose of the following materials according to local regulations:

• Wooden frame
• Wooden pallet
• Polyethylene sheet
• Plywood
• Silicagel

2.5 Disposal of Components

At the end of the life time of the converter dispose of the following
components according to local regulations:
• Batteries
• Capacitors
• Printed circuit boards
• Electronic devices

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Chapter 3 - Mechanical Installation

NOTICE!
All installation work must be carried out by qualified personnel in
compliance with local regulations.
See Chapter 1 - Safety for explanation on how the safety messages are
categorized and used in this manual.

3.1 Overview of Mechanical Installation

The mechanical installation of the converter includes the following steps:

• Preparing the installation site
see 3.2 Installation Site
• Installing the converter
see 3.3 Installing the Converter

3.2 Installation Site

3.2.1 Ambient Conditions

Ambient factors such as temperature, relative humidity, air contamination,
shock and vibration must be in compliance with the stated maximum
permissible levels. See Appendix B - Technical Data for limit values.
If the condition of the installation site is not within the specifications or if
the transportation or the installation require special measures, contact the
ABB service organization.

3.2.2 Dimensions and Clearances

The converter must be mounted with adequate free space. The
dimensions of transport units, the overall dimensions of the converter and
the clearances are provided in Appendix C - Mechanical Drawings.

3.2.3 Foundation, Floor Levelling and Cable Ducts

The floor must be of non-flammable material, with smooth and non-
abrasive surface, protected against humidity diffusion, levelled and able to
support the weight of the converter (min. 1’000 kg/m2).

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Chapter 3 - Mechanical Installation ABB
The maximum allowable overall unevenness is ≤ 5 mm / 5 m. If the
mounting surface is uneven, the cabinet doors become misaligned and do
not open or close properly.
Cable ducts must be of non-flammable material with non-abrasive
surface.
Suitable fire protection measures must be applied to prevent fire from
spreading into the converter.
All cable entries and exits must be protected to prevent dust, humidity and
animals from entering into the converter.
See Layout Drawing in Appendix C - Mechanical Drawings for exact
dimensions, if holes and channels for cables and water pipes have to be
cut into the floor and mounting holes have to be drilled.

3.3 Installing the Converter

3.3.1 Mechanical Door Interlock

The doors of the medium voltage units are interlocked with the grounding
switch. If the doors of medium voltage units cannot be opened contact the
ABB service organization.

3.3.2 Installation Procedure

Observe the following points when installing the converter:

CAUTION!

! When installing the converter ensure that no dirt enters. Always close the
doors when work is discontinued and completely cover openings. Metallic
dust in particular may cause malfunction when the converter is powered
up and cause damage.

Proceed as follows:
1 Drill the floor fixing holes before moving the converter to the final
location.
2 Be careful when moving the converter.
See Chapter 2 - Transportation, Storage and Disposal, 2.1 Transpor-
tation for information to be observed.

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ABB Chapter 3 - Mechanical Installation

3 Check if the doors are misaligned.

If the doors do not open and close properly place levelling plates
(80 x 300 x 0.5 mm) under the base:
1 Lift the converter by crane at the corresponding side
(see Figure 3-1).
2 Place the required number of plates under the base.

place levelling plates here

place levelling plates here

Figure 3-1 Levelling the Converter

4 Fix the converter to the floor.

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Chapter 3 - Mechanical Installation ABB
5 Assemble and mount the air exhaust hood.

A B

C D

Figure 3-2 Mounting Air Exhaust Hood

3.3.3 Redundant Fan Unit

If the converter is supplied with a redundant fan unit, see Appendix A -
Additional Manuals, manual Redundant Fan Unit, for information on
installation.

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Chapter 4 - Electrical Installation

NOTICE!
All installation work must be carried out by qualified personnel in
compliance with local regulations.
See Chapter 1 - Safety for explanation on how the safety messages are
categorized and used in this manual.
Power must not be applied to the drive system without the consent of the
ABB commissioning staff.

DANGER!
Hazardous voltage!
To ensure safety, the converter must be installed in accordance with the
instructions in this manual. Improper work can lead to life-threatening
injury or death.Take appropriate measures to prevent that mains and
auxiliary power can be switched on.

4.1 Overview

The electrical installation includes the following steps:

• Ground Cable
see 4.3 Ground Connections.
• Power Cables
see 4.4.2 Connecting Incoming Feeder and Motor Cables.
• Auxiliary Power Cables
see 4.5 Connecting Auxiliary Power and Control Cables.
• Control Cables
see 4.5 Connecting Auxiliary Power and Control Cables.

Understanding Designation, cross-reference and device-identification conventions are

Electrical Drawings defined on the diagrams in Appendix D - Electrical Diagrams.

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4.2 Cables

Power Cables See Power Cable Specification for information on suitable power cables
(incoming feeder cables, motor cables, braking resistor cables) or contact
ABB.

Auxiliary Power Cable A 3-phase cable is required for the auxiliary power supply. A neutral
connector is not required. Type and rating is to be selected according to
local regulations.

Control Cables Control cables should be provided in accordance with Table 4-1. Either
single or multiple twisted pair cables may be used.
Control cables should not be laid in parallel to the power cables. If this
cannot be avoided, a minimum distance of 30 cm (12 in) must be
maintained between control and power cables. Control and power cables
should be crossed at an angle of 90°.
Table 4-1 Control Cable Requirements

Signal Type General Cable Type Cross-Section

Analog In 0.5 to 2.5 mm2 /

Twisted pair(s) - Overall Shield
AWG 20 to AWG 12

Analog Out 0.5 to 2.5 mm2 /

Twisted pair(s) - Overall Shield
AWG 20 to AWG 12

Digital In 0.5 to 2.5 mm2 /

Twisted pair(s) - Overall Shield
AWG 20 to AWG 12

Digital Out 0.5 to 2.5 mm2 /

Twisted pair(s) - Overall Shield
AWG 20 to AWG 12

Speed Encoder Twisted pair cable with overall shield 0.5 mm2
and separately shielded pairs 4 x (2+1)

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4.3 Ground Connections

It is important that the converter is properly grounded to maintain safety

and to ensure smooth functioning of the equipment. For this reason, the
converter’s ground cable must be securely tied to the grounding system of
the installation site (system ground).
The ground cable is tied to a ground busbar inside the power terminal
section. The connection must be in compliance with local regulations.
The ground cable is entered through an EMC sleeve of the entry plate. If
there is no free entry hole available, the ground cable is entered together
with a phase conductor. See section 4.4.2 Connecting Incoming Feeder
and Motor Cables for information on entering cables into the cabinet.

Figure 4-1 Ground Cable and Phase Conductor in one EMC Sleeve

4.4 Power Cables

4.4.1 Cable Entry

The feeder cables and motor cables are connected to their associated
busbars in the power terminal section (see Figure 4-2 and Figure 4-3).
Cable entry into the power terminal section is through the top or the bottom
of the cabinet. The power terminal section is located behind the control
swing frame of the converter and is accessible after the separating door
behind the swing frame has been opened. The terminal bars can be
identified by their phase designations.
Details on entry plates (dimensions, number of entry holes, maximum
cable diameter) and on busbars (dimensions, layout) are provided in
Appendix C - Mechanical Drawings.
If cable entry is from below, the entry plate mounted on top of the control
section must be relocated to the base of the cabinet. The orientation of the
entry plate does not have to be changed.

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PE Transformer
System a1 b1 c1 a2 b2 c2
ground

Armouring
Shielding

System
ground 1U1 1V1 1W1 2U1 2V1 2W1
U2 V2 W2 Converter
PE

Control swing frame V

U W
PE Motor

2V1

Terminal section
2W1
2U1 2U1
2V1 2V1
2W1 2W1
U2 U2
V2 V2
W2 W2
1U1 1U1
1V1 1V1
1W1 1W1

Connection point of Top cable entry Bottom cable entry

cable shield ends

Figure 4-2 Power Cable Termination in 12-pulse Version

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PE Transformer
System a1 b1 c1 a2 b2 c2 a3 b3 c3 a4 b4 c4
ground

Armouring
Shielding

System
ground 1U1 1V1 1W1 2U1 2V1 2W1 3U1 3V1 3W1 4U1 4V1 4W1
U2 V2 W2 Converter
PE

V
U W
PE
Motor

2U1 4U1 2U1 4U1

2V1 4V1 2V1 4V1
2W1 4W1 2W1 4W1
U2 U2
V2 V2
W2 W2
1U1 3U1 1U1 3U1
1V1 3V1 1V1 3V1
1W1 3W1 1W1 3W1

Connection point of Top cable entry Bottom cable entry

cable shield ends

Figure 4-3 Power Cable Termination in 24-pulse Version

Minimum Creepage When using spacers for cable connection to a busbar, the minimum
Distance required creepage distance must be observed. Depending on the
Comparative Tracking Index (CTI) of the insulation material of the cable
the following Minimum Creepage Distances (MCD) apply:

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Table 4-2 Creepage Distance

MCD in mm CTI

63 600

71 400....600

80 175....400

If the CTI value of the insulation material is unknown, the values in row
three of the table apply.

4.4.2 Connecting Incoming Feeder and Motor Cables

Proceed as follows:
1 Enter a cable into the terminal section to measure the conductor
length.
Mark the required conductor length and withdraw the cable. Cut it to
the correct length, strip the conductor ends and mount the cable lugs
suitable for M12 bolts. Cables must be terminated with lugs according
to the specification of the cable manufacturer.

NOTICE!
Do not cut cables inside the terminal section. Make sure that waste from
cable cutting and stripping cannot enter the converter. Any waste which
accidentally dropped into the converter must be retrieved. The waste
could cause damage or malfunction.

2 Enter the conductors through the EMC sleeves of the entry plate as
shown in Figure 4-4 and Figure 4-5:
• Strip the cable insulation at the point of entry. Tighten
the EMC sleeve on the stripped part of the cable with
cable ties.
• If necessary, remove the entry plate and slide it onto
the cable. Fasten the entry plate, after the ground
connections have been made.
• IP 42: Remove the rubber grommets from the entry
plates and cut them to adequate diameter for the
transformer and the motor cables (Figure 4-5). To
ensure proper sealing, cut along the diameter
marking that corresponds to the cable diameter. Slide
the grommet onto the cable (Figure 4-4). The
grommet must fit tight to prevent water from entering
the cabinet. If necessary, seal the junctions with
silicone rubber.

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Outer sheath

1st. insulated conductor

2nd. insulated conductor

Mounting bracket
3rd. insulated conductor
Strip conductor
Rubber grommet insulation to
expose shield

Entry plate

EMC sleeve

3rd. insulated conductor

Strip conductor
insulation to
2nd. insulated conductor
expose shield
1st. insulated conductor
Mounting bracket

Outer sheath

Top entry Bottom entry

Figure 4-4 Cable Entry for Power Cables (IP 20 and IP 22).

A B C

Figure 4-5 Cutting Rubber Grommets to Size

3 Check the insulation of each cable before connection and verify that
the results are within the specifications of the cable manufacturer.

NOTICE!
Do not drill inside the terminal section. Make sure that waste from drilling
cannot enter the converter. Any waste which accidentally dropped into the
converter must be retrieved. The waste could cause damage or
malfunction.

If holes have to be drilled into busbar terminations, remove the

busbars and drill the holes outside of the cabinet.

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Approx. 60 mm

5 mm

Removable busbar terminations

80 mm

Figure 4-6 Removable Busbar Terminations

4 Connect the phase conductors to the corresponding busbars.

See the specification of the manufacturer of the cable lugs for
tightening torques.

CAUTION!

! High voltages will be present in the terminal section. High voltages can
cause flashover between the potential of a phase conductor and ground.
A minimum clearance of 20 mm must be maintained between each cable
and the terminals of any other phase.

5 Connect the shield ends of all conductors to the ground busbar.

6 Fasten entry and blanking plates with the supplied screws (M6).

IMPORTANT!

! All provided screws must be mounted and tightened to achieve best EMC.

4.5 Connecting Auxiliary Power and Control Cables

Cable entry is through the roof or through the bottom of the control unit.
Proceed as follows:
1 Enter the cables through the EMC slot of the entry plate that leads to
the front area of the control unit.
• Shielded cables: Remove the outer cable sheath in
the entry area. The conductive cushions of the EMC

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ABB Chapter 4 - Electrical Installation

slot must be in contact with the cable shield (see

Figure 4-7).

Side view Bottom view

Entry plate
EMC conductive cushions

Screw holes
Base plate

Entry plate

Figure 4-7 Auxiliary Power Cable and Control Cable Entry

Stripped cable Conductive surface of Stripped part covered

screen made visible with copper foil

Copper foil

Cable Screened twisted pair

Ground wire

Figure 4-8 EMC Cable Preparation

• IP 42 and cable entry from above: Remove the

rubber grommets from the entry plate and cut them to
adequate diameter of the cable (see Figure 4-5). To
ensure proper sealing, cut along the diameter
marking that corresponds to the cable diameter. Slide
the grommet onto the cable. The grommet must fit
tight to prevent water from entering the cabinet. If
necessary, seal the junctions with silicone rubber.
• Loosen the screws of the entry plate and enter the
cables.
• Push the two halves of the entry plate together and
tighten the screws. The EMC conductive cushions
should press tightly around the bare screens.

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Chapter 4 - Electrical Installation ABB
2 Connect the cables. For easy identification, it is recommended to
mark each conductor appropriately before connection.
Auxiliary power cable:
Connect the auxiliary power cable according to Appendix D - Elec-
trical Diagrams.
To identify the terminals see Figure 4-9 and Location Drawings in
Appendix C - Mechanical Drawings.
If a shielded cable is used connect the cable shield to PE.
Control cables:
Connect the control cables to terminals X300, X301 and to the IOEC
boards (see Figure 4-9).
For identification, see Figure 4-9 and Appendix C - Mechanical Draw-
ings. For connection details see Appendix D - Electrical Diagrams.

IOEC board 2

Aux. power terminals

Terminals X300, X301

IOEC board 3

IOEC board 4

Figure 4-9 Control Unit

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ABB
Chapter 5 - Information on Commissioning

5.1 Customer Assistance and Acceptance

Commissioning, parameter adjustments and functional tests are to be

carried out by certified commissioning personnel. Information on the
commissioning procedure and conditions for the commissioning to start
can be obtained from ABB. For address see section General Information.
During the commissioning period, the customer is requested to provide
qualified personnel for assistance, who are
• familiar with medium and low voltage equipment and with local safety
regulations,
• familiar with the driven process,
• authorized to operate associated medium and low voltage equipment
(MCB, other medium and low voltage switchgear etc.),
• authorized to operate the driven process for functional tests.
When commissioning is completed, the commissioning report is signed by
the responsable commissioning engineer and by the customer as a sign
of acceptance. A copy of the report and a copy of the actual parameter
settings are handed out to the customer.

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Chapter 5 - Information on Commissioning ABB

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ABB
Chapter 6 - Operation

NOTICE!
Only qualified personnel shall operate the drive system, i.e. personnel
who are familiar with the machine and the operation of the drive system
and the hazards involved.
See Chapter 1 - Safety for explanation on how the safety messages are
categorized and used in this manual.

This chapter outlines the local operation of the converter using the CDP
control panel and the control switches as illustrated in section 6.1 Control
Panel after the converter has been installed and commissioned. If the
control interface has been modified to accommodate project-specific
requirements see the applicable Operating Instructions in Appendix A -
Additional Manuals.
Remote control of the converter via a PLC or remote stations is not
described in this chapter. If the converter is controlled from remote, see
the applicable manuals for information.

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Chapter 6 - Operation ABB

6.1 Control Panel

Control Panel
• used to start and stop the motor
• displays status messages of the converter
• displays alarm and fault messages
• used to reset alarm and fault messages

Illuminated Pushbuttons
• OFFline opens main circuit breaker
• ONline closes main circuit breaker

Lamp Grounding Switch Unlocked

• indicates when DC link is discharged and
grounding switch can be turned to position
“grounded”

Emergency Off Button

• prevents start-up if actuated at standstill
• main circuit breaker opens and DC link dis-
charges, if activated during operation

Figure 6-1 Control Panel

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ABB Chapter 6 - Operation

6.2 Starting

6.2.1 Checks before Switching on

Proceed as follows:
1 Check that no tools and foreign objects are left inside the converter.
2 Verify that:
• all internal circuit breakers of the converter have
been closed,
• the auxiliary power supply of the converter has been
switched on.
See Appendix D - Electrical Diagrams to identify the circuit breakers.
3 Check that all doors have been closed and locked and all covers have
been mounted.
Medium voltage units of the converter include an interlocking system
which operates in conjunction with the grounding switch and the
electrical interlocks from the main circuit breaker.
The interlocking system ensures that power cannot be initialized to
the converter unless all doors have been closed and the grounding

switch has been turned to position (not grounded).

The interlocking system also ensures that the doors of medium
voltage units cannot be opened until the main power source has been
disconnected, the DC link capacitors have been discharged and

the grounding switch has been turned to position (grounded).

The door of the control cabinet is not integrated into the interlocking
system and can always be opened.

DANGER!
High Voltage!
All bolted covers must be fitted to prevent unintended touching of
energized components.

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Chapter 6 - Operation ABB
4 Check that the grounding switch is in position “not grounded”.

Figure 6-2 Grounding Switch in Position Not Grounded

5 Check that the main circuit breaker is in operating position.

6.2.2 Starting-up the Converter

LOC
6 Set the CDP control panel to LOCAL mode by pressing the REM
button.
See also Chapter 7 - CDP Control Panel for information on selecting
this mode.
7 Check that the converter is ready.
No alarm or fault message on the CDP control panel must be present.
8 If a fault message is displayed on the CDP control panel reset the
RESET
fault, by pressing the button.
See Chapter 7 - CDP Control Panel for information on resetting a
fault.
If a fault cannot be reset, it must be rectified by the responsible
personnel.
When the converter is ready, the CDP control panel displays Rdy
MCB on meaning that the main circuit breaker can be closed:

1 L -> 0.0 rpm 0

Status... Rdy MCB on
MotorSpeed 0.00 rpm
Power 0.0 %

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9 Press the ONLlNE button to close the main circuit breaker. After the
main circuit breaker has been closed, the DC link of the converter is
charged. The status line of the display changes to Charging:

1 L -> 0.0 rpm 0

Status... Charging
MotorSpeed 0.00 rpm
Power 0.0 %

After charging has been finished, the converter is Ready to Start:

1 L -> 0.0 rpm 0

Status... Rdy to Strt.
MotorSpeed 0.00 rpm
Power 0.0 %

10 Enter a setpoint.
See Chapter 7 - CDP Control Panel for information on entering a
setpoint.

1 L -> [ 600.0 rpm ]

Status... Rdy to Strt.
MotorSpeed 0.00 rpm
Power 0.0 %

11 Press the button of the CDP control panel to start the motor.
First, the motor is magnetized:

1 L -> 600.0 rpm 0

Status... Magnetizing
MotorSpeed 0.00 rpm
Power 0.0 %

After the motor has been magnetized, the motor speed is ramped up
to the setpoint. As soon as the motor starts to turn, the display
indicates that the motor is Running:

1 L -> 600.0 rpm 1

Status... Running
MotorSpeed 600.00 rpm
Power 30.0 %

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Chapter 6 - Operation ABB

6.3 Stopping

Proceed as follows to stop the motor:

To stop the motor, press the button of the CDP control panel.
The motor stops according to the preset stop function and the
converter stops modulating. Stop modes are preset in parameters.
While the motor stops, the status line of the display shows Stopping:

1 L -> 600.0 rpm 1

Status... Stopping
MotorSpeed 300.00 rpm
Power 20.0 %

As long as the stopping sequence is in progress, the converter can

always be restarted by pressing the button of the CDP control
panel.
When the converter has stopped modulating, the CDP control panel
displays Ready to Start:

1 L -> 600.0 rpm 0

Status... Rdy to Strt
MotorSpeed 0.00 rpm
Power 0.0 %

As long as the main circuit breaker has not been opened, the motor
can be started again.

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ABB Chapter 6 - Operation

6.4 De-energizing the Converter

DANGER!
Hazardous voltage!
Do not try to gain access to the converter transformer, the medium voltage
units of the converter nor the motor as long as the drive system is
energized and not grounded.

To disconnect the converter from the main power supply, do the following:
1 Stop the motor as described in the previous section.
2 Press the Offline button to disconnect the converter from the main
power supply. The following happens:
• Main circuit breaker opens.
• DC link discharges.
• Offline button lights up.
After the DC link has been discharged, the display shows:

1 L -> 600.0 rpm 0

Status... Rdy MCB on
MotorSpeed 0.00 rpm
Power 0.0 %

3 Rack-out, lock-out and tag-out the main circuit breaker.

4 Turn the grounding switch to position “grounded”.

IMPORTANT!

! Do not turn the grounding switch to position “grounded”, before the

light GROUNDING SWITCH UNLOCKED is on. Otherwise, the switch will
be damaged.

Figure 6-3 Grounding Switch in Position “Grounded”

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Chapter 6 - Operation ABB
After the grounding switch is in position “grounded”, the CDP control
panel displays:

1 L -> 600.0 rpm 0

Status... ErthIsoClos
MotorSpeed 0.00 rpm
Power 0.0 %

5 Switch off all auxiliary voltages from external sources.

See Appendix D - Electrical Diagrams to identify the circuit breakers.
The converter is now dead, and safe access is possible.

6.5 Emergency Off

The emergency off button is located on the control section of the converter
(see also Figure 6-1).

Figure 6-4 Emergency Off Pushbutton

If the pushbutton is pressed during operation, the following happens:

• The main circuit breaker opens.
• The drive coasts down.
• The message Emergency Off comes up on the control panel display.

1 L -> 600.0 rpm 0

ACS 1000 9133WR
*** Fault “**
Emerg Off

• The DC link discharges.

The converter can be started again after the emergency off button has
been extracted and the reset button on the control keypad has been
pressed. The emergency off button returns to its initial position when
turned to the right.

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6.6 Alarms and Faults

When a malfunction occurs in the converter or in the equipment monitored

by the converter, the control panel displays a corresponding alarm or fault
message. The message can also be viewed and saved in the fault logger
of the converter when a PC with the DriveWindow or DriveDebug tool is
available.
Two error message levels are used in the converter:
• Alarm (warning): an alarm does not shut down the converter.
However, a persisting alarm condition can often lead to a fault if the
condition causing the alarm is not corrected. An alarm cannot be
manually reset. The alarm message will be deleted from the display
as soon as the alarm condition has been corrected.
• Fault: a fault always shuts down the whole drive. The type of shut-
down depends on the origin of the fault.
In general, a fault condition must be corrected and the fault be
manually reset before the converter can be started again.
Depending on the type of fault, the main circuit breaker (MCB) is
opened by the converter or stays closed. Since the MCB is controlled
and monitored entirely by the converter, no external opening
command must be given to the MCB when a fault condition occurs.
Some of the alarm and fault messages are related to other equipment in
use (MCB, transformer, cooling system) and the configuration of the drive
system. For more information on alarms and faults see Signal and
Parameter Table.

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ABB
Chapter 7 - CDP Control Panel

7.1 Overview

The CDP control panel is the basic user interface for operating, controlling
and monitoring the converter.
The panel messages and parameter settings used in this chapter are
typical examples to illustrate the related instructions and display functions.
They may differ from the actual messages and parameter settings in your
converter.

1 L -> 1242,0 rpm I

MotCurr 76.00 A Alphanumeric display
MotSpeed 1242.0 rpm (4 lines x 20 characters)
Torque 86.00 %

Mode selection buttons

Selection and changing buttons Enter button

Reset button Setpoint setting button

Local, remote button Start button

Forward, reverse buttons Stop button

Figure 7-1 CDP Control Panel

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Chapter 7 - CDP Control Panel ABB
Keypad Modes The CDP control panel provides the following modes:
• Identification mode
• Actual Signal Display mode, selected by the ACT button
• Parameter mode, selected by the PAR button
• Function mode, selected by the FUNC button
• Drive Selection mode, selected by the DRIVE button.

7.2 Identification Mode

After the converter has been energized or after the panel has been
connected to the converter for which the auxiliary voltage has been
switched on already, the identification display appears showing the panel
version and then the ID-number of the converter. When the control panel
is being initialized the display changes as follows:

CDP312 PANEL V5.30

........
After 2-3 seconds:

ACS 1000 xxxx

< Device Name >

ID-NUMBER 1

After another few seconds, the display changes to the Actual Signal
Display mode.

1 L -> 0.0 rpm 0

Status... Earth Iso clos
MotorSpeed 0.00 rpm
Power 0.0 %

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ABB Chapter 7 - CDP Control Panel

7.3 Actual Signal Display Mode

Two displays can be selected in the Actual Signal Display mode:

• Actual Signal Display
• Fault History Display.
The Actual Signal Display appears first when the Actual Signal Display
mode has been selected. However, when the converter is in a fault
condition, the Fault Display will be shown instead.
The Actual Signal Display is used to monitor the converter without
interferring the operation of the converter.Three preselectable actual
values are shown continuously on the display.
The panel will automatically return to the Actual Signal Display mode
from other modes within one minute when no buttons are pressed
(exceptions: Status Display and Common Reference Display when in
Drive Selection mode and Fault Display mode).
A complete list of selectable actual signals can be found in Signal and
Parameter Table.
The fault memory includes information on the 64 most recent fault events
that occurred in the converter. The name of the fault and the actual time
are displayed. The procedure for selecting and clearing the fault history is
described in Table 7-3.
When a fault or warning is generated in the converter, the message will be
displayed immediately, except when in Drive Selection mode.
Changing from the Fault Display mode to other display modes is possible
without resetting the fault first. When no buttons are pressed, the fault or
warning text is displayed as long as the fault is pending.
The Actual Signal Display mode is selected by pressing the ACT button.

1 L -> 600.0 rpm 0

ACT Status... Rdy MCB on
MotorSpeed 0.00 rpm
Power 0.0 %

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When in Actual Signal Display mode, the fast UP/DOWN buttons allow
to toggle between Actual Signal Display and Fault History Display.

1 L -> 600.0 rpm 0

1 LAST FAULT
Overspeed
001231 12:30:02.3256

Table 7-1 Displaying three Actual Signals

Button to be
Step Function Display
pressed

1. to display the full name of HOLD

the three actual signals 1 L -> 600.0 rpm 1
ACT
DriveStatusWord
MotorSpeed
Power

2. to return to the Actual RELEASE

Signal Display mode 1 L -> 600.0 rpm 1
ACT
DriveStatus Running
MotorSpeed 600.00 rpm
Power 75.0 %

Table 7-2 Selecting Actual Signals

Button to be
Step Function Display
pressed

1. to enter the Actual

Signal Display mode 1 L -> 600.0 rpm 0
ACT
Status ReadyOn
MotorSpeed 0.00 rpm
Power 0.0 %

2. to select a row where the

actual signal is to be 1 L -> 600.0 rpm 0
displayed (a blinking Status ReadyOn
cursor indicates the MotorSpeed 0.00 rpm
selected row) Power 0.0 %

3. to enter the actual signal

selection function 1 L -> 600.0 rpm 0
1 Actual Signals
ENTER
13 Power
0.0 %

4. to select a parameter
group 1 L -> 600.0 rpm 0
2 Actual Signals
01 Excitation Cur

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ABB Chapter 7 - CDP Control Panel

Table 7-2 Selecting Actual Signals (Continued)

Button to be
Step Function Display
pressed

5. to select an actual signal

1 L -> 600.0 rpm 0
1 Actual Signals
09 NP Voltage
0.0 V

6.a to accept the selection

and to return to the 1 L -> 600.0 rpm 0
Actual Signal Display Status ReadyOn
ENTER
mode MotorSpeed 0.00 rpm
NP Voltage 0.0 V

6.b to cancel the selection

and keep the original ACT PAR 1 L -> 600.0 rpm 0
selection, press any of Status ReadyOn
the mode buttons MotorSpeed 0.00 rpm
FUNC DRIVE Power 0.0 %
the selected keypad
mode is entered

Table 7-3 Displaying a Fault and Resetting Fault History

Button to be
Step Function Display
pressed

1. to enter the Actual

Signal Display mode 1 L -> 600.0 rpm 0
ACT
Status ReadyOn
MotorSpeed 0.00 rpm
Power 0.0 %

2. to enter the Fault

History Display 1 L -> 600.0 rpm 0
1 Last Fault
+ Panel Lost
Power 0.0 %

3. to select the previous

(UP) or next fault 1 L -> 600.0 rpm 0
(DOWN) 2 Last Fault
Speed Ref Lost
980224 10:45:32.0705

to clear the fault history 1 L -> 600.0 rpm 0

RESET 1 Last Fault
the fault history is empty
H Min S

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Chapter 7 - CDP Control Panel ABB
Table 7-3 Displaying a Fault and Resetting Fault History (Continued)

Button to be
Step Function Display
pressed

4. to return to the Actual

Signal Display mode 1 L -> 600.0 rpm 0
Status ReadyOn
MotorSpeed 0.00 rpm
Power 0.0 %

Table 7-4 Displaying and Resetting an Active Fault

Button to be
Step Function Display
pressed

1. to display an active fault

1 L -> 600.0 rpm 0
ACT
ACS 1000
*** Fault ***
Panel Lost

2. to reset the fault

1 L -> 600.0 rpm 0
RESET
Status ReadyOn
MotorSpeed 0.00 rpm
Power 0.0 %

7.4 Parameter Mode

NOTICE!
Parameters must only be set by qualified personnel. Do not change any
parameter, if the meaning of the parameter and the effects of the change
are not fully understood. Running the drive system with incorrect data can
result in improper operation, reduction of control accuracy and damage of
equipment.

Parameters allow the converter to be configured and set-up specifically for

an application (see also Signal and Parameter Table).
Parameters are organized in functional groups. All control functions are
represented by a parameter group and can be activated and set-up
individually.

Selecting Parameters The Parameter mode is used to check and change parameters. When this
mode is entered for the first time after the auxiliary voltage of the converter
has been switched on, the display will show the first parameter of
parameter group 11. The next time, the Parameter mode is entered, the
previously selected parameter is shown.

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ABB Chapter 7 - CDP Control Panel

Some parameter values cannot be changed while the converter is running.

If tried, the following warning will be displayed:

** Warning **
Write Access Denied
Parameter Setting
Not Possible

Table 7-5 Selecting a Parameter and Changing the Value

Button to be
Step Function Display
pressed

1. to enter the Parameter

mode 1 L -> 600.0 rpm 0
PAR
75 OPTION MODULES
01 IOEC3 OptionBoard
YES

2. to select a different
group 1 L -> 600.0 rpm 0
75 OPTION MODULES
01 IOEC3 OptionBoard
YES

3. to select a parameter
1 L -> 600.0 rpm 0
75 OPTION MODULES
02 IOEC4 OptionBoard
NO

4. to enter the parameter

setting function 1 L -> 600.0 rpm 0
75 OPTION MODULES
ENTER
02 IOEC4 OptionBoard
[NO]

5. to change the parameter

value 1 L -> 600.0 rpm 0
(slow change for 75 OPTION MODULES
numbers and text) 02 IOEC4 OptionBoard
(fast change for numbers [YES]
only)

6.a to accept the selection

and to return to the 1 L -> 600.0 rpm 0
Actual Signal Display 75 OPTION MODULES
ENTER
mode 02 IOEC4 OptionBoard
YES

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Chapter 7 - CDP Control Panel ABB
Table 7-5 Selecting a Parameter and Changing the Value (Continued)

Button to be
Step Function Display
pressed

6.b to cancel the setting and

keep the original ACT PAR
1 L -> 600.0 rpm 0
selection, press any of 75 OPTION MODULES
the mode buttons 02 IOEC4 OptionBoard
FUNC DRIVE NO
the selected keypad
mode is entered

7.4.1 Parameter Lock

Unwanted parameter entry can be prevented by activating the Parameter
Lock function which is part of group 16 SYSTEM CTR INPUTS.
The Parameter Lock is activated by setting parameters 16.02 and 16.03
accordingly. The user pass code can be changed by setting parameters
16.04 and 16.05. For more details see Signal and Parameter Table.
To activate the Parameter Lock:
1 Select parameter 16.02 PARAMETER LOCK.
2 Set parameter 16.02 to LOCKED.
3 Save the setting and exit the Parameter mode.
To open the Parameter Lock:
1 Select parameter 16.03 PASS CODE.
2 Set the correct pass code. If not known see Signal and Parameter
Table for details.
3 Save the setting and exit the Parameter mode.

7.5 Function Mode

Setting the Display The Function mode is used to set the contrast of the display.
Contrast

Table 7-6 Setting the Contrast of the Panel Display

Button to be
Step Function Display
pressed

1. to enter the Function

mode 1 L -> 0.0 rpm 0
FUNC
UPLOAD <= <=
DOWNLOAD => =>
CONTRAST 4

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Table 7-6 Setting the Contrast of the Panel Display (Continued)

Button to be
Step Function Display
pressed

2. to select a function (a
blinking cursor indicates 1 L -> 0.0 rpm 0
the selected function) UPLOAD <= <=
DOWNLOAD => =>
CONTRAST 4

3. to enter the contrast

setting function 1 L -> 0.0 rpm 0
CONTRAST [4]
ENTER

4. to set the contrast

1 L -> 0.0 rpm 0
CONTRAST [6]

5.a to accept the selection

and to return to the 1 L -> 0.0 rpm 0
Actual Signal Display UPLOAD <= <=
ENTER
mode DOWNLOAD => =>
CONTRAST 6

5.b to cancel the setting

and keep the original ACT PAR
1 L -> 0.0 rpm 0
selection, press any of UPLOAD <= <=
the mode buttons DOWNLOAD => =>
FUNC DRIVE CONTRAST 4
the selected keypad
mode is entered

7.6 Operational Commands

7.6.1 Selecting Local/Remote

LOC
Local control mode is selected by pressing the REM button of the control
panel.

Local Control When the panel is switched to LOCAL, operation via the pushbuttons on
the front door of the COU and the CDP control panel is possible. Control
commands from remote have no effect. LOCAL can only be selected
when the converter has been stopped and no remote run command is
active. Switching from LOCAL to REMOTE while the converter is running
stops the converter.

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Chapter 7 - CDP Control Panel ABB
Remote Control When the panel is switched to REMOTE, the pushbuttons on the front
door of the control section and the operational buttons of the control panel
are disabled. Operational commands and reference value from a remote
control station are transmitted via fieldbus or remote I/O to the converter.
Switching from REMOTE to LOCAL while the converter is running is not
possible.
Table 7-7 Selecting Local/Remote

Button to be
Step Function Display
pressed

1. to select LOCAL control

1 ->L 550.0 rpm 1
LOC
(the local control location Status Running
is indicated by the letter L) REM MotorSpeed 0.00 rpm
Power 0.0 %

2. to select REMOTE control

1 -> 550.0 rpm 1
LOC
(the remote control Status Running
location is indicated by a REM MotorSpeed 0.00 rpm
blank) Power 0.0 %

7.6.2 Setting the Direction of Rotation

The direction of rotation is selected on the control panel using the
button for forward direction and the button to reverse the direction.
Both buttons can be used when the control panel is in LOCAL mode.
An arrow on the display indicates the direction:
• When the motor is running, the arrow indicates the actual sense of
rotation.
• When the motor is not running, the arrow indicates the preselected
sense of rotation.
In the example below, reverse direction is shown.

1 L <- 600.0 rpm 1

Status Running
MotorSpeed 600.00 rpm
Power 40.0 %

When the direction of rotation is changed while the motor is running, the
speed will automatically ramp to zero and the motor will accelerate in
opposite direction to the preset speed. The direction of the arrow on the
display changes to the new direction when the motor has reached zero
speed.

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7.6.3 Entering a Setpoint

The setpoint can be changed via the control panel at any time, when set
to LOCAL.
Table 7-8 Entering a Setpoint

Button to be
Step Function Display
pressed

1. to enter a keypad mode

displaying the status ACT PAR 1 L -> 600.0 rpm 1
row, press a mode Status Running
button FUNC MotorSpeed 600.00 rpm
Power 50.0 %

2. to enter the Setpoint

Setting function 1 L -> [ 600.0 rpm] 1
REF
Status Running
MotorSpeed 600.00 rpm
Power 50.0 %

3. to change the setpoint

1 L -> [ 550.0 rpm] 1
(slow change) Status Running
MotorSpeed 550.00 rpm
(fast change) Power 50.0 %

4. to exit the Setpoint

Setting mode, press any ACT PAR 1 L -> 550.0 rpm 1
of the mode buttons Status Running
MotorSpeed 550.00 rpm
the selected keypad FUNC DRIVE Power 50.0 %
mode is entered

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ABB
Chapter 8 - Maintenance and Troubleshooting

Maintenance and parts replacement on the converter must only be carried

out by qualified personnel in compliance with local regulations.
It is strongly recommended to carry out all maintenance work according to
the maintenance schedule at the end of this chapter and the applicable
service instructions, on time and at the stated intervals.
During the warranty period, any repair work must be carried out
exclusively by ABB service personnel. After the warranty period, repair
work may only be carried out by qualified personnel.
ABB offers maintenance and service training courses. Customer staff
having successfully attended such courses, will be certified to do
maintenance and repair work on the converter. To maintain safe and
reliable operation of the converter, ABB recommends taking out a service
contract with the ABB service organization. For more information contact
the ABB service organization. For contact address see section General
Information.
All maintenance activity should be recorded in the maintenance log book
including:
• Date and time of the maintenance work
• Description of the maintenance work
• In case of water-cooled converters:
Conductivity, temperature, pressure and water level
of the cooling water before and after the maintenance
routine
Supplementary information on maintenance and troubleshooting can be
obtained from the following manuals:
• Service and Maintenance Manual with instructions on checking and
replacing semiconductors, changing phase modules and replacing
components
• User’s Manual for Water Cooling System in Appendix A - Additional
Manuals (only in case of water cooled converters)
• Signal and Parameter Table
• Troubleshooting Manual. The document supplements the Signal and
Parameter Table and provides explanations of alarm and fault
messages, associated parameters and I/Os and hints for rectification.

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Chapter 8 - Maintenance and Troubleshooting ABB

8.1 Safety Instructions

DANGER!
Hazardous voltage!
Do not try to gain access to the converter transformer, the high voltage
unitss of the converter nor the motor as long as the drive system is
energized and not grounded.

DANGER!
Voltages from external control circuits may be present inside the
converter, even if mains and auxiliary power are shut off. Take appropriate
measures before working on the converter: de-energize and disconnect all
external devices!

DANGER!
The driven machine can cause the motor to rotate! Always disconnect,
short-circuit or block the motor before work is started.

NOTICE!
Before power is applied to the converter, check that:
• Mains and motor connections are ok
• Auxiliary power and control cable connections are ok
• No tools or other foreign objects are left in the cabinet
• All doors of the power sections are properly closed

NOTICE!
The cooling system may start automatically as soon as the auxiliary
voltage is switched on.

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ABB Chapter 8 - Maintenance and Troubleshooting

8.2 Specific Maintenance Tasks

8.2.1 Cleaning
Dust on electrical components and wiring can cause malfunction and
damage the components.
Proceed as follows:
1 De-energize the drive system according to Chapter 6 - Operation.
2 Carefully clean compartment floors with the vacuum cleaner fitted
with a soft nozzle to prevent component damage.
3 When finished, restart the drive system as described in Chapter 6 -
Operation.

8.2.2 Checking Wire and Cable Connections

Vibration can loosen electrical connections and cause occasional
malfunction or equipment failure. Dust and moisture can build up in loose
connections and cause loss of low-level signals.
Proceed as follows:
1 De-energize the drive system according to Chapter 6 - Operation.
2 Check all power and control cable connections and tighten them if
necessary. Check that all plugs and connectors are tight.

IMPORTANT!

! Capacitor bushings will be damaged when excessive force is applied. Do

not exceed the maximum tightening torque when tightening the capacitor
terminals. The tightening torque values are printed on a label which is
attached on the capacitor. If not otherwise specified, the maximum torque
must not exceed 20 Nm.

3 When finished, restart the drive system as described in Chapter 6 -

Operation.

8.3 Standard Procedure for Troubleshooting

Proceed as follows:
1 Do not switch off the auxiliary voltage or try to reset a fault message
before all essential information at the time of the occurance of the
fault condition has been saved.

ACS 1000 User’s Manual 3BHS213401 ZAB E01 Rev. - 8-3 (4)
Chapter 8 - Maintenance and Troubleshooting ABB
2 Call up the Fault History Display on the CDP control panel. See
Chapter 7 - CDP Control Panel for further information.
Do not clear the fault buffer now!
3 Identify the fault and make a logbook entry.
4 Save the content of the data logger, when a PC is available which has
the DriveWindow or DriveDebug tool installed.
The data logger provides useful information (e.g. waveforms of
voltage, current, torque etc.) for efficient troubleshooting.
5 Try to rectify the fault following the Troubleshooting Manual.
6 Contact ABB service if a fault cannot be rectified.
When calling ABB service, it is recommended to have the following
data available at the time when the fault occurred:
• Operating, ambient and load conditions
• Unusual events
• In case of water-cooled converters:
Conductivity, temperature, pressure and water level
of the cooling water
After the fault has been rectified, start the converter as described in
Chapter 6 - Operation.

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ABB

Maintenance Schedule

Years from start-up

0 1 2 3 4 5 6 7 8 9 10 11 12

Start-up P

Estimated Working Time (hours) 20 30 20 30 20 30 20 30 20 30 20 50

Cooling

Air Cooled Unit:

Air filters R R R R R R R R R R R R
Cooling fan I I I R I I I R I I I R
Redundant cooling fans I I I I I I I R I I I I
Water Cooled Unit:
De-Ionizer I R I R I R I R I R I R
Micro filter I R I R I R I R I R I R
Cooling pump seal I R I I I R I I I R I I
Cooling pump I I I R I I I R I I I R
Redundant cooling pump seals I I I R I I I I I I I R
Redundant cooling pumps I I I I I I I R I I I I
Aux cooling fan I I I R I I I R I I I R
Redundant aux cooling fans I I I I I I I R I I I I
Strainer I I I I I I I I I I I I

Aging

Power capacitors (C, CR, CF) P P P P P P P P P P P R

Other capacitors (CCL, CM, CB) P P P P P P P P P P P R
Battery I R I R I R I R I R I R

Connections & Surroundings

Fiber optic cables P P P P P P P P P P P P

Cable connections I I I I I I I I I I I I
Dustiness, corrosion and
I I I I I I I I I I I I
temperature

Improvements

SW / HW upgrade I I I I I I I I I I I I
Based on product notes I I I I I I I I I I I I

Measurements

Basic measurements with aux.

P P P P P P P P P P P P
supply voltage
Insulation test - P - P - P - P - P - P

Spare Parts

Spare parts I I I I I I I I I I I I

Legend:
Replacement of component R
Inspection (visual inspection, correction and replacement if needed) I
Performance of on-site work (commissioning, tests, measurements, etc.) P

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