Acs 1000

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SYSTEM DRIVES
ACS1000 air-cooled
User manual
OWNING ORGANIZATION DATE STATUS SECURITY LEVEL

System Drives, ABB Switzerland Ltd. 2023-09-13 Approved Public
DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE
User manual 3BHS213401 E01 L en 1/164
© Copyright 2011 ABB All rights reserved.
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LEGAL DISCLAIMER
This document contains information about one or more ABB products and may include a description of or
a reference to one or more standards that are relevant to the ABB products. The presence of any such
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referenced in this document include all the features of the described or referenced standard. In order to
determine the specific features included in a particular ABB product, the product specifications for the
particular ABB product apply.
The buyer acknowledges the proprietary and confidential nature of the information contained in this
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oblige ABB to furnish any particular information to the buyer.
The information in this document is subject to change without notice and should not be construed as a
binding declaration of ABB. ABB assumes no responsibility for any errors or omissions in this document.
Products described or referenced in this document are designed to be connected with networks and
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TRADEMARKS
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All rights to copyrights, registered trademarks, and trademarks reside with their respective owners.
Copyright © 2011 ABB.

All rights reserved.
PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE

ACS1000A User manual 3BHS213401 E01 L en 2/164
CONTENTS
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CONTENTS
1. About this manual................................................................................................................. 12
1.1. Equipment covered by this manual ............................................................................................. 12
1.2. Structure of the user documentation ......................................................................................... 12
1.3. Terms and abbreviations................................................................................................................ 13
1.4. Related documents ........................................................................................................................ 15
1.4.1. Maintenance ..........................................................................................................................15
1.4.2. Technical data .......................................................................................................................15
1.4.3. Schematics.............................................................................................................................15
1.4.4. Specifications and guidelines........................................................................................... 15
1.4.5. Serial communication interfaces .....................................................................................15
1.4.6. Encoder...................................................................................................................................15
1.5. Target groups and required qualification.................................................................................. 16
1.5.1. Handling ................................................................................................................................. 16
1.5.2. Mechanical installation ....................................................................................................... 16
1.5.3. Electrical installation ........................................................................................................... 16
1.5.4. Operation ............................................................................................................................... 16
1.5.5. Maintenance .......................................................................................................................... 16
1.6. User’s responsibilities ..................................................................................................................... 17
1.7. Intended use of equipment ........................................................................................................... 17
1.8. Quality certificates and applicable standards ..........................................................................18
1.9. Items covered by delivery ............................................................................................................... 19
1.10. Identifying the delivery .................................................................................................................. 20
1.11. Document conventions .................................................................................................................. 20
2. Important safety information............................................................................................. 21
2.1. Safety messages and safety signs in this document ............................................................. 21
2.1.1. Safety messages .................................................................................................................. 21
2.1.2. Safety signs............................................................................................................................ 21
2.2. Product safety labels .......................................................................................................................22
2.3. Electrical safety.................................................................................................................................22
2.3.1. General safety instructions................................................................................................22
2.3.2. The seven steps that save lives.........................................................................................23
2.3.3. Possible residual risks.........................................................................................................25
2.4. Main circuit breaker protection device ...................................................................................... 26
2.4.1. Safety and protection requirements...............................................................................27
2.4.2. Minimum requirements for MCB and MCB control .....................................................27
2.5. Maintenance recommendation.................................................................................................... 28
3. Power electronics and cabinet features ............................................................................29
3.1. Overview ............................................................................................................................................ 29
3.2. Drive topology .................................................................................................................................. 30
3.3. Power supply configurations......................................................................................................... 31
3.3.1. Main power supply configurations .................................................................................. 31
3.3.2. Auxiliary power supply configurations ...........................................................................32
3.4. Drive topology ...................................................................................................................................33
3.4.1. Overview .................................................................................................................................33
3.4.2. Control compartment and terminal compartment.....................................................33
3.4.3. Rectifier and inverter compartment............................................................................... 35
3.4.4. Grounding switch................................................................................................................ 36

CONTENTS
3.4.5. Rectifier.................................................................................................................................. 36
3.4.6. Protection IGCTs.................................................................................................................. 36
3.4.7. Inverter ....................................................................................................................................37
3.4.8. Filter.........................................................................................................................................37
3.4.9. Optional Braking Chopper ................................................................................................ 38
3.5. Cooling system..................................................................................................................................41
3.5.1. Fan configurations...............................................................................................................41
3.5.2. Type of fan .............................................................................................................................41
3.5.3. Starting, stopping the cooling system...........................................................................41
3.5.4. AC redundant fans - operating principles..................................................................... 42
3.5.5. EC redundant fans – operating principles .................................................................... 43
3.5.6. Air flow overview (AC and EC fans) ................................................................................. 44
3.5.7. Monitoring the air pressure.............................................................................................. 45
3.5.8. Adjustable parameters ...................................................................................................... 45
3.6. Cabinet design ................................................................................................................................. 46
3.7. Door locking system ....................................................................................................................... 46
3.7.1. Optional cabinets.................................................................................................................47
3.8. Arc resistant design (optional) .....................................................................................................47
3.8.1. Internal arc classification (IAC) .........................................................................................47
3.8.2. Associated protection requirement ................................................................................47
3.9. Space heaters ................................................................................................................................... 48
4. Control system......................................................................................................................49
4.1. Overview ............................................................................................................................................ 49
4.2. Main components ........................................................................................................................... 50
4.2.1. Local control panel............................................................................................................... 51
4.2.2. AMC circuit board.................................................................................................................52
4.3. I/O interfaces.................................................................................................................................... 56
4.3.1. IOEC I/O modules ............................................................................................................... 56
4.3.2. Serial communication interface (fieldbus) ....................................................................61
4.3.3. Pulse encoder interface NTAC (option) ..........................................................................61
5. Transportation, storage and disposal ...............................................................................62
5.1. Safety.................................................................................................................................................. 62
5.2. Transport conditions...................................................................................................................... 62
5.3. Unpacking and inspection ............................................................................................................ 62
5.4. Lifting and transportation ............................................................................................................ 63
5.4.1. Lifting attachment types .................................................................................................. 64
5.4.2. Lifting with the top lifting rails........................................................................................ 65
5.4.3. Lifting with rotating eyebolts (redundant fan unit)....................................................67
5.4.4. Reinstalling lifting attachments .......................................................................................67
5.4.5. Sling configuration for top lifting rails .......................................................................... 68
5.5. Storage............................................................................................................................................... 68
5.5.1. Storage conditions ............................................................................................................. 68
5.5.2. Storing the drive.................................................................................................................. 68
5.5.3. Storage and handling of spare parts ............................................................................. 70
5.6. Disposal of packaging materials and components ............................................................... 70
6. Mechanical installation ........................................................................................................ 71
6.1. Safety................................................................................................................................................... 71
6.2. Overview of installation work ........................................................................................................ 71
6.3. General notes on installation ........................................................................................................ 71
6.3.1. Dimensions and clearances............................................................................................... 71

CONTENTS
6.3.2. Cabinet roof........................................................................................................................... 71

6.3.3. Fire protection ...................................................................................................................... 71
6.3.4. Cable duct material ............................................................................................................. 71
6.4. Preparing the floor...........................................................................................................................72
6.5. Fixing the cabinet to the floor ......................................................................................................72
6.6. Assembling and installing the air exhaust hood ......................................................................73
6.7. Installing the redundant fan unit..................................................................................................74
7. Electrical installation ........................................................................................................... 78
7.1. Safety...................................................................................................................................................78
7.2. Overview of installation work ........................................................................................................78
7.3. Cable requirements .........................................................................................................................78
7.3.1. Additional cable requirements for a UL certified drive ..............................................78
7.4. Cable entries......................................................................................................................................79
7.4.1. Cable entry with EMC plates .............................................................................................79
7.4.2. Cable entry with type 1 sealing modules....................................................................... 80
7.4.3. Cable entry with type 2 sealing modules ...................................................................... 80
7.4.4. Cable entry with cable glands...........................................................................................81
7.5. Power cables, ground cables and equipotential bonding conductor ................................81
7.5.1. Preparing the cable entry and the cables ......................................................................81
7.5.2. Connecting the cables ....................................................................................................... 88
7.5.3. Minimum creepage distance between cable and busbar ........................................ 90
7.5.4. Bolted connections..............................................................................................................91
7.6. Auxiliary power, control and serial communication cables .................................................. 92
7.6.1. Preparing the cable entry and the cables ..................................................................... 92
7.6.2. Connecting the cables ....................................................................................................... 96
7.7. Power supply cable for redundant fan unit ...............................................................................97
7.8. Final checks....................................................................................................................................... 98
8. Commissioning .....................................................................................................................99
8.1. Overview ............................................................................................................................................ 99
8.1.1. Required qualification........................................................................................................ 99
8.1.2. Commissioning procedure ............................................................................................... 99
8.1.3. Commissioning checklist .................................................................................................. 99
8.1.4. Customer assistance.......................................................................................................... 99
8.1.5. Customer acceptance ........................................................................................................ 99
8.2. Commissioning checklists .......................................................................................................... 100
8.2.1. Mechanical installation checklist................................................................................... 100
8.2.2. Electrical installation checklist....................................................................................... 100
8.2.3. Main circuit breaker (MCB) checklist ............................................................................ 100
8.2.4. Input transformer checklist ............................................................................................. 101
8.2.5. Motor checklist ................................................................................................................... 101
8.2.6. Insulation tests checklist.................................................................................................. 101
8.2.7. Power supply checklist...................................................................................................... 101
8.2.8. Miscellaneous checklist .................................................................................................... 101
9. Operation............................................................................................................................. 102
9.1. Safety.................................................................................................................................................102
9.2. Overview ...........................................................................................................................................102
9.3. Operating conditions ....................................................................................................................102
9.4. Sound pressure level......................................................................................................................102
9.5. Local operator panel......................................................................................................................103
9.6. Status messages ........................................................................................................................... 104

CONTENTS
9.6.1. Start sequence of the drive .............................................................................................105

9.6.2. Stop sequence of the drive............................................................................................. 106
9.6.3. Emergency off sequence of the drive ........................................................................... 107
9.7. Starting the drive............................................................................................................................ 107
9.7.1. Checks before starting the drive.................................................................................... 107
9.7.2. Starting the drive remotely.............................................................................................. 107
9.7.3. Starting the drive locally .................................................................................................. 108
9.8. Stopping the drive......................................................................................................................... 109
9.9. Emergency-off .................................................................................................................................111
9.9.1. Initiating an emergency-off..............................................................................................111
9.9.2. Starting the drive after an emergency-off................................................................... 112
10. CDP control panel ............................................................................................................... 113
10.1. Overview ........................................................................................................................................... 113
10.2. CDP control panel functions........................................................................................................ 114
10.3. CDP control panel modes............................................................................................................. 114
10.3.1. Identification mode ........................................................................................................... 114
10.3.2. Actual signals mode .......................................................................................................... 115
10.3.3. Parameters mode............................................................................................................... 122
10.3.4. Functions mode..................................................................................................................128
10.4. Local and remote control ............................................................................................................. 131
10.4.1. Local control ........................................................................................................................ 131
10.4.2. Remote control ...................................................................................................................132
10.5. Operational commands................................................................................................................133
10.5.1. Setting the direction of rotation ....................................................................................133
10.5.2. Entering a reference value................................................................................................134
11. Preventive and corrective maintenance........................................................................... 136
11.1. General information.......................................................................................................................136
11.1.1. Required qualification.......................................................................................................136
11.1.2. Maintenance schedule ......................................................................................................136
11.1.3. Logbook................................................................................................................................136
11.1.4. Spare parts...........................................................................................................................136
11.2. Identifying electrical equipment ................................................................................................ 137
11.2.1. Device identification.......................................................................................................... 137
11.2.2. Cables and wires ................................................................................................................ 137
11.2.3. Understanding wiring diagrams.................................................................................... 137
11.3. Alarm / fault indications...............................................................................................................138
11.3.1. Messages..............................................................................................................................138
11.3.2. Error message levels..........................................................................................................138
11.3.3. Fault handling .....................................................................................................................138
11.3.4. Standard troubleshooting procedure...........................................................................139
11.4. Removing the CDP control panel............................................................................................... 140
11.5. LEDs and switches on circuit boards........................................................................................ 141
11.5.1. AMC circuit board............................................................................................................... 141
11.5.2. IOEC I/O modules ..............................................................................................................142
11.6. Corrective maintenance ................................................................................................................143
11.6.1. Safety.....................................................................................................................................143
11.6.2. De-energizing the drive locally........................................................................................145
11.6.3. Grounding ........................................................................................................................... 146
11.6.4. Grounding switch is not released .................................................................................. 147
11.6.5. Checking the release conditions for the grounding switch ................................. 148
11.6.6. Visual checks on the drive ............................................................................................... 149

CONTENTS
11.6.7. Cleaning the drive ............................................................................................................. 149

11.6.8. Checking wire and cable connections ......................................................................... 150
11.6.9. Cleaning and replacing filter mats................................................................................ 150
11.6.10. Inspecting and replacing batteries ...............................................................................153
11.6.11. Replacing the non-redundant fan ..................................................................................155
11.6.12. Replacing a redundant fan...............................................................................................158

FIGURES
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FIGURES
Fig. 1. Delivered items ....................................................................................................... 19
Fig. 2. Product warning label examples (label placement depends on
the drive) ................................................................................................................. 22
Fig. 3. Drive system overview ........................................................................................... 26
Fig. 4. MCB opening timing diagram .............................................................................. 28
Fig. 5. ACS1000 air-cooled ............................................................................................... 29
Fig. 6. Block diagrams of an ACS1000A with a (A) 12-pulse rectifier and a
drive with a (B) 24-pulse rectifier ........................................................................ 30
Fig. 7. Drive overview with power supplies ..................................................................... 31
Fig. 8. ACS1000 air-cooled topology ................................................................................ 33
Fig. 9. Control and terminal compartments ................................................................... 34
Fig. 10. Rectifier compartment .......................................................................................... 35
Fig. 11. Grounding switch .................................................................................................. 36
Fig. 12. Three-level voltage source inverter principle ...................................................... 37
Fig. 13. Voltage and current waveforms at drive output ................................................. 37
Fig. 14. ACS1000A with braking chopper (1) .................................................................... 38
Fig. 15. Principle diagram .................................................................................................. 38
Fig. 16. Braking chopper design ........................................................................................ 39
Fig. 17. Operating times of the AC fan units during continuous (A) drive
operation and (B) Intermittent drive operation ..................................................42
Fig. 18. Operating principles of redundant EC fans ........................................................ 43
Fig. 19. Air flow: (1) non-redundant fan configuration ................................................... 44
Fig. 20. Air flow: redundant fan configuration ................................................................. 44
Fig. 21. Air pressure switches ............................................................................................ 45
Fig. 22. Door locks ............................................................................................................... 46
Fig. 23. IAC label example .................................................................................................... 47
Fig. 24. Space heaters ......................................................................................................... 48
Fig. 25. Block diagram of control system with (A) customer interface, (B)
control system, and (C) power electronics ......................................................... 49
Fig. 26. Control compartment ............................................................................................ 50
Fig. 27. Control compartment – I/O devices ..................................................................... 51
Fig. 28. AMC circuit board ................................................................................................... 52
Fig. 29. Direct torque control ............................................................................................. 53
Fig. 30. PID control mode ................................................................................................... 55
Fig. 31. IOEC interfaces overview ...................................................................................... 56
Fig. 32. IOEC module ........................................................................................................... 59
Fig. 33. IOEC module identification .................................................................................. 60
Fig. 34. NTAC-02 pulse encoder interface ......................................................................... 61
Fig. 35. Lifting attachment types ...................................................................................... 64

FIGURES
Fig. 36. Top lifting rails with (1) recommended lifting points ....................................... 65
Fig. 37. Mounting bolts and washers for top rail ............................................................ 66
Fig. 38. Sling configuration - standard case with top lifting rails ................................ 68
Fig. 39. Leveling the drive .................................................................................................... 72
Fig. 40. Fixing the cabinet to the floor .............................................................................. 73
Fig. 41. Assembling and installing the air exhaust hood ................................................. 73
Fig. 42. Redundant fan unit – Removing lifting rails (1) and fan access
cover (2) ................................................................................................................... 74
Fig. 43. Redundant fan unit – Installation ......................................................................... 75
Fig. 44. Recommended sequence for attaching the sound absorbing panels
on the right side of the fan unit ........................................................................... 76
Fig. 45. Recommended sequence for attaching the sound absorbing panels
on the left side of the fan unit .............................................................................. 77
Fig. 46. EMC plate example ................................................................................................ 79
Fig. 47. EMC cushion ........................................................................................................... 79
Fig. 48. Type 1 sealing modules (example) ....................................................................... 80
Fig. 49. Type 2 sealing modules example ......................................................................... 80
Fig. 50. Cable entry with cable glands ............................................................................... 81
Fig. 51. Cable termination bar (A) top and (B) bottom cable entry; busbar
thickness is 5 mm ...................................................................................................82
Fig. 52. Preparing cables for EMC plates: (A) cables with an outer screen
or shield, (B) cables without an outer screen or shield .................................... 85
Fig. 53. Preparing power cables for sealing modules ..................................................... 86
Fig. 54. Preparing power cables for cable glands ............................................................ 87
Fig. 55. Power cable terminals in (A and C) 12-pulse ACS1000A and (B and
D) 24-pulse ACS1000A ........................................................................................... 89
Fig. 56. Grounding the drive system ................................................................................. 90
Fig. 57. Bolted busbar connections ................................................................................... 91
Fig. 58. Cable entry from (A) top and from (B) bottom .................................................. 92
Fig. 59. Frame with sealing modules ................................................................................ 94
Fig. 60. Preparing control cables for sealing modules ................................................... 95
Fig. 61. Preparing control cables for cable glands .......................................................... 95
Fig. 62. Shield grounding point for encoder cable .......................................................... 96
Fig. 63. Routing, connecting the cable of the redundant fan unit ................................. 97
Fig. 64. Local operator panel ............................................................................................ 103
Fig. 65. CDP control panel ................................................................................................. 113
Fig. 66. Control panel - Actual signals mode ................................................................... 117
Fig. 67. Control panel - Parameters mode ....................................................................... 124
Fig. 68. Control panel - Functions mode ......................................................................... 128
Fig. 69. Device identification ............................................................................................ 137
Fig. 70. AMC circuit board ................................................................................................. 141
Fig. 71. IOEC module .......................................................................................................... 142

FIGURES
Fig. 72. Location of I/O modules and fuses .................................................................... 147

Fig. 73. Filter panel (1) and filter mat (2) on rectifier and inverter
compartment ........................................................................................................ 152
Fig. 74. Control compartment – battery location ........................................................... 153
Fig. 75. Control compartment - replacing the batteries ................................................ 154
Fig. 76. Fan location, dimensions and weight ................................................................ 155
Fig. 77. Fan - tools and devices ........................................................................................ 155
Fig. 78. Replacing the non-redundant fan ....................................................................... 156
Fig. 79. Installing the non-redundant fan ........................................................................ 157
Fig. 80. Redundant fans – location, dimensions, and weight ....................................... 158
Fig. 81. Redundant fans - tools and devices ................................................................... 159
Fig. 82. Redundant fan unit – removing the panels ........................................................ 160
Fig. 83. Redundant fan unit – Unplugging the power supply cable ............................. 160
Fig. 84. Redundant fan unit – removing the fixing bolts ............................................... 161
Fig. 85. Redundant fan unit – using a crane .................................................................... 162
Fig. 86. Redundant fan unit – using a platform .............................................................. 162

TABLES
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TABLES
Table 1 Standards ..........................................................................................................................................18
Table 2 Braking ratings................................................................................................................................ 40
Table 3 ABB arc resistant classes...............................................................................................................47
Table 4 IOEC module configuration - analog inputs ............................................................................57
Table 5 IOEC module configuration - analog outputs .........................................................................57
Table 6 IOEC module configuration - digital inputs .............................................................................57
Table 8 24 V internal voltage supply......................................................................................................... 58
Table 7 IOEC module configuration - digital inputs ............................................................................ 58
Table 9 IOEC module identification ......................................................................................................... 60
Table 10 Lifting attachment specifications ..............................................................................................67
Table 11 Maximum number of cables per phase.................................................................................... 82
Table 12 Minimum creepage distance between cable and busbar.................................................... 90
Table 13 Parameter groups ......................................................................................................................... 122
Table 14 Filter mat specifications............................................................................................................. 150

ABOUT THIS MANUAL
1. About this manual
1.1. Equipment covered by this manual

This manual covers a standard drive and provides generic information on the drive. The manual
does not claim to cover all variations and details of the drive, nor to consider all eventualities
that may arise during installation, commissioning, operation and maintenance of the drive.
If the drive is adapted to specific customer needs or applications, and handling, installation and
operation of the drive are affected by these modifications, information on these modifications
is provided in the appropriate documentation (eg, layout drawings, wiring diagrams, technical
data, engineering notes).
If information is required beyond the instructions in this manual, refer the matter to ABB.
1.2. Structure of the user documentation

The documentation for a standard drive consists of this document and the following project-
specific appendices.
NOTE – These appendices are NOT included in this document.
– Appendix A - Additional manuals provides manuals about additional equipment delivered
with the drive (such as project-specific options such as pulse encoder or fieldbus
interfaces), or information on modifications of the standard drive.
– Appendix B - Technical data contains the technical data sheets of the drive.
– Appendix C - Mechanical drawings provides the outline drawings of the drive. The drawings
are generated according to the customer-specific project.
– Appendix D - Wiring diagrams contains the circuit diagrams with information on device
identification, cross-reference and device identification conventions. The diagrams are
generated according to the customer-specific project.
“Setting of protective devices” is generated according to the customer-specific project.
– Appendix E - Parts list produced for each project and contains all information to identify a
component.
– Appendix F - Test reports and certificates provides the test reports of the drive. Quality
certificates, and codes and standards the drive complies with are added if necessary for the
project.
– Appendix G - Signal and parameter table includes descriptions of actual signals, control
and status words, and control parameters and their default settings.

ABOUT THIS MANUAL
1.3. Terms and abbreviations

The following table lists terms and abbreviations you should be familiar with when using this
user manual. Some of the terms and abbreviations used in this user manual are unique to ABB
and might differ from the normal usage.
Term/Abbreviation Definition
ACS1000A ACS1000 air-cooled drive
Application and Motor Controller
AMC circuit board
The digital signal processor is the heart of the control system of the drive.
A cluster is a synonym for a group of hardware modules of the drive
Cluster
control system.
Control and display panel
CDP Basic user interface for operating and monitoring the drive when local
operating mode is selected.
Distributed drive control system
DDCS DDCS is an acronym for a serial communication protocol designed for data
transfer via optical fibers.
Drive Short form for ACS1000A drive
The drive system includes all equipment used to convert electrical into
Drive system
mechanical power to give motion to the machine.
DriveBus Communication link dedicated for ABB drives
DriveDebug is part of ABB’s DriveWare® software tools for drives using the
DDCS communications protocol. DriveDebug runs on computers with
DriveDebug
Windows® operating systems. DriveDebug is a specialist’s tool used to
diagnose, tune and troubleshoot ABB drives.
DriveWindow is a DriveWare® product. DriveWindow is a 32 bit Windows®
DriveWindow application for commissioning and maintaining ABB drives equipped with
optical communication links.
Equipment Frequency converter and related equipment
Electromagnetic compatibility
All measures to suppress electromagnetic disturbances caused by different
EMC
electrical equipment in the same electromagnetic environment, and to
strengthen the immunity of the equipment to such disturbances.
Ground Earth
The conducting path (eg, conductor) between the electric equipment (eg,
To ground frequency converter) and the earth. The electric equipment is connected to the
earth, eg, by a grounding set or a grounding switch.
Inverter unit of the drive. The INU converts the DC voltage to the required AC
INU
motor voltage and frequency.
The IOEC module is an active input and output device for digital and
IOEC module
analog signals.
Line voltage RMS voltage of the main power supply of the drive
Main circuit breaker
MCB The MCB is a major protection device of the drive and is the main connection
and disconnection point between the main power supply and the drive.

ABOUT THIS MANUAL
Term/Abbreviation Definition
Molykote Brand name for lubricants
Monitoring and diagnostics tool that allows access to the drive from any
NETA-21
location in the world via a secure Internet connection.
PCB Printed circuit board
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
PCC
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.
Proportional-integral-derivative controller
PID controller Control loop feedback system for controlling process variables (eg, pressure,
flow)
PE Protective earth
Power plate communication system
PPCS is an acronym for a serial communication protocol designed for data
PPCS
transfer via optical fibers between AMC circuit board and INTerface circuit
boards.
Resistance temperature detector or device
RTD The RTD is a temperature sensor where the change in electrical resistance is
used to measure the temperature.
Supervisory signal Indicates the operating condition of a circuit or device.
SW Software
TC Short form for terminal compartment of the drive
UPS Uninterruptible power supply
Used in the manual to indicate that the drive has reached the value “zero
Zero speed threshold speed” that is set in a parameter. The value can be set in the range of 0 and
maximum speed (the unit for the speed is rpm).

ABOUT THIS MANUAL
1.4. Related documents

1.4.1. Maintenance
Title Document number
ACS1000A preventive maintenance schedule 3BHS855276 E01
1.4.2. Technical data

Technical data from DriveSmart 1 (configuration software for medium

voltage drives)
1
Configuration software for medium voltage drives
1.4.3. Schematics
Layout drawing Project-specific
1.4.4. Specifications and guidelines

Retrofit guideline 3BHS301179 E01
Input circuit breaker engineering guideline 3BHS104785 E01
Main transformer specification 3BHS356582 E01
Induction motor specification 3BHS260163 E01
Power cable specification 3BHS189994 E01
Power cables engineering guideline 3BHS542290 E01
Auxiliary power and control cables guideline 3BHS813742 E01
Permission for working and permit to work for test work at test stations 3BHS817511 E30
1.4.5. Serial communication interfaces

Ethernet - NETA-21 remote monitoring tool user manual 3AUA0000096939
Modbus - NMBA-01 installation and start-up guide 3AFY58919772
Profibus - NPBA-12 installation and start-up guide 3BFE64341588
DeviceNet - NDNA-02 installation and start-up guide 3AFY58919829
1.4.6. Encoder
Installation and start-up guide for the pulse encoder module NTAC-0x 3AFY58919730

ABOUT THIS MANUAL
1.5. Target groups and required qualification

The drive presented in this manual is part of an industrial environment where voltages are
present that contain a potential hazard of electric shock and / or burn. For this reason, only
personnel who have a thorough knowledge of the drive and the industrial environment and have
obtained the required qualification should handle, install, operate, or maintain the drive.
The manual addresses personnel who are responsible for unpacking, transportation,
installation, operation and maintenance of the drive. The personnel must carry out the below
listed tasks in a manner that does not cause physical harm or danger, and ensures the safe and
reliable functioning of the drive.
IMPORTANT! Commissioning of the drive must only be performed by qualified and certified
ABB personnel.
1.5.1. Handling
The personnel must be skilled and experienced in unpacking and transporting heavy equipment.
1.5.2. Mechanical installation

The personnel must be qualified to prepare the installation site according to the site and
equipment requirements and to perform the installation accordingly.
1.5.3. Electrical installation

The personnel must have a sound knowledge of the relevant electrical codes and specifications
covering low and medium voltage equipment, be experienced with electrical wiring principles
and know the electrical symbols typically used in wiring diagrams.
1.5.4. Operation
The personnel include all persons who operate the drive from the local operator panel of the
drive. The personnel must know the functions of the operator panel, be adequately trained for
the drive, and know the driven process. Special knowledge of frequency converter technology is
not required.
1.5.5. Maintenance
The personnel include all persons who
– Are qualified to carry out preventive and corrective maintenance on drive as described in this
manual
– Are thoroughly familiar with the drive
– 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 drive and act
correspondingly
– Know the safe shutdown and grounding procedures for the drive system

ABOUT THIS MANUAL
1.6. User’s responsibilities

It is the responsibility of those in charge of the drive to ensure that each person involved in the
installation, operation or maintenance of the drive has received the appropriate training and
has thoroughly read and clearly understood the instructions in this manual and the relevant
safety instructions.
1.7. Intended use of equipment

Those in charge of the drive must ensure that the drive is only used as specified in the
contractual documents, operated under the conditions stipulated in the technical
specifications and on the rating plate of the drive, and serviced in the intervals specified by ABB.
Use of the drive outside the scope of the specifications is not permitted.
Intended equipment use also implies that only spare parts recommended and approved by ABB
must be used.
Unauthorized modifications and constructional changes of the drive are not permitted.

ABOUT THIS MANUAL
1.8. Quality certificates and applicable standards

The following certificates and conformity declarations are available with ABB:
– ISO 9001 and ISO 14001 certificates stating that ABB Switzerland Ltd has implemented and
maintains a management system which fulfills the requirements of the normative standards
– EC declaration of conformity
– List of standards the drive complies with
TABLE 1 Standards
Standard Title
ANSI Z535.6 American national standard for product safety information in product manuals,
instructions, and other collateral materials
ISO 3864-2 2004 (E) - Graphical symbols – Safety colors and safety signs – Part 2: Design
principles for product safety labels
ISO 7010 2011 (E) - Graphical symbols - Safety colours and safety signs - Registered
safety sign
EN 50110 European standard code for electrical work safety
ISO 13849-1 Safety of machinery - Safety-related parts of control systems - Part 1: General
principles for design, section 6.2.6 Category 3
IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part 1: General
requirements
IEC 60721-3-1 Classification of environmental conditions: Classification of groups of
environmental parameters and their severities; Storage
IEC 60721-3-2 Classification of environmental conditions - Part 3-2: Classification of groups of
environmental parameters and their severities - Transportation and Handling
IEC 60721-3-3 Classification of environmental conditions - Part 3: Classification of groups of
environmental parameters and their severities - Section 3: Stationary use at
weather-protected location
IEC 62477-2 Safety requirements for power electronic converter systems and equipment –
Part 2: Power electronic converters from 1 000 V AC or 1 500 V DC up to 36 kV AC
or 54 kV DC
IEC 81346-1 Industrial systems, installations and equipment and industrial products -
Structuring principles and reference designations - Part 1: Basic rules

ABOUT THIS MANUAL
1.9. Items covered by delivery

Delivery typically comprises the following items:
– Drive that is shipped in sea freight or airfreight packaging.
– Optional components and cabinets
– Set of door keys attached to lifting rail (1 in Fig. 1)
– Set of door keys inside the drive
– Rating label (2 in Fig. 1)
– Box with USB stick (3 in Fig. 1), which contains the user manual and related documents.
– Strain relief rails
– Air exhaust hood
– Redundant fan unit (option)
– Set of bolts, nuts and washers
4 5
Key:
(1) Door keys
(2) Rating label
(3) Box with USB stick
(4) Control compartment door
(5) Inside control compartment door
Fig. 1. Delivered items
For a complete list of the items in the delivery, see the shipping note.

ABOUT THIS MANUAL
1.10. Identifying the delivery

The drive and accessories are identified by the type code printed on the rating label.
The label provides information on the type of drive, the rated voltage, the frequency and the
current of the main and the auxiliary power supply.
1.11. Document conventions

The document uses the following font formats and symbols. See also Section 2.1, “Safety
messages and safety signs in this document”, page 21.
Font formats
Convention Description
 Prerequisite for a task
1. Sequential procedural steps in a task
–
Non-sequential procedural steps in a task or items in a list
•
→ Instructions on how to avoid a safety hazard
1) Numbered list
Explanation for callout keys in legend under an illustration or refers to a

(1) callout key in the main text, eg, “Lift fan (1)” or “Remove cover (1, Fig. 2)
and…”
Italic text Identifies software parameters, eg, 16.02 PARAMETER LOCK.
Depending on the context, indicates a safety hazard, the text that you type,
Bold text
a software or physical button, or a link to another part of the document
Underlined text Identifies a hyperlink
Courier font Identifies software file names and file paths
Cursor Represents blinking text on a screen
Symbols
Symbol Description
1 2 3 Callout keys on an illustration
These pictograms refer to the subject matter of the text.
See Section 2.1.2, “Safety signs”, page 21.

IMPORTANT SAFETY INFORMATION
2. Important safety information

Read this material carefully before working on or around the equipment. Failure to do
so can result in serious Injury or DEATH! Keep for future reference.
2.1. Safety messages and safety signs in this document

This document uses ANSI Z535.6 signal words, ISO 7010 safety signs, and ISO 3864-2 colors to
highlight safety-related information.
2.1.1. Safety messages

This is the safety alert symbol. It is used to alert you to potential physical injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
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 physical injury, but which can
result in equipment damage.
2.1.2. Safety signs

Sign Description
Electrostatic discharge susceptible
Hazardous voltage warning
Arc flash warning

2.2. Product safety labels

Product safety labels on the equipment alert you to the hazards that can occur when you work
on or operate the equipment.
– Always follow the instructions on the labels to avoid the hazard
– Keep the labels in a perfectly legible condition
For the location of the labels, see the label placement document for the drive.
1 3
2 4
Key:
(1) Danger label
(2) Warning label
(3) Caution label
(4) Notice label
Fig. 2. Product warning label examples (label placement depends on the drive)
2.3. Electrical safety

The following electrical safety instructions are based on EN 50110.
2.3.1. General safety instructions

– Minimize hazards
– Before energizing the drive:
• Before energizing the drive:
• Remove all foreign objects from the drive
• Fasten all internal and external covers securely
• Close, lock, and/or bolt all doors
• Move the release dial of the door safety switches into the locked position
• Before working on the drive:
• Turn off, lock out, and tag out the main and auxiliary power supplies to the drive
• De-energize the drive
• Ensure that the safety ground connections are in place

• Ensure that the appropriate personal protective equipment (PPE) is available and used
when required
• Inform the involved personnel about the potential safety hazards
• Wear hearing protection when a drive is running.
– While working on the drive:
• DO NOT step on the roof
• DO NOT install foreign objects on the roof
– Before working simultaneously on the drive and on other drive system equipment:
• Observe the relevant safety codes and standards
• Turn off all energy sources for the equipment
• Ensure that all lockout and tagout devices are in place
• Install barriers around and use appropriate covers on the equipment that is still
energized
• Inform the involved personnel about the potential safety hazards
– In case of fire in the drive room:
• Observe the established rules and regulations for fire safety
• Only allow firefighters with the appropriate PPE to enter the drive room
2.3.2. The seven steps that save lives

ABB’s seven steps that save lives concept is a series of actions that must take place prior to
commencing work on or near electrical installations.
1) Prepare for the work: do an on-site risk assessment or job hazard analysis that considers
the limits of approach for shock and arc-flash.
• Be in possession of a clear work order to execute the work.
• When required, the access or work permit is to be obtained by a person who is authorized
for the specific electrical system.
• Engage the person responsible for electrical equipment or system to review single-line
diagrams, schematics, switching plans, etc.
• Ensure the competence of workers.
• Check for proper tools for the job.
• Determine and select the proper arc-rated Personal Protective Equipment (PPE).
• Decide of the appropriate work methods and initiate the Permit To Work (PTW) process.
For an example “Permit to Work”, see “Permission for working and permit to work for
test work at test stations” , 3BHS817511 E30
2) Clearly identify the work location and equipment.
• Use your senses (sight, hearing and smell) to identify problem areas.
• Define the work area via barriers and barricading and label equipment.
• Avoid distractions such as talking or texting on the phone.
3) Disconnect all sources of supply and secure against reconnection by applying
Lockout/Tagout.
• If ABB is responsible for switching and it cannot be done remotely, then the person
performing the switching must be properly trained and wearing the proper PPE
identified in step 1.

• The Person in Charge of Work (PICW) must ensure that switching is performed in the
proper manner by witnessing it from a safe distance if present on site or by engaging the
person responsible for switching to identify all isolation points.
• Apply Lockout/Tagout (LOTO) to the energy isolation device and if multiple energy
isolation devices are involved, then Group LOTO must be implemented with the PICW
serving as the Group LOTO Leader.
4) Verify the absence of operating voltage: always test before you touch!
Only use properly rated and inspected voltage detection devices and wear proper PPE
identified in step 1:
• Test voltage detection device
• Test for voltage
• Test voltage detection device
It is highly important that the voltage detection device is tested on a known voltage source
such as a Proving Unit or by performing an internal self-test, according to the
manufacturer’s instructions, before and after testing for the absence of operating voltage.
5) Carry out earthing and short-circuiting.
• Close and lock the earthing switch if the electrical equipment is designed for this
purpose or apply portable equipment for earthing and short-circuiting.
If this is carried out by the customer, then the PICW must ensure that this equipment is
properly earthed as a part of the integration/verification and during step 7 when the
PICW walks the PTW.
6) Protect against adjacent live parts and take special precautions when close to bare
conductors.
• Determine minimum approach distances, apply screening or shrouding, and when
applicable, padlock both cable and busbar shutters.
• If working within the restricted approach boundary or vicinity zone where inadvertent
movement could cause contact with live parts, special precautions must be employed,
such as the use of the properly rated insulated gloves and tools.
7) Complete the permit to work and “Walk the Permit”.
• Check isolation points
• Verify that all circuits are isolated and secured
• Ensure all parties are integrated with the Lockout/Tagout
• Check the earths are properly applied
• Answer specific questions from the working group
• Ensure the work can proceed without danger
• Complete and verify the “Permit to Work”

2.3.3. Possible residual risks

Residual risks must be considered by the drive system integrator and/or plant owner when
assessing the hazards of the equipment to personnel. The following risks can pose a hazard to
drive system personnel
– Electric power equipment generates electro-magnetic fields which can cause a hazard to
people with metal implants and / or a pacemaker.
– Drive system components can move unintentionally when being commissioned, operated,
or serviced due to:
• Operation of the equipment outside the scope of the specifications
• Incorrectly assembled or installed equipment
• Wrongly connected cables
• External influence on, or damage of the equipment
• Wrong parameter settings
• Software errors
• Faulty hardware
– Hazardous touch voltages can be present on drive system components, which can be
caused by:
• External influence on, or damage of the equipment
• Induced voltages by external equipment
• Condensation on equipment components, or pollution
• Faulty hardware
– High temperatures, noise, particles, or gases can be emitted from drive system
components caused by:
• External influence on or damage of the equipment
• Wrong parameter settings
• Software errors
• Faulty hardware
– Hazardous substances can be emitted from drive system components, eg, due to incorrect
disposal of components

2.4. Main circuit breaker protection device

The main circuit breaker (MCB) is a major protection device of the drive. If a serious fault occurs
in the drive, the MCB must disconnect the main power supply to the drive immediately. The main
power supply must be disconnected without delay on an open or trip command from the drive
to prevent hazard to the personnel and further damage to the equipment. The MCB is located
on the primary side of the converter transformer.
5 6 7 8
Key:
(1) Main power supply (6) Protection relay
(2) MCB control interface (7) Converter transformer
(3) Higher-level control system (8) Drive
(4) Local MCB control (9) Motor
(5) MCB
Fig. 3. Drive system overview
NOTE – MCBs and protection relays are not included in the drive supply.
Typical MCBs devices

– Vacuum circuit breakers
– SF6 circuit breakers
– Fused contactors or motor control centers
Dedicated protection relay

– Transformer or drive primary cable protection (DTL)
– Transformer protection (if applicable)
– Transformer secondary cable protection (if applicable)
– Backing up the drive protection

2.4.1. Safety and protection requirements

For safety and protection reasons, the MCB must meet the stipulated minimum requirements
of the specifications of ABB MV Drives. It is the system integrator's responsibility to ensure that
the minimum requirements are met. The minimum requirements for the MCB are stated in this
note and in the respective MCB specifications, which are available for each medium voltage
drive from ABB.
The safety requirements for the drive are based on the following standards:
– ISO 13849-1
– IEC 60204-1
2.4.2. Minimum requirements for MCB and MCB control

The following safety requirements are also in the MCB specifications for the drive:
– The MCB open and / or trip command has to be wired directly from the drive to the MCB.
• It is not permitted to wire the trip command through any PLC or DCS system if it is not
certified to meet SIL three-level requirements and to fulfill the timing requirements
outlined below.
• Opening of the MCB by the drive must be possible at any time. It is not permitted to
interrupt the open and / or trip command, eg, by a local-remote switch in the MCB.
– When the MCB is in service position, the drive must have exclusive control of closing the
MCB. Local closing of the MCB is not permitted.
– The maximum opening time of the MCB must never exceed the product- or project-specific
maximum time defined in the MCB specifications.
Typical maximum values for the drive are defined as follows:
– Maximum protection trip time: 120 ms
The maximum protection trip time is the maximum allowed breaking time (open and arcing)
of the breaking device after the open command has been initiated to prevent further
damage to the drive, such as diode failures.
– Maximum safety trip time: 250 ms
The maximum safety trip time is the maximum allowed time to ensure safe disconnection of
the main power supply to prevent any hazard to personnel.

3 4
Key:
(1) Short-circuit occurs
(2) Open and or trip command is set at the drive control output
(3) No further damage to the drive
(4) No hazard to personnel
(5) Maximum protection trip time
(6) Maximum safety trip time
Fig. 4. MCB opening timing diagram
In order to meet the stipulated safety requirements, ABB recommends one of the following:
– MCB is equipped with 2 independent opening coils
– MCB is equipped with an opening coil and an undervoltage coil for monitoring of the control
voltage
– Upstream protection coordination scheme is provided which uses the “breaker failure”
(ANSI 50BF) signal to automatically trip the upstream breaker, in case the MCB does not
open.
IMPORTANT! The upstream breaker must open within the maximum safety trip time after a
failure has occurred.
2.5. Maintenance recommendation

The MCB trip circuits should be checked annually.

POWER ELECTRONICS AND CABINET FEATURES
3. Power electronics and cabinet features
3.1. Overview
The ACS1000 air-cooled drive is a general-purpose frequency converter for the control of
standard induction motors.
For information on the power and voltage range of the drive, see the Technical specifications
and the rating plate of the drive.
The following sections provide an overview of:
– Drive topology and main features
– Available main and auxiliary power configurations
– Power electronic components of the drive
– Cooling system
– Cabinet features such as the grounding switch and the electro-mechanical door interlock
Fig. 5. ACS1000 air-cooled

3.2. Drive topology

A
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Key:
(1) Medium voltage switchgear, including main circuit breaker and transformer protection
(2) Transformer
(3) Rectifier
(4) Protection IGCTs
(5) DC link
(6) Inverter
(7) Filter
(8) Motor
Fig. 6. Block diagrams of an ACS1000A with a (A) 12-pulse rectifier and a drive with a (B)
24-pulse rectifier
The drive system consists of the following main components:

– Main circuit breaker (MCB): see Section 2.4, “Main circuit breaker protection device”,
page 26.
– Transformer: see the Transformer specification.
– Drive
– Asynchronous motor: see the motor specification.

3.3. Power supply configurations

The drive requires 2 independent power supplies:
– Main power supply for the power electronic components
– Auxiliary power supply for the control and cooling system
5
1 4
10
7 14
11 12 13
Key:
(1) Auxiliary power supply
(2) ACS1000A
(3) Control and cooling system
(4) Auxiliary power distribution
(5) Cooling system
(6) Control system
(7) Main power supply
(8) MCB
(9) Transformer
(10) Power electronic components
(11) Rectifier
(12) DC link
(13) Inverter
(14) Motor
Fig. 7. Drive overview with power supplies
3.3.1. Main power supply configurations

The drive is connected to the main power supply via a three-winding oil or dry-type transformer.

3.3.2. Auxiliary power supply configurations

The total auxiliary power demand of the drive includes:
– Auxiliary power for the cooling system
– Auxiliary power for the control hardware and the gate units which are used to trigger the
power semiconductors
The total auxiliary power can be fed to the drive in the following ways:
– Through a common power supply
• The total auxiliary power is supplied to the drive by a three-phase AC power supply.
• If the power supply is interrupted, drive internal batteries provide a backup for the
control system, thus enabling the drive to ride-through and/or to perform a controlled
shutdown.
– Through separate power supplies
• The auxiliary power is supplied to the drive by a three-phase AC power supply and by an
UPS to a separate one-phase AC or DC input.
• Feeding the control power separately by an UPS has the advantage that the main control
hardware will remain energized, the full ride-through capabilities of the drive can be
used, and the communication to a higher-level control system will not be lost in the event
of an auxiliary power outage.
IMPORTANT! The power feed for the auxiliary supply must be protected with a suitable circuit
protection rated for the inrush current.
For more information on the auxiliary power interface of the drive, see “Appendix D -
Wiring diagrams”. For information on the rated voltage(s) and current(s), see the rating plate of
the drive.

3.4. Drive topology

This section describes the main design features and introduces the major power electronics
components of a typical drive.
3.4.1. Overview
1 2
Key:
(1) Control compartment and terminal compartment
(2) Rectifier and inverter compartment
Fig. 8. ACS1000 air-cooled topology
3.4.2. Control compartment and terminal compartment

The left compartment of the drive comprises:
– Control compartment at the front (1, Fig. 9): contains the hardware of the control system
of the drive.
For more information on the control hardware, see Chapter 4, “Control system”, page 49.
– Terminal compartment at the back (1, Fig. 9) contains the busbars for the feeder and
motor cables, the ground cable and the cable screens. A hinged bolted partition separates
the terminal compartment from the control compartment.
For more information on cable entry and cable connection, see Chapter 7, “Electrical
installation”, page 78.

120°
Key:
(1) Control compartment
(2) Terminal compartment
(3) Swing frame
Fig. 9. Control and terminal compartments

3.4.3. Rectifier and inverter compartment
3 4 5
8 9 10
Key:
(1) Second 12-pulse rectifier
(2) 12-pulse rectifier with protection IGCTs
(3) Inverter phase U
(4) Inverter phase V
(5) Inverter phase W
(6) Grounding switch
(7) Common mode choke (option)
(8) Filter choke
(9) Filter capacitors
(10) DC-link capacitors
Fig. 10. Rectifier compartment

3.4.4. Grounding switch

The grounding switch is a safety device that enables safe access to the medium voltage
compartments of the drive.
When the switch is in position grounded, the DC link of the drive is connected to the PE
ground busbar.
The grounding switch is electro-mechanically interlocked with a discharge monitoring circuit
that prevents closing of the switch while the DC link capacitors are still charged.
Grounding the drive is only possible after the main power supply has been disconnected, and
the DC link has discharged. When the voltage is below 50 V (DC), the lamp grounding switch
unlocked (1 in Fig. 11) on the door of the control compartment lights up, and the grounding
switch can be turned to position grounded (2, Fig. 11).
Key:
(1) Grounding switch unlocked lamp is on
(2) Grounding switch in grounded position
Fig. 11. Grounding switch
When the grounding switch is in position grounded, the doors of the medium voltage
compartments are released, and the doors can be opened.
3.4.5. Rectifier
The diode rectifier converts the AC voltage of the main power supply and connects its output to
the minus, neutral point, and plus side of the DC link.
Depending on the harmonics requirements for the main power supply, the drive is equipped
with a 12-pulse or a 24-pulse rectifier.
3.4.6. Protection IGCTs

The drive features a fuseless protection design. The IGCTs are placed between the rectifier and
the DC link. If necessary, the IGCTs directly isolate the inverter from the main power supply.

3.4.7. Inverter
The compartment contains the inverter and the DC-link capacitors and filter capacitors.
The inverter converts the DC voltage to the required AC motor voltage and frequency.
Each phase of the three-phase inverter consists of a combination of four IGCTs and two NP
diodes for three-level switching operation. The output is switched between positive DC voltage,
neutral point (NP) and negative DC voltage. Hence, the drive can control the output voltage and
the frequency continuously from zero to maximum using direct torque control.
For more information, see Section 4.2.2.4, “Direct torque control”, page 53.
U=
-
Fig. 12. Three-level voltage source inverter principle
3.4.8. Filter
The filter at the drive output reduces the harmonic content of the motor voltage and generates
a nearly sinusoidal motor-friendly voltage waveform. The filter also eliminates all high dv/dt
effects. Therefore, standard motors can be used, and voltage reflections in the motor cables
are eliminated.
Output voltage: 4.16 kV

Output frequency: 60 Hz
Fig. 13. Voltage and current waveforms at drive output

3.4.9. Optional Braking Chopper

The optional braking chopper uses resistor braking to provide motor braking and shorter
deceleration times, eg, for:
– Reduction of coasting down time, eg, for conveyor belts, fans, and pumps
– Emergency stops
The braking chopper cabinet connects to the right side of the drive as well as to the braking
resistors, which are external to the ACS1000A and not part of the product scope.
Fig. 14. ACS1000A with braking chopper (1)
The braking chopper is controlled and monitored by the ACS1000A.
1 2 3
VC1
C1
4 Rb
VCs2 C2
VC2
Key:
(1) Rectifier
(2) Braking chopping
(3) Inverter
(4) Braking resistor
Fig. 15. Principle diagram

3.4.9.1. Control principle

If the DC-link voltage rises above a preset limit, the control system of the ACS1000A
automatically activates the braking chopper. A rise of the DC-link voltage can be caused by a
machine, feeding into the DC link or by an increase of the voltage in the rectifier of
the ACS1000A.
Key:
(1) Semiconductor stack
Fig. 16. Braking chopper design
3.4.9.2. Monitoring and protective functions
Current monitoring
Input currents of the braking chopper are monitored for overcurrent and imbalance in order to
detect any defective component in the circuit. The current can become imbalanced if one of the
IGCTs conducts a current permanently or if an IGCT fails to be switched on.
If a short-circuit or an imbalance is detected in the braking chopper, the drive is shut down.
Thermal protection
The braking chopper and the braking resistors are monitored for over-temperature by
the ACS1000A.
In addition, an external thermal protection device can be connected to a digital input. As soon
as the temperature of the braking resistors exceeds the response threshold of the external
thermal protection device, the operation of the braking chopper is disabled and an alarm
message is displayed on the control panel of the ACS1000A. Braking is then only possible when
the temperature falls below the threshold.

3.4.9.3. External cooling for braking resistors

A digital output and a digital input can be used to control and monitor an external cooling fan
or pump for the braking resistors.
3.4.9.4. Braking chopper ratings

The maximum braking power is limited to 60% of the nominal power of the ACS1000A and must
not be greater than 2.5 MW (Table 2).
The relation between maximum braking energy (Ebrake max) and maximum chopper braking
power (Pchopper max) is as follows:
E brake max  MWs  = P chopper  max   MW   30 sec [1]
After a braking period of 30 s with maximum braking power (2.5 MW), a cooling time of one hour
is required. If two braking sequences of 30 s are necessary within an hour, the maximum braking
power has to be reduced to 50% of the maximum possible braking power.
TABLE 2 Braking ratings

ACS1000A Braking chopper
Type Maximum DC-link Maximum braking Maximum braking Maximum braking
voltage (V) power (MW) power (MW) energy (MWs)
ACS1012-A1 4200 0.426
ACS 1013-A1 6000 0.426 2.5 75
ACS 1014-A1 7270 0.426
ACS1012-A2 4200 0.672
ACS 1013-A2 6000 0.672 2.5 75
ACS 1014-A2 7270 0.840
ACS1012-A3 4200 0.960
ACS 1013-A3 6000 1.080 2.5 75
ACS 1014-A3 7270 0.960
ACS1012-W1 4200 1.350
ACS 1013-W1 6000 1.500 2.5 75
ACS 1014-W1 7270 1.350
ACS1012-W2 4200 1.680
ACS 1013-W2 6000 2.130 2.5 75
ACS 1014-W2 7270 2.130
ACS 1013-W3 6000 2.500
2.5 75
ACS 1014-W3 7270 2.500

3.4.9.5. Cabinet dimensions and weight
Length 644 mm
Depth 902 mm
Width 2002 (2070 including lifting eyes)
Height 460 kg
3.4.9.6. Braking resistor cables
Cable type Shielded

Minimum cross sectional area 70 mm2
Voltage rating Half of maximum converter DC-link voltage
If a multi-core cable is used, the full DC-link voltage must be taken
into consideration.
Maximum length 50 m
The configuration and dimensions of the braking resistors depend on the specific application.
For information, see the “Dimensioning of braking resistors” application note.
3.5. Cooling system
3.5.1. Fan configurations

The cooling system of the drive is equipped with one of the following fan configurations:
– Non-redundant: The fan (1 in Fig. 19) is installed inside the cabinet.
– Redundant: Fan 1 and fan 2 (1 and 2 in Fig. 20) are installed on the roof. This configuration
enables continuous operation of the drive if a fan fails.
3.5.2. Type of fan

The drive is equipped with one of the following types:
– AC fans: The AC fans are turned on and off with digital signals which switch contactors to
connect or disconnect the 3-phase auxiliary power. The AC fan speed is not controlled.
– EC fans: The electronically commutated (EC) fans are controlled via an analog signal from
the drive based on the inverter current. The EC fan speed is controlled depending on the
required cooling.
3.5.3. Starting, stopping the cooling system

The drive switches on the cooling system when the main circuit breaker (MCB) closes. When the
MCB opens, the cooling system switches off after a delay. The delay corresponds to the
discharging time of the drive and takes up to 5 minutes.

3.5.4. AC redundant fans - operating principles

Default settings:
– Cycle time during which AC fan 1 and AC fan 2 run alternately: 10 h
– Operating time of AC fan 1: 6 h
– Operating time of AC fan 2: 4 h
A B
1
4 4
7
8 2
5 5
7
8 3
6
Key:
(1) Cycle time
(2) Fan 1
(3) Fan 2
(4) 10 hours
(5) 6 hours
(6) 4 hours
(7) On
(8) Off
Fig. 17. Operating times of the AC fan units during continuous (A) drive operation and
(B) Intermittent drive operation
When the drive operates continuously, AC fan 1 switches off after six hours and fan 2 switches
on for four hours.
When the drive operates intermittently, the AC fan that is due for operation is switched on and
off in the same pattern as the drive until the programmed operating time has elapsed.
If one AC fan fails, the second AC fan switches on and runs continuously.

3.5.5. EC redundant fans – operating principles

When no EC fan failure exists, all EC fans are turned on and are running at a lower speed
(typically the minimum speed). When one EC fan fails, the second EC fan will speed up to ensure
the required cooling.
100%
3
1
6
Both fans are running
Fan 1 fails, fan 2 increases speed
Fan 1 is stopped, Fan 2 is running at nominal speed
Fan 1 resumes operation, fan 2 decreases speed
Key:
(1) Fan 1
(2) Fan 2
(3) Drive load
(4) Nominal fan speed
(5) Reduced fan speed
(6) Minimum fan speed
Fig. 18. Operating principles of redundant EC fans

3.5.6. Air flow overview (AC and EC fans)
Fig. 19. Air flow: (1) non-redundant fan configuration
1 2
Key:
(1) Fan 1
(2) Fan 2
Fig. 20. Air flow: redundant fan configuration

3.5.7. Monitoring the air pressure
3.5.7.1. Air pressure in the drive (AC fans only)

This type of supervision is only required for AC fans, which are used for UL or cUL certified
drives. For EC fans, the supervision is integrated in the EC fan electronic board.
A pressure switch (1, Fig. 21) in the control compartment monitors the air pressure in the drive.
1 Key:
2 (1) Air pressure switch
(2) Location of optional air pressure switch
Fig. 21. Air pressure switches
When the pressure decreases and the response threshold of the pressure switch is reached, the
following takes place:
– Drives with non-redundant fan configuration: The alarm FanDiffPres displays on the local
control panel and the drive shuts down.
– Drives with redundant fan configuration: The alarm FanDiffPres displays on the local
control panel and the drive switches on the stand-by fan. When the stand-by fan also fails,
the drive shuts down.
3.5.7.2. Air pressure across filter mat (AC and EC fan types)
A separate optional air pressure switch (2 in Fig. 21) monitors the pressure drop across the filter
mat in the air intake. When the filter mat is clogged and the pressure drop reaches the specified
final pressure loss, the alarm AirFiltSupv displays on the local control panel. The reaction of the
drive on the alarm is programmable.
3.5.8. Adjustable parameters

For information on the parameters for the cooling system and their settings, see “Appendix G -
Signal and parameter table”.

3.6. Cabinet design

The riveted and folded cabinet construction of the drive ensures a strong, flexible and self-
supporting framework. The construction avoids the need for additional skeletal support and
provides effective protection against electromagnetic emissions.
EMC has been achieved by applying a cabinet design consisting of folded, galvanized sheet
metal plates (approximately 2 mm thick) and minimizing the space between the rivets. The
inside walls of the cabinet are not painted, because paint tends to reduce the effectiveness of
metallic bonding which is important for successful EMC.
Accordingly, only the front of the cabinet is painted while all other walls are galvanized.
However, the cabinet can be ordered optionally with the whole of the outside painted. EMC
performance is further enhanced by the use of metal cable ducts.
3.7. Door locking system

To ensure safety and to prevent the doors being opened unintentionally, all doors are lockable.
The doors of compartments where medium voltages are present during operation (2, Fig. 22)
are electro-mechanically secured.
Additionally, the doors of the medium voltage compartments have locks with different inserts
than the control compartment door. The different lock inserts ensure that these doors can only
be opened by personnel authorized to do so.
1 2 2 2
Key: Explanation
Partition of terminal compartment behind control
(1) Door of control compartment
compartment: bolted
(2) Doors of rectifier and inverter compartment Electro-mechanically locked doors cannot be
opened when the drive is energized.
Fig. 22. Door locks

3.7.1. Optional cabinets

If medium voltages are present in an optional cabinet during operation (eg, braking chopper
and output disconnector), the door is secured by an electro-mechanical lock as well as a door
monitoring switch. If the cabinet is UL certified, the door is further secured with extra screws.
The lock and the switch release the door after the DC link of the drive has discharged and the
drive has been grounded.
3.8. Arc resistant design (optional)

The optional “Arc Resistant Design” provides the drive with arc fault protection in accordance
with IEC 62477-2.
The ABB arc resistant classes in Table 3 indicate the type of arc proofing that a drive uses.
Depending on the drive configuration, classes I and II are available for an ACS1000A.
For information on the arc resistant design class of your drive, see the project-specific
“Converter Data Sheet” (“Appendix B - Technical data” of the ACS1000A user manual).
TABLE 3 ABB arc resistant classes
ABB class Description
Class I Protection based on arc prevention (NOT certified according to IEC 62477-2)
Protection based on arc resistant cabinet structure, IAC certified by 3rd body according
Class II
to IEC 62477-2
Protection based on external arc fault limitation and elimination. HV fuses are applied
Class III
externally to limit the arc fault current, IAC certified by 3rd body according to IEC 62477-2
Class IV Fast arc detection and elimination, IAC certified by 3rd body according to IEC 62477-2
3.8.1. Internal arc classification (IAC)

The arc fault rating, which is based on arc fault tests, is on the label underneath the drive rating
plate of the drive.
Internal Arc Classification (IAC)

ABB Class II
IAC F L R T B IA tA APR SC
IEC 62477-2 2b 2b 2b 1 1 5 kA 0.5 s Yes No
Distance [m] 0.3 0.3 0.3 - -
3BHB049908R1205
Fig. 23. IAC label example
3.8.2. Associated protection requirement

The arc resistant design requires associated protections that are not included in the scope of
the delivery, ie, a main circuit breaker.
For more information on the MCB:
– MCB overview: Section 2.4, “Main circuit breaker protection device”, page 26
– MCB requirements: “Input circuit breaker engineering guideline” , 3BHS260163 E01

3.9. Space heaters

The optional space heaters protect the cabinet from condensation.
The drive switches on the space heaters when the cooling system is switched off.
Fig. 24. Space heaters

CONTROL SYSTEM
4. Control system
4.1. Overview
The control compartment incorporates the hardware for the control, monitoring and protection
functions of the drive, and the communication interfaces to the local control panel and to the
remote control devices. Depending on the control concept of the drive system, the remote
control devices include a higher-level control system and / or remote operator stations.
A 4
1 2
3
5 6 5 9
B 8
5
5
10
5 13
14
11
15
12 16
11
Key:
(1) ABB Ability (9) PC tools
(2) Cloud connectivity (10) AMC circuit board
(3) Fieldbus (11) Fiber-optics
(4) Higher-level control system (12) INT circuit board
(5) DDCS (13) IOEC1
(6) NETA-21 (14) IOEC2
(7) RS485 (15) IOEC3 (optional)
(8) CDP control panel (16) IOEC4 (optional)
Fig. 25. Block diagram of control system with (A) customer interface, (B) control system, and
(C) power electronics

CONTROL SYSTEM
4.2. Main components

This section provides an overview of the main hardware components of the control system and
their interconnection.
3
4
Key:
(1) Control power supply (6) NETA-21
(2) AMC circuit board and INT circuit board (7) Motor starters and circuit breakers
(3) Pulse encoder (option) (8) Control power supply
(4) Fieldbus interface (option) (9) Local control panel
(5) IOEC1 module
Fig. 26. Control compartment

CONTROL SYSTEM
Key:
(1) IOEC2 module (standard)
(2) IOEC4 module (option)
(3) Auxiliary voltage terminals
(4) IOEC3 module (option)
Fig. 27. Control compartment – I/O devices
For more information on the devices present in the control compartment, see “Appendix D -
Wiring diagrams”.
4.2.1. Local control panel

The local control panel on the door of the control compartment serves as the basic user
interface for monitoring, control, operation of the drive, and setting of parameters.
For more information, see Chapter 9, “Operation”, page 102 and Chapter 10, “CDP control
panel”, page 113.

CONTROL SYSTEM
4.2.2. AMC circuit board

The AMC circuit board is the major component of the drive’s control system and performs
general drive control, motor control, and closed loop functions. The main internal control
devices and the peripheral input and output interfaces to the customer communicate with the
AMC circuit board via optical fibers.
The circuit board is fitted with a Motorola DSP processor and features two PPCS and eight
DDCS communication channels. These communication channels are used for high-speed data
transfer via the INT circuit board to the inverter.
Key:
(1) AMC circuit board
(2) Interface circuit board (INT)
Fig. 28. AMC circuit board
4.2.2.1. Control tasks

The AMC circuit board has specific control and closed-loop tasks assigned to it. It processes
drive and status information, performs the speed and torque control tasks, and monitors the
operation of the drive.
All relevant drive variables (eg, speed, torque, current, voltage) are continuously monitored by
the control system. Pre-programmed protection functions ensure that these variables remain
within certain limits in order to maintain safe operation of the drive. These internal functions
are not programmable by the user.
Optionally, the AMC circuit board can monitor signals from external equipment. These can be
activated and adjusted with parameters.
Other general control, protection and monitoring tasks regarding the whole drive include
control and monitoring of:
– Section 2.4, “Main circuit breaker protection device”, page 26
– Section 3.4.4, “Grounding switch”, page 36
– Section 3.5, “Cooling system”, page 41

CONTROL SYSTEM
4.2.2.2. Parameters
The control system is configured, customized, and tuned with a set of application parameters.
The application parameters are organized in functional groups and have factory-set default
values. The default parameter values are adjusted during commissioning to the specific
application of the drive in order to activate the specific control, monitoring and protection
functions for the driven process, and to define the signals and data transferred between drive
and external equipment.
For more information on the parameters for signal allocation, signal type selection, signal
inversion, scaling, and filtering, see “Appendix G - Signal and parameter table”.
4.2.2.3. Main circuit breaker

The main circuit breaker (MCB) is an important switching and protection device of the drive
system. Therefore it must only be controlled and monitored by the drive.
For more information, see the Main circuit breaker engineering guideline and Section 2.4, “Main
circuit breaker protection device”, page 26.
4.2.2.4. Direct torque control

The speed and torque of the motor is controlled by DTC (Direct Torque Control). DTC provides
accurate speed and torque control, and high dynamic speed response.
5 6 8
9
3
7 10
11
12
Key:
(1) Torque reference (7) Motor model
(2) Speed reference (8) Switching logic
(3) Actual reference (9) Switch positions
(4) Speed controller (10) Voltage
(5) Torque reference controller (11) Current
(6) Torque-flux comparator (12) Motor
Fig. 29. Direct torque control
Switching of the semiconductors in the inverter is directly controlled in accordance with the
motor core variables flux and torque.

CONTROL SYSTEM
The measured motor currents and DC link voltages are inputs to an adaptive motor model. The
model produces exact values of torque and flux every 25 microseconds. Motor torque and flux
comparators compare the actual values to reference values which are produced by the torque
and flux reference controllers.
Depending on the outputs from the hysteresis controllers, the switching logic directly
determines the optimum switch positions every 50 microseconds and initiates switching
whenever required.
4.2.2.5. Peripheral I/O devices

The peripheral input and output devices connected to the AMC circuit board include:
– Local CDP control panel
– IOEC I/O modules for parallel signal transfer to external devices (see Section 4.3.1, “IOEC I/O
modules”, page 56)
– Serial communication interface (fieldbus) for serial data transfer to a higher-level
control system (see Section 4.3.2, “Serial communication interface (fieldbus)”, page 61)
– Pulse encoder interface NTAC (option) (see Section 4.3.3, “Pulse encoder interface NTAC
(option)”, page 61)
– PC-based service tools comprising:
• DriveWare® software tools, commissioning and maintenance tools, ie, DriveWindow and
DriveDebug, and DriveOPC for data transfer between ABB drives and Windows®-based
applications.
• NETA-21 for monitoring and diagnostics tool that allows access to the drive from any
location in the world via a secure Internet connection.
4.2.2.6. Control modes

The drive provides the following control modes:
– Speed control mode: Default control mode of the drive. The control mode can be used for
applications where constant speed is required, such as pumps, fans and conveyors.
– Torque control mode: used for processes that require torque control (eg, mixers and slave
drives). The torque reference comes from a process control system or a control panel.
– PID control mode: controls the process variable (eg, pressure, level or flow) by adjusting the
speed of the motor accordingly.

CONTROL SYSTEM
1 Key:
(1) Reference value
(2) Level transducer
(3) Actual value
(4) Pump
3 2
Fig. 30. PID control mode
Application examples
– Booster pumps of municipal water supply systems
– Automatic level control of water reservoirs
– Booster pumps of district heating systems
– Speed control of different types of material handling systems where the material flow has
to be regulated.
– Sequential control mode: used in processes that require different constant speed settings
and/or different acceleration and/or deceleration settings in addition to an adjustable
speed reference value.
Up to seven constant speed settings and two acceleration and/or deceleration settings are
possible. The selection of the different settings can be automated by a process control
system or can be made manually by selector switches that are connected to the
corresponding digital inputs of the drive.
The preset values of a control mode can be left unchanged or they can be set individually by the
commissioning engineer as required for the application.
For more information on control mode settings, see“Appendix G - Signal and parameter table”.

CONTROL SYSTEM
4.2.2.7. Operating modes

The drive provides the following operating modes:
– Master-follower operating mode: used for applications with several drives where the motor
shafts are coupled to each other (eg, gearing, chain, belt). Owing to the master- follower
operating mode the load can be evenly distributed between the drives or at some adjustable
other ratio which depends on the process.
– Hand-auto operating mode: suitable for applications where the speed has to be controlled
automatically by a process automation system and manually by an external control panel.
The active control station is selected via a digital input.
The operating mode is also recommended when two external control stations exist from
where the reference value can be set and the drive can be started and stopped. The external
control station is selected via a digital input.
4.3. I/O interfaces
4.3.1. IOEC I/O modules

Internal and external, analog and binary I/O signals are connected to the control system by IOEC
modules.
The standard I/O includes one external module (IOEC 2, IOEC 3) and one module that is internal
to the drive operation (IOEC 1). The standard I/O provides standard control and supervision
functionalities sufficient for most applications.
The drive can include an optional expansion I/O that includes an external module (IOEC 4).
These expansion modules provide extra inputs and outputs for control and supervision as may
be required by the drive or the customer to support various control options.
1 2 3 4
6 6 7 7
Key:
(1) IOEC 1 (5) AMC circuit board
(2) IOEC 2 (6) Standard
(3) IOEC 3 (7) Option
(4) IOEC 4
Fig. 31. IOEC interfaces overview

CONTROL SYSTEM
4.3.1.1. IOEC module configuration

Each IOEC module is configured with both analog and digital inputs and outputs as shown in
the following tables.
TABLE 4 IOEC module configuration - analog inputs

No. of I/O 4
Resolution 10 bit
Signal interface Floating, galvanically isolated
0 - 20 mA, 4 - 20 mA, 0 - 10 V, 2 - 10 V
Signal level
Individually scalable by parameter
Rin = 105 Ω for current input
Input resistance
Rin = 250 k Ω for voltage input
Common mode voltage Maximum: 48 V

Isolation level 350 V (AC)
TABLE 5 IOEC module configuration - analog outputs

No. of I/O 2
Signal range 0 - 20 mA (load impedance: max. 250 Ω)
Resolution 12 bit
TABLE 6 IOEC module configuration - digital inputs

No. of I/O 14
22 - 120 V (DC) *
Signal level *for the 80 to 120V range, an IOEC adapter board is required
22 - 250 V (AC)
Logical threshold < 13 V (AC or DC) ≙ “0”, > 16 V (AC or DC) ≙ “1”
13 mA steady state (14 mA max. inrush) at 24 V (DC)
Input current 11.5 mA steady state (80 mA max. inrush) at 120 V (DC)
10.5 mA steady state (92 mA max. inrush) at 230 V (AC)

CONTROL SYSTEM
TABLE 7 IOEC module configuration - digital inputs

No. of I/O 6
Signal level Maximum: 120 V (DC) or 250 V (AC)
Switching capacity Voltage Switching current Steady state current
24 V (DC) 8A 6A
24 V (AC) 8A 6A
48 V (DC) 1A 6A
48 V (AC) 8A 6A
120 V (DC) 0.4 A 6A
120 V (AC) 8A 6A
230 V (AC) 8A 6A
4.3.1.2. Internal voltage supply (24 V)

One isolated DC/DC converter supplies an overload protected voltage of 24 V (DC) to operate
digital inputs from passive contacts. The output is protected by a PTC-resistor against short-
circuit and external applied overvoltages.
TABLE 8 24 V internal voltage supply

Output voltage Available output voltage
Unregulated 24V 180 mA

CONTROL SYSTEM
4.3.1.3. Module terminals

The IOEC module has terminal blocks for internal wiring and indicator LEDs for diagnostic and
I/O status.
X21-1 A3
A3411
341
411
411
X21
X21-2
DO1 6
RX
X
DDCS TX
TX
MCB-OFF IN
X21-3
DDCS R
X22-1
7
D
X22-2
X22 X22-3
DO2
2 4V DC
X6-1
X23-1 X6-2 8
X6-3
X23-2
X23 X23-3
DO3 X6-4
1 X24-1
X24-2 DO4
X24 X24-3
POWER
OK
X25-1
X25-2 DO5
X25 X25-3
X26-1
LINK
X26-2 DO6 ERROR
X28 X26-3 NODE
ADDRESS
X11-1 DI1
DI1
X11-2
X11-3 DI2
DI2
X11-4
X11 X11-5
DI3
X11-6
DI3
X11-7 DI4
DI4
X11-8
X11-9
DI5 DI5
X11-10
X12-1
DI6 DI6
X12-2
X12-3
DI7 DI7
X12-4
2 X12 X12-5
DI8 DI8
X12-6
X12-7
DI9
X12-8 DI9
X12-9
DI10
X12-10 DI10
X13-1
DI11 9 10
X13-2 DI11
X13-3
DI12
X13-4 DI12
X13
X13-5
DI13
X13-6 DI13
X13-7
AI1 20mA AI1 20mA
VIR OK
DI14
X13 8
X
X13-
X1
X13-8 DI14
AI1 10 V AI1 10 V
X13-9
9 24 VIR
3 S1 AI2 20mA S1 AI2 20mA
X13-10
10
0 O IR
OV
S1
AI2 10 V AI2 10 V
AI1 20mA
AI3 20mA AI3 20mA
1
OV +10V 2 AI1 10V
3 AI2 20mA
X32 X31
-AI1 +AI1 4
AI2 10V
4 AI3 10 V AI3 10 V
S2 S2
-AI2 +AI2 S2
-AI3
-AI4
+AI3
+AI4
1
2
3
AI3
AI3
AI4
20mA
10V
20mA
AI4 20mA AI4 20mA
-AO1 +AO1
4
AI4 10V
AI4 10 V AI4 10 V
X32 X31
OFF
ON
5 -AO2 +AO2
IOEC
OFF
OFF
I/O-INTERFACE
ON
ON
Key:
(1) Digital outputs (6) DDCS fiber optics
(2) Digital inputs (7) I/O Emergency OFF function
(3) 24 V internal voltage (8) Power supply (factory-installed wiring)
(4) Analog inputs (9) Voltage mode
(5) Analog outputs (10) Current mode
Fig. 32. IOEC module

CONTROL SYSTEM
4.3.1.4. I/O device identification

The I/O modules are identified on the part with an identification label (1, Fig. 33), in the wiring
diagram, and in the software by the wiring diagram identification number (2, Fig. 33).
1 2
A5191
A5191
Key:
(1) Identification label
(2) Identification number
Fig. 33. IOEC module identification
The way the identification number is built directly corresponds to the wiring diagram as can be
seen in Fig. 33. The letter A represents the kind of part we have, an assembly, the next three
digits are the page number the part is located on, page 191, and the last digit, 1, means that our
part is the first assembly on the page. This identification label number is the key to track
electrical devices throughout the drive and in the ABB documentation.
The designation for each IOEC module is shown in Table 9 .
TABLE 9 IOEC module identification
I/O module type Wiring diagram designation for module identification
IOEC1 A5191
IOEC2 A5201
IOEC3 A5211
IOEC4 A5221

CONTROL SYSTEM
4.3.2. Serial communication interface (fieldbus)

To identify the serial communication interface in the drive, see “Appendix D - Wiring diagrams”.
For more information on the device, consult the relevant manual:
– Modbus TCP - “Ethernet - NETA-21 remote monitoring tool user manual”, 3AUA0000096939
– Modbus RTU - “Modbus - NMBA-01 installation and start-up guide”, 3AFY58919772
– Profibus - “Profibus - NPBA-12 installation and start-up guide”, 3BFE64341588
– DeviceNet - “DeviceNet - NDNA-02 installation and start-up guide”, 3AFY58919829
4.3.3. Pulse encoder interface NTAC (option)

The NTAC interface is part of the control system of the drive if pulse encoder feedback is used
to control the motor.
For more information on the device, see “Installation and start-up guide for the pulse encoder
module NTAC-0x” , 3AFY58919730.
Terminals X1 Terminals X2
1 A+ Channel A 1 -V 0V
2 A- 2 -V 24 V
3 B+ Channel B 3 +V
+24V 0V 24 15 24/15 +V -V -V
X2 4 B- 4 24/25
5 Z+ Channel Z 5 15
6 Z- 6 24
7 SH Shield 7 0V
X1
A+ A- B+ B- Z+ B- SH SH 8 SH 8 +24 V
Fig. 34. NTAC-02 pulse encoder interface

TRANSPORTATION, STORAGE AND DISPOSAL
5. Transportation, storage and disposal

5.1. Safety
The drive must only be handled by personnel who are skilled and experienced in
unpacking and transporting heavy equipment.
5.2. Transport conditions

The transport conditions for the drive are based on IEC 60721-3-2.
– Transport conditions: 2K12 / 2B1 / 2C2 / 2S5 / 2M4
– Maximum transport time: 2 months
5.3. Unpacking and inspection

1. Remove all packaging material carefully.
2. Check the drive and accompanying equipment for damages.

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 (include photographs of the damaged parts).

5.4. Lifting and transportation

WARNING
Risk of serious injury! Incorrect securing and lifting of loads can cause serious injury
and damage the equipment.
→ Lift operations MUST be performed by qualified personnel in accordance with local
lifting laws!
→ Use a crane; DO NOT use a forklift
→ If the drive is delivered in several transport units, DO NOT lift and move the drive by
crane after the transport units have been joined
→ Use suitable lifting gear for the load weight, eg, web slings, chain slings, round
slings, and shackles
→ Only use the original lifting attachments with the original mounting bolts and
washers to transport the equipment
→ For a drive with the optional redundant fan (Section 6.7, “Installing the redundant
fan unit”, page 74), DO NOT use the rotating eyebolts on the fan housing when you
lift the drive
→ Before use, always check the lifting attachments for damage, eg, corrosion and
cracks; DO NOT attempt to lift equipment with a damaged lifting attachment;
contact ABB for a replacement before you proceed
→ Always transport the load in an upright position
→ Always observe the center of gravity
→ DO NOT lift more than one load at a time
Refer to “Appendix C - Mechanical drawings” for relevant dimensions and weights.
NOTICE
Risk of component damage! Dirt and metallic dust can cause failure when the drive is
energized.
→ Keep the cabinet doors closed during lift operations

5.4.1. Lifting attachment types

IMPORTANT! The lifting attachments, which are included with the delivery, are intended
exclusively for use with ACS1000A equipment. Any use beyond this is strictly prohibited. Only
use the original lifting attachments to transport the equipment.
Key: Explanation
(1) Top lifting rail For lifting a standard drive
(2) Top lifting rail For lifting an additional cabinet
(3) M8 Rotating eyebolt For lifting redundant fan unit
Fig. 35. Lifting attachment types

5.4.2. Lifting with the top lifting rails

The top lifting rails are on the roof of standard drives and additional cabinets.
1. Attach slings to the hole with the recommended lifting point labels (1) on each of the 4 top
lifting rails, eg, with shackles (see Fig. 38).
NOTICE If the labels are not visible, attach the slings to the middle holes of the rails.
1
3BHB054509R0001
Fig. 36. Top lifting rails with (1) recommended lifting points
2. Ensure that the maximum vertical slope angle of the slings is 60° (2, Fig. 38).
3. Lift the drive slowly and steadily to the required clearance height.
CAUTION! If the horizontal position of the load does not remain stable, lower the drive to
the floor, attach the slings to different holes on the top rails, and then lift the load again
while checking the horizontal position.
If you need to remove the top lifting rails (special case only – ABB recommends that the rails
remain on the roof):
4. Unbolt and remove the top rails (3, Fig. 37).
5. Grease and re-insert the bolts with the washers from Step 4 into the mounting holes for the
top rails on the roof.
6. Tighten the bolts to the torque that is specified in Table 10.
The IP rating of the drive is restored.
7. Store the top rails in a dry, non-corrosive environment for when you need to move the drive
again, eg, when the drive is at end of life (see Section 5.4.4, “Reinstalling lifting
attachments”, page 67).

3
2
Key:
(1) Mounting bolt (min. A2-70)
(2) Ripp-Lock washer
(3) Top rail
Fig. 37. Mounting bolts and washers for top rail

5.4.3. Lifting with rotating eyebolts (redundant fan unit)

Rotating eyebolts, which are required to lift a redundant fan unit, are installed in the factory.
The following instructions describe how to use the eyebolts during a lifting operation. For
instructions on how to lift and install a redundant fan unit, see Section 6.7, “Installing the
redundant fan unit”, page 74).
The lifting procedure requires a crane with a lift frame or a spreader frame.
1. Rotate the eyebolts (1) in the pull direction (3), 2

ie, sling direction, and then attach slings to the
1
eyebolts with safety hooks or shackles (2).
CAUTION! DO NOT run slings through the
eyebolts!
Referring to Fig. 38, page 68:

2. Protect the edges and other protrusions on the load from direct contact with the lifting
gear, eg slings.
3. Lift the load slowly and steadily, with no abrupt stops, in an upright position to the
required clearance height.
CAUTION! Keep an eye on the horizontal position of the load and reposition the slings when
necessary.
5.4.4. Reinstalling lifting attachments

If you need to reinstall factory-mounted lifting attachments, eg, when the drive is at end of life,
tighten the mounting bolts to the torque that is specified in Table 10.
TABLE 10 Lifting attachment specifications
Type Mounting bolt and washer Torque ABB ID
(Nm)
4 × M16×40 (A2-70) NB 312350P0464
Top lifting rail for standard drive 204
Washer Ripp lock 9ABA450078P0008
Top lifting rail for additional
3 × M8×25 combi screw 8.8 24 9ABA450093R0311
cabinet
M8 rotating eyebolt M8 10 3BHE015753P0008

5.4.5. Sling configuration for top lifting rails
2 2
60° 60° 1
max max
Key:
(1) Shackle
(2) Sling slope angle (maximum 60°)
(3) Top lifting rail
Fig. 38. Sling configuration - standard case with top lifting rails
5.5. Storage
5.5.1. Storage conditions

The minimum requirements for storage are based on IEC 60721-3-1.
– Conditions: 1K22 / 1B1 / 1C2 / 1S11 / 1M11
5.5.1.1. Storage time

The drive can be stored for up to one year in the original packaging as long as it is not damaged
or opened.
NOTE – For information on longer storage periods, contact the ABB service organization.
5.5.2. Storing the drive

If the drive is taken out of service for a longer time proceed as follows:
1. Remove the batteries (if applicable).
2. Cover all cable inlets and ventilation slots with an impermeable plastic or aluminum foil and
a wooden panel.

3. Add a desiccant of the appropriate quality:

• 1 unit desiccant (30 g) absorbs 6 g water vapor.
The following quantity is required when using a polyethylene foil:
• 10 units/m2 foil
4. Close and lock the doors of the cabinet.
5. Use polyethylene or equivalent for packaging:
• 0.3 g/m2/24h water vapor diffusion
6. Attach humidity indicators to the packaging.
The storage conditions and the packaging should be checked regularly. Any damages that occur
during the storage period should be repaired immediately.

5.5.3. Storage and handling of spare parts
NOTICE
Risk of component damage! Electronic devices (eg, circuit boards, semiconductors)
are sensitive to electrostatic discharge (ESD), which can damage these devices.
Observe the following to maintain spare parts in good condition and to keep the
warranty valid during the warranty period:
→ Apply ESD handling precautions before handling these devices.
5.5.3.1. Warranty information

IMPORTANT! Check the spare parts immediately after receipt for damages and report any
damage to the shipping company and the ABB service organization.
– Keep spare parts in their original packaging
– Store printed circuit boards in antistatic bags or boxes
– Storage temperature range: -5 °C to +55 °C
– 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 with NO condensation
• Relative air humidity: 5 to 85%
If in doubt whether the maximum allowed humidity is exceeded, protect the spare parts
with an external heater.
– 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
5.6. Disposal of packaging materials and components

Dispose of the packaging materials and the components at the end of the lifetime of the drive
according to local regulations.

MECHANICAL INSTALLATION
6. Mechanical installation
6.1. Safety
All installation work must be carried out by qualified personnel according to the site
and equipment requirements and in compliance with local regulations.
6.2. Overview of installation work

The installation includes the following work:
– “Preparing the floor”, page 72
– “Fixing the cabinet to the floor”, page 72
– “Assembling and installing the air exhaust hood”, page 73
– “Installing the redundant fan unit”, page 74
6.3. General notes on installation
NOTICE
Risk of component damage! Foreign matter and particularly metallic dust can cause
failure and damage when the drive is energized.
→ Ensure that foreign matter cannot enter the cabinet:
• Close the doors and cover openings completely when work is discontinued.
• Retrieve any foreign matter which accidentally dropped into the cabinet.
6.3.1. Dimensions and clearances

See “Appendix C - Mechanical drawings” for information on:
– Cabinet dimensions
– Clearances to be observed
– Mounting hole sizes
6.3.2. Cabinet roof

The cabinet roof is not designed as a mounting base for, eg, foreign devices, cable ducts.
Therefore, it is not permitted to install any foreign device on the roof.
6.3.3. Fire protection

To prevent fire spreading into the drive, apply suitable fire protection measures.
6.3.4. Cable duct material

– Use non-flammable material with non-abrasive surface.
– To prevent dust, humidity and animals entering the cabinet, protect the cable entries.

6.4. Preparing the floor

Condition of the floor:
– Must support the weight of the cabinet
– Overall incline across 5 m must not exceed 5 mm
– Even
– Non-flammable, smooth and non- abrasive
– Protected against humidity diffusion
6.5. Fixing the cabinet to the floor

IMPORTANT! If the doors of medium voltage compartments cannot be opened, contact the
ABB service organization
1. Drill fixing holes into the floor as indicated on the layout drawing.
2. When the cabinet is in place, check if the doors are misaligned.

NOTE – If the doors DO NOT open and close properly, place leveling plates at the
appropriate points (arrows in Fig. 39).
3. Recommended size: 80 x 300 x 0.5 mm
Fig. 39. Leveling the drive
4. Fix the cabinet to the floor.

NOTE – Floor fixings are not supplied. ABB recommends anchor bolts (Fig. 40) or M16
screws and nuts.

5. Insert the screws from the ends of the cabinet base or via the holes inside the cabinet.
Fig. 40. Fixing the cabinet to the floor
6.6. Assembling and installing the air exhaust hood

This section applies to drives with an internal fan.
– Assemble and install the air exhaust hood as illustrated.
– Use the supplied screws.
1 2
3 4
Fig. 41. Assembling and installing the air exhaust hood

6.7. Installing the redundant fan unit

This section applies to drives with a redundant fan unit.
– Included in delivery: mounting screws
IMPORTANT! Move the drive to its final location before you install the redundant fan unit.
1. Remove the top lifting rails (1, Fig. 42) and then remove the cabinet access cover for the fan
unit (2, Fig. 42).
IMPORTANT! Keep the mounting bolts and Ripp-lock washers for the next step.
2
1
Key:
(1) Top lifting rails (2) Fan access cover
Fig. 42. Redundant fan unit – Removing lifting rails (1) and fan access cover (2)
2. Grease and reinstall the mounting bolts and Ripp-lock washers from the lifting rails in the
drive cabinet roof.
NOTICE Tighten the bolts to a torque of 204 Nm to preserve the IP rating of the drive.

3. Attach the lifting gear to the rotating eye bolts (3, Fig. 43) of the redundant fan unit
(1, Fig. 43).
CAUTION! The redundant fan weighs approximately 300 kg.
4. Orientate the redundant fan unit with the cable pointing to the left (2, Fig. 43).
5. Lift the redundant fan unit above the cabinet.
6. Before you lower the redundant fan unit onto the cabinet roof, check that the gasket
between cabinet roof and redundant fan unit is properly placed.
3
1
Key:
(1) Redundant fan
(2) Cables
(3) Rotating eye bolt
Fig. 43. Redundant fan unit – Installation

7. Fasten the redundant fan unit on both sides to the cabinet roof.
8. Attach the sound absorbing panels on the right side of the redundant fan unit.
Recommended sequence: 1, 2, and 3.
1
3
Fig. 44. Recommended sequence for attaching the sound absorbing panels on the right side
of the fan unit

9. Route the power supply cable of the redundant fan unit with the transformer and motor
cables into the cabinet,
10. Attach the sound absorbing panels on the left side of the redundant fan unit.
Recommended sequence: 1, 2, and 3.
3
2
Fig. 45. Recommended sequence for attaching the sound absorbing panels on the left side of
the fan unit
11. Continue with the electrical installation of the power supply cable.
See Section 7.7, “Power supply cable for redundant fan unit”, page 97.

ELECTRICAL INSTALLATION
7. Electrical installation
7.1. Safety
DANGER
Hazardous voltage! Improper work can result in DEATH or life-threatening injury.
→ The electrical installation must be carried out by qualified personnel according to
the site and equipment requirements, and the relevant electrical codes.
→ When the electrical installation is completed, the main and auxiliary power supply
to the drive must not be switched on without the consent of the ABB
commissioning personnel.
→ Take appropriate measures to prevent main and auxiliary power supply being
switched on during installation.
7.2. Overview of installation work

The electrical installation includes the following wire and cable connections:
– “Power cables, ground cables and equipotential bonding conductor”, page 81
– “Auxiliary power, control and serial communication cables”, page 92
– “Power supply cable for redundant fan unit”, page 97
7.3. Cable requirements

For information on the requirements for power cables, ground cable, and equipotential bonding
conductor, see:
– “Power cable specification”, 3BHS189994 E01
– “Power cables engineering guideline”, 3BHS542290 E01
For information on the requirements for the auxiliary power cable and the control cables, see
the “Auxiliary power and control cables guideline”, 3BHS813742 E01.
7.3.1. Additional cable requirements for a UL certified drive

The UL standard has the following additional requirements for field connection cables on the
power input and output side of a UL certified drive:
– Maximum diameter of 177 mm2 (350 kcmil), which is determined by the ampacity that is
required for a minimum temperature rating of 60 °C
– Connection angle of 30°, which is provided by the customer connection plate (see
Section 7.5.1.2, “Orientation of cables with 2-hole cable lugs on terminal busbar”, page 82)
– Termination with 2-hole NEMA pad cable lug (prevents rotation)
– Minimum tightening torque of 36.7 Nm (325 lbf-in) for the terminals

7.4. Cable entries

The cables can be entered through the roof or the floor of the cabinet.
The cabinet is equipped with one of the following cable entries:
– Cable entry with EMC plates
– Cable entry with sealing modules, type 1
– Cable entry with sealing modules, type 2
– Cable entry with cable glands
For information on location and dimensions, see “Appendix C - Mechanical drawings”.
7.4.1. Cable entry with EMC plates

– Usage:
• Power cables, ground cables and bonding conductors
• Auxiliary power cables and control cables
– Included in delivery: galvanized plate with net-like EMC sleeves (1 in Fig. 46) and sealing
grommets (2)
2 1.5 mm
2
1
Ø45 mm
Key:
(1) EMC sleeves
(2) Sealing grommets
Fig. 46. EMC plate example
– EMC cushions (1, Fig. 47) on the underside of the EMC plate if the cable entry is used for
control cables.
Fig. 47. EMC cushion

7.4.2. Cable entry with type 1 sealing modules

– Usage: power cables, ground cables and bonding conductors
– Included in delivery: cable entry frame (1, Fig. 48)
– Not included in delivery: sealing modules (2, Fig. 48), accessories and tools
Key:
(1) Cable entry frame
(2) Sealing modules
Fig. 48. Type 1 sealing modules (example)
7.4.3. Cable entry with type 2 sealing modules

– Usage: auxiliary power cables and control cables
– Included in delivery: frame (1, Fig. 49)
– Not included in delivery: tools, accessories and EMC sealing modules (2, Fig. 49)
– Supplier: Roxtec AB (https://www.roxtec.com/)
Key:
(1) Frame
(2) EMC sealing modules
Fig. 49. Type 2 sealing modules example

7.4.4. Cable entry with cable glands

– Usage:
• Power cables, ground cables and bonding conductors
• Auxiliary power cables and control cables
– Included in delivery: undrilled plate for cable glands
– Not included in delivery: cable glands, tools and accessories
Fig. 50. Cable entry with cable glands
7.5. Power cables, ground cables and equipotential

bonding conductor
See the layout drawings in “Appendix C - Mechanical drawings” for information on:
– Project-specific cable entry
– Distance between point of cable entry and terminals
– Busbar and fastening hole dimensions
– Busbar designations
See “Appendix D - Wiring diagrams” for information on conventions for cross-reference and
device identification.
7.5.1. Preparing the cable entry and the cables
NOTICE
Risk of damage or malfunction! Waste inside the cabinet can cause damage or
malfunction.
→ If possible, DO NOT cut cables inside the terminal compartment
→ Remove any waste that was accidentally dropped in the cabinet

7.5.1.1. Maximum number of cables per phase

The maximum number of cables that can be used per phase depends on the type of the drive
and its nominal voltage.
TABLE 11 Maximum number of cables per phase

ACS1000A type 2.3 kV nominal 3.3 kV nominal 4.0 kV nominal
voltage voltage voltage
A1 1 cable per phase 1 cable per phase 1 cable per phase
A2 2 cables per phase 1 1 cable per phase 1 cable per phase
A3 2 cables per phase1 2 cables per phase 1 cable per phase

1Depending on the cable entry type in the 24-pulse variant, you might be limited to one cable per phase. For more
information, see the 'Cable entry and connection drawing' in “Appendix C - Mechanical drawings”.
7.5.1.2. Orientation of cables with 2-hole cable lugs on terminal busbar

IMPORTANT! For drives with UL certification, 2-hole NEMA pad cable lugs
(shown) are mandatory for the terminal busbar connections.
The indication holes (1, 3, Fig. 51) on the factory-installed busbars show the
cable lug orientation with respect to the cable entry, ie, for top cable entry,
the hole is at the top of the busbar and for bottom cable entry, the hole is
at the bottom of the busbar.
Use the indication holes to verify the cable orientation on-site. If the
orientation does not match the location of the cable entry, you need to
unbolt, flip, and then re-attach the busbars with the bolts tightened to a
torque of 30 Nm.
For details on the cable entry and high voltage cable termination, see the
relevant cable entry and connection diagrams (3BHS853475 E01 or
3BHS853475 E02) in “Appendix C - Mechanical drawings”.
A 1 B û14 mm
44.5 mm 44.5 mm
2
2 110 mm
30°
30°
110 mm
44.5 mm
44.5 mm
û14 mm 3
Key:
(1) Indication hole on top
(2) Terminal busbar
(3) Indication hole on bottom
Fig. 51. Cable termination bar (A) top and (B) bottom cable entry; busbar thickness is 5 mm

7.5.1.3. Determining the cable length

1. Determine the required length of a cable between the point of entry and the connection
point inside the cabinet.
2. Cut the cable to the required length before connection.
7.5.1.4. Splitting multi-core cables

This section applies to drives without an additional cabinet.
– Check the distance between point of cable entry and closest busbar.
– Check the cable diameter.
– If distance and cable diameter do not allow for the bending the cable inside the terminal
compartment, separate the conductors outside of the terminal compartment.
Continue with:
– Section 7.5.1.5, “Preparing cables for EMC plates”, page 84
– Section 7.5.1.6, “Preparing cables for cable entries with sealing modules”, page 86
– Section 7.5.1.7, “Preparing cables for cable entries with cable glands”, page 87

7.5.1.5. Preparing cables for EMC plates

As a standard, the cabinet is delivered for cable entry through the roof of the terminal
compartment. If cables are entered through the floor, swap entry plate and cover plate.
The orientation of the EMC plates is the same for cable entry through the roof and through the
floor, ie, the sealing grommets face upwards.
1. Remove the grommets.
2. To ensure proper sealing, cut along the marking that corresponds to the cable diameter
and slide the grommet onto the cable.
IMPORTANT! The grommet must fit tightly to prevent water entering the cabinet. The
grommets can be discarded if cables are entered through the floor.
3. If necessary, remove the entry plate and push the cable through the entry holes.

4. Prepare the cables as illustrated.

• A in Fig. 52 illustrates how cables with an outer cable screen or shield are prepared for
EMC bonding with the metal enclosure of the cabinet.
• B in Fig. 52 illustrates how cables without an outer screen or shield are prepared.
A B
5
2
7
3
Key:
(1) Grommet (6) Entry plate
(2) EMC sleeve (7) Conductor insulation removed to expose
(3) Cable tie cable shield
(4) Heat-shrinkable termination (8) Cable screen extension to connect to the
(5) Outer cable sheath PE busbar
Fig. 52. Preparing cables for EMC plates: (A) cables with an outer screen or shield, (B) cables
without an outer screen or shield
5. Route the equipotential bonding conductor through an unused hole in the entry plate.
NOTE – If all of the holes are used for conductors, route the equipotential bonding
conductor together with a conductor.

7.5.1.6. Preparing cables for cable entries with sealing modules

As a standard, the cabinet is delivered for cable entry through the roof of the terminal
compartment. If cables are entered through the floor, swap entry plate and cover plate.
– Prepare cables with an outer cable screen or shield for EMC bonding with the metal
enclosure of the cabinet as illustrated in Fig. 53.
1 7
2
8
4
9
10
11
Key:
(1) Sealing module (8) Cable sheath removed to expose cable shield
(2) Frame (9) Shield extension to be connected to PG
(3) Conductive foil of sealing module busbar
(4) Cable clamp (10) Screen extension to be connected to the
(5) Shrinkable sheath seal PG busbar
(6) Heat-shrinkable termination (11) Cable lug as specified by the cable supplier
and suitable for M12 bolt
(7) Outer cable sheath
Fig. 53. Preparing power cables for sealing modules
– Install the sealing modules according to the instructions of the sealing module supplier.

7.5.1.7. Preparing cables for cable entries with cable glands

Prepare cables with an outer cable screen or shield for EMC bonding with the metal enclosure
of the cabinet as illustrated in Fig. 54.
Key:
(2) Cable gland
(3) Conductor insulation removed to expose cable shield
(4) Plate
(5) Screen extension to be connected to PE ground busbar
(6) Heat-shrinkable termination
Fig. 54. Preparing power cables for cable glands

7.5.2. Connecting the cables
7.5.2.1. Checking the cable insulation

– Check the insulation of each cable before connection and verify that the results are within
the specification of the cable manufacturer.
– Leave the cable conductors unconnected at both ends until the commissioning engineer has
given permission.
7.5.2.2. Connections
CAUTION
Risk of flashover! High voltages will be present in the terminal compartment. High
voltages can cause flashover between conductors with different electric potential, and
between a conductor and earth. When you route and connect the cables, maintain the
following minimum clearances:
→ 20 mm between cable lugs of conductors with different potentials
→ 40 mm between cable lugs of conductors and the parts with earth potential
Power and grounding cables

– Connect the following feeder cable conductors to the busbars with the fasteners and the
tightening torque that are specified in Section 7.5.4, “Bolted connections”, page 91:
• 1U1, 1V1, 1W1, 2U1, 2V1, 2W1 (12-pulse and 24-pulse drive, 2, Fig. 55)
• 3U1, 3V1, 3W1, 4U1, 4V1, 4W1 (24-pulse drive, 2, Fig. 55)
– Connect the motor cables to busbars U2, V2, W2 (3, Fig. 55).
– Connect the screens of all conductors and the shields of all cables to the PE ground busbar
(4, Fig. 55).
– Connect the equipotential bonding conductor to the PE ground busbar.
– Tie the cables to the strain relief rails (1, Fig. 55).
For the phase numbering of the busbars, see the relevant cable entry and connection
diagrams (3BHS853475 E01 for a 12-pulse drive 3BHS853475 E02 for a 24-pulse drive) in
“Appendix C - Mechanical drawings”.

A 5 B 5
1 1
1 1
2 2
1 3 1 3
2 2
4 4
C D
2 2
1 1 3
3
2 2
4 4
1 1
1 1
6 6
Key:
(1) Strain relief (4) PE ground busbar

(2) Feeder cable busbars (5) Top cable entry
(3) Motor cable busbars (6) Bottom cable entry
Fig. 55. Power cable terminals in (A and C) 12-pulse ACS1000A and (B and D) 24-pulse
ACS1000A

1 U1 V1 W1
4
U2 V2 W2 U2 V2 W2 PE
5
5
1U1 1V1 1W1 2U1 2V1 2W1 PE
2
ACS1000
U2 V2 W2
3 U V W PE
Key:
(1) Input transformer (5) Ground cable
(2) Drive (6) Cable screen
(3) Motor (7) Equipotential bonding conductor
(4) Earth electrode (8) Motor
Fig. 56. Grounding the drive system
7.5.3. Minimum creepage distance between cable and busbar

If spacers are used to connect a cable to a busbar, observe the minimum creepage distance.
Depending on the comparative tracking index (CTI) of the insulation material of the cable, the
following minimum creepage distances apply:
TABLE 12 Minimum creepage distance between cable and busbar

CTI Minimum creepage distance
1 600 63 mm
2 400 - 600 71 mm
3 175 - 400 80 mm

7.5.4. Bolted connections
7.5.4.1. Material requirements

Use stainless steel bolts and nuts with the appropriate steel grade and property class for the
connection (recommended: A2-70; designation according to ISO 3506).
NOTE – Nuts with bonded coating can be used as an alternative to uncoated stainless steel
nuts.
7.5.4.2. Connection type

The following connection type is recommended when a cable lug (4, Fig. 57) is connected to
a busbar:
– Spring washer (1, Fig. 57) and flat washer (2, Fig. 57) on each side of the busbar (3, Fig. 57).
NOTE – Other washers can be used, provided they maintain the required contact pressure.
4
2
1
3
2 Key:
1 (1) Spring washer
(2) Flat washer
(3) Busbar
(4) Cable lug
Fig. 57. Bolted busbar connections
7.5.4.3. Lubrication
If stainless steel bolts and nuts are used, lubricate the thread and head contact surface of the
bolt using recommended pasts, eg, Molykote D paste.
NOTE – If a coated nut (eg, with bonded molybdenum-disulfide [MoS2] coating) is used, the
connection does not need to be lubricated.
7.5.4.4. Tightening torque

For bolted connections, use the recommended nominal torque for the bolt size (M10 to M14)
that you use.
For drives with UL certification, the minimum tightening torque for bolts to attach the two-hole
NEMA pad cable is 37.6 Nm.

7.6. Auxiliary power, control and serial

communication cables
See the layout drawings in “Appendix C - Mechanical drawings” for information on:
– Project-specific cable entry
– Dimensions between point of cable entry and terminals
See “Appendix D - Wiring diagrams” for information on:
– Conventions for cross-references and device identification
– Terminal designations
7.6.1. Preparing the cable entry and the cables
7.6.1.1. Determining the cable length

1. Determine the required length of a cable between the point of entry and the connection
point (1, Fig. 58) inside the cabinet.
2. Cut the cable to the required length before connection.
A B
Fig. 58. Cable entry from (A) top and from (B) bottom

7.6.1.2. Preparing cables for EMC plates

1. Remove the grommets.
2. To ensure proper sealing, cut along the marking that corresponds to the cable diameter
and slide the grommet onto the cable.
IMPORTANT! The grommet must fit tightly to prevent water entering the cabinet. The
grommets can be discarded if cables are entered through the floor
3. If necessary, remove the entry plate and pull the cable through the entry holes.
4. Loosen the screws of the EMC cushion brackets and push the cushions apart (arrows).
5. If the outer cable screen is non-conductive, cut open the cable screen in the middle of the
stripped area (1), pull the screen ends over the cable insulation (2) and then connect the
screen ends with a continuous conducting foil (3).
3
1 3

6. Pull the cables through the EMC cushions.

7. Push the cushions together so they fit tightly around the bare screen and tighten
the screws.
7.6.1.3. Preparing cables for cable entries with sealing modules

1. Unscrew the frame and remove the sealing modules.
For information on removing and installing the sealing modules and using the compression
wedge (1), see “Appendix A - Additional manuals”.
Key:
(1) Sealing modules
(2) Compression wedge
Fig. 59. Frame with sealing modules

2. Prepare the cables with an outer cable screen for EMC bonding with the metal enclosure of
the cabinet as illustrated in Fig. 60.
1
2
3
Key:
(1) Sealing module
(2) Conductive foil
(3) Cable sheath removed to expose cable shield
(4) Conductor screen extension to be connected
to PE terminal
4
Fig. 60. Preparing control cables for sealing modules
7.6.1.4. Preparing cables for cable entries with cable glands

– Prepare the cables with an outer cable screen for EMC bonding with the metal enclosure of
the cabinet as illustrated in Fig. 61.
Key:
2 3
4 (2) Cable gland
(3) Conductor insulation removed to expose cable shield
(4) Plate
(5) Conductor screen extension to be connected to PE terminal
Fig. 61. Preparing control cables for cable glands

7.6.2. Connecting the cables
7.6.2.1. IOEC modules

– Connect the cables for digital and analog input and output signals to the
distribution terminals.
7.6.2.2. Conductors
– If a twisted pair cable is used, leave the unshielded cable ends twisted until they reach
the terminals.
– Leave unshielded conductor ends as short as possible (not longer than 50 mm).
7.6.2.3. Cable shields

– Connect the shield of serial communications cables to the fieldbus adapter.
– Connect the overall shield and the individual shields of the encoder cable to the separate
shield grounding bracket (2, Fig. 62).
IMPORTANT! DO NOT connect the shields directly to the encoder adapter (1, Fig. 62).
To accommodate encoder cables of different diameters, ground clamps (3, Fig. 62) of different
sizes are supplied.
2
3
Key:
(1) Encoder adapter
(2) Shield ground bracket
(3) Grounding clamp
Fig. 62. Shield grounding point for encoder cable

7.7. Power supply cable for redundant fan unit

This section applies to drives that are equipped with the optional redundant fan.
For information on the cable connection, see “Appendix D - Wiring diagrams”.
1. Enter the pre-fabricated multi-core cable into the cabinet as close as possible to the
redundant fan unit and according to the type of control cable entry used.
For more information on cable entry, see:
• Section 7.6.1.2, “Preparing cables for EMC plates”, page 93
• Section 7.6.1.3, “Preparing cables for cable entries with sealing modules”, page 94
• Section 7.6.1.4, “Preparing cables for cable entries with cable glands”, page 95
The braided metal cable sleeve (1 in Fig. 63) does not have to be grounded at the point of
entry. If necessary, seal the gaps according to the type of cable entry used.
2. Route the wires to the terminals (2 and 3, Fig. 63) as illustrated.
NOTE – Connection 3 in Fig. 63 depends on the type of fan, eg, AC or EC.
3 3
3 3
Fig. 63. Routing, connecting the cable of the redundant fan unit
3. Connect the wires according to the terminal number on the marker sleeves.

7.8. Final checks

– Check that the entry plates are properly
secured.
– If you used EMC entry plates check that the
grommets fit tightly (arrows) to prevent water
entering the cabinet.
– If required, seal gaps with silicone.

COMMISSIONING
8. Commissioning
8.1. Overview
The following sections provide an overview of the commissioning process for your drive.
8.1.1. Required qualification

Commissioning, parameter adjustments and functional tests must be carried out only
by qualified commissioning personnel that have been certified by ABB.
8.1.2. Commissioning procedure

Information on the commissioning procedure and the start conditions for
commissioning can be obtained from ABB.
8.1.3. Commissioning checklist

In order to ensure uncomplicated and speedy commissioning, it is important that drive
and associated equipment are ready for commissioning. Reviewing and completing the
items in the commissioning checklist before the commissioning personnel arrive on
site will help to achieve this.
8.1.4. Customer assistance

During the commissioning period, the customer is requested to provide qualified
personnel for assistance, who are:
– Experienced with medium and low voltage equipment and with the local
safety regulations,
– Familiar with the driven process
– Authorized to operate associated medium and low voltage equipment (eg, input
circuit breaker, other low and medium voltage switchgear)
– Authorized to operate the driven process for functional tests
8.1.5. Customer acceptance

When commissioning has been completed, the commissioning report is signed by the
responsible commissioning personnel 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.

COMMISSIONING
8.2. Commissioning checklists

The checklists are designed to help you prepare the drive and associated equipment
for commissioning.
8.2.1. Mechanical installation checklist 
8) Drive installed according to the instructions in this user manual (3BHS213401 E01). 
9) Drive securely fastened to the floor (if applicable). 
10) Redundant fan unit installed (if applicable). 
11) Visual inspection: 
• No badly affixed or damaged components

• No foreign objects left in the cabinet
• No dirt, dust or moisture in the cabinet
8.2.2. Electrical installation checklist 
1) Types and cross sections of control cables suitable for the signal type and signal level. 
2) Types and cross sections of power cables selected according to the instructions in 
this user manual (3BHS213401 E01).

3) Pulse encoder cable shields are connected to the shield earthing point and not 
connected directly to the pulse encoder interface (applies only to drives with pulse
encoder interface).
4) Cable entries prepared according to the instructions in the user manual (3BHS213401 
E01).
5) Control cable screens and conductors are connected as instructed in the user manual, 
labeled appropriately, and the customer side connections are completed.

6) Equipotential bonding conductor of drive securely connected at both ends. 
7) Converter transformer and motor cables not connected at both ends (cables and 
drive must be insulation resistance tested (Megger test) before connection)
8.2.3. Main circuit breaker (MCB) checklist 
1) Type of MCB selected as per the MCB specification from ABB 
2) High-voltage power connections completed 
3) MCB ready to be tested with drive 
4) MCB protection relay settings tested 
5) Safety devices (eg, door locks) are tested and in operation. 

COMMISSIONING
8.2.4. Input transformer checklist 
1) Grounding is completed 
2) Transformer auxiliaries (eg, dehydrating breathers, cooling, protection devices) are 
ready.
3) Safety devices (eg, door locks) are tested and in operation. 
8.2.5. Motor checklist 
1) Motor is installed, aligned and alignment protocol available. 
2) Motor is not coupled to driven load. 
3) Grounding is completed 
4) Motor auxiliaries (eg, bearing lubrication) are ready 
5) Control and monitoring signals are connected. 
8.2.6. Insulation tests checklist 
1) All power cables to converter transformer, between converter transformer and drive, 
and from drive to motor insulation resistance tested (Megger test), and measured
values within the required limits.
2) Test report of the Megger insulation resistance test available 
IMPORTANT! If the test is carried out by the commissioning engineer of the drive, an
additional day per drive motor combination needs to be reserved. After the test, the
feeder cables can be connected, except at the drive end. The test must comply with the
specification.
8.2.7. Power supply checklist 
1) Medium voltage available for start-up of drive. 
2) Low voltage is available for start-up of drive. 
8.2.8. Miscellaneous checklist 
1) Sufficient number and correct type of spare parts available 
2) Air conditioning of drive room ready for load run of drive 
3) Optional equipment ready 

OPERATION
9. Operation
9.1. Safety
WARNING
Risk of electric shock The IPXXB/IP20 rating of the low voltage compartment is not
fulfilled by live parts with voltages > 50 V AC. If the compartment door is open during
drive operation, contact with these accessible live parts can result in DEATH or serious
injury!
→ Drive system must ONLY be operated by qualified and authorized personnel who
are familiar with the operation of the drive system and the hazards involved
9.2. Overview
The chapter outlines the local operation of the drive.
Control of the drive via a PLC or higher-level control systems is not described in this chapter. If
the drive is controlled from remote, see the appropriate manuals for information.
The panel messages and parameter settings used in this chapter are typical examples to
illustrate the related instructions and display functions and can therefore differ from the actual
messages and parameter settings in the drive.
9.3. Operating conditions

The operating conditions for the drive are according to IEC 60721-3-3.
– Conditions: 3K22 / 3B1 / 3S6 / 3M11
If the operating conditions are not within the specifications, contact ABB.
9.4. Sound pressure level

– Single fan: < 75 dB (A)
– Redundant fan: < 85 dB (A)

OPERATION
9.5. Local operator panel

Under normal operating conditions, the local operator
panel allows you to operate the drive without
restrictions. For example, you can use the panel to
perform the following actions:
– Connect and disconnect the main power supply
– Set the reference value
1
– Start and stop the drive
– Display actual values, status messages, alarms and
fault messages
– View and setting parameters
– Reset alarm and fault messages
2 3 – Activate the emergency off circuit
For more information, see Chapter 10, “CDP control
4
panel”, page 113.
Key: Explanation
(1) Control and data panel (CDP) – Starts and stops the motor
– Displays status messages
– Displays alarm and fault messages of the drive and
monitored foreign equipment
– Resets alarm and fault messages
(2) Main Supply OFF illuminated push – Opens the main circuit breaker
button
(3) Main Supply ON illuminated push – Charges the DC link and closes the main circuit breaker
button
(4) Gnd Switch Unlocked push button – Lights up to indicate that the grounding switch of the
drive can be turned to the grounded or ungrounded
position
(5) Emergency Off push button – Prevents starting when pressed at standstill of the drive
– Main circuit breaker opens immediately and DC link
discharges when pressed during operation of the drive
Fig. 64. Local operator panel

OPERATION
9.6. Status messages

This section lists the messages of the main operating states the drive passes through, when it
is put into operation, when it is stopped, or when a fault condition has occurred. The messages
are sent to the higher-level control system and are displayed on the CDP control panel of
the drive.
For information on other status messages, such as fault status messages in particular, see the
status words in the “Appendix G - Signal and parameter table” of the drive.
RdyForMCBOn
The status message signals that the drive is healthy and ready for the ON command.
The ON command initiates the closing of the MCB and then the charging of the DC-link
capacitors. Depending on the control place, the command can either be sent from the
higher-level control system to the drive or be initiated by pressing the Main circuit
online push button on the control compartment door.
Charging
The status message RdyForMCBOn changes to Charging when the DC-link capacitors
of the drive are being charged.
Rdy to Strt
The status message Rdy to Strt tells the operator that the drive is energized and ready
for operation. As soon as the start command is initiated, the motor is magnetized and
the drive starts to modulate.
Magnetizing
The status message Rdy to Strt changes to Magnetizing when the firing pulses of the
inverter are released.
Running
When the drive is in Running state, it is running and operating according to the set
speed or torque reference value. When in remote control mode, the reference value is
set by the higher-level control system. When in local control mode, the value is entered
into the CDP control panel.
Stopping
Indicates that the drive has received a stop command and that a ramp or coast stop
has been initiated. The stopping mode depends on the parameter setting. The status
message changes to Rdy to Strt when the zero speed threshold is reached.
When a start command is given while the drive is stopping, the drive resumes operation
and the status message changes to Running again.
Discharging
The status message Rdy to Strt changes to Discharging when the MCB has opened and
the DC-link capacitors are discharging.
Tripped
The status message indicates that a fault condition has occurred that requires a
shutdown of the drive. The status message always alternates with the specific fault
message. The type of shutdown depends on the fault class the fault condition is
assigned to in the drive software.

OPERATION
9.6.1. Start sequence of the drive

1) NotReadyOn
ReadyOn conditions:
• Doors closed and locked
• Drive not grounded
• No emergency off
• No fault
2) ReadyForMCBOn
3) On command
4) Charging
• MCB closes
• DC link charges
• Fan switches on
5) Rdy To Strt
6) Start command
• Inverter starts to modulate
7) Magnetizing
8) Running
9) Operation

OPERATION
9.6.2. Stop sequence of the drive
1) Operation
2) Running
3) Stop command
4) Stopping
• Speed ramps down
• Inverter stops modulating
5) Ready To Strt
6) Off command
7) Discharging
• MCB opens
• DC link discharges
• Fan switches off after a delay
8) RdyForMCBOn
• Drive is grounded
• Doors are released for opening
• Auxiliary supply is switched off
9) NotReadyOn

OPERATION
9.6.3. Emergency off sequence of the drive
1) Operation
2) Running
3) Emergency off command

• MCB opens
• Inverter stops modulating
• Speed coasts down
4) Not ready on
9.7. Starting the drive

DANGER
Hazardous voltages! Unintentional contact with energized components can cause
serious injuries or DEATH.
→ All covers must be screwed in place
9.7.1. Checks before starting the drive

Consult the following reference material for the initial local start of the drive after
commissioning:
– “Appendix D - Wiring diagrams” to identify the circuit breakers to be switched on
– Chapter 10, “CDP control panel”, page 113 for information on functions and features of the
CDP control panel
When the drive is put into service after it has been commissioned, or after it has been taken out
of service for a longer period, check the drive according to the following list:
– Tools and foreign objects are inside the cabinet.
– All auxiliary power supplies from external sources are switched on.
– All internal circuit breakers of the drive are closed.
– All covers are mounted and the doors are closed, locked or bolted.
– Grounding switch is in the ungrounded position.
– MCB is in operating position.
– No run interlocks are active.
9.7.2. Starting the drive remotely

When the drive is operated from remote through a higher-level control system or an operator
control desk, follow the instructions in the appropriate manuals.

OPERATION
9.7.3. Starting the drive locally

1. Enable the local control mode of the drive.
LOC
REM
2. Check that no alarm or fault messages are displayed on the CDP control panel.
• If a fault message is displayed on the CDP control panel, reset the fault.
RESET
• If a fault cannot be reset, it must be rectified by the responsible personnel.

When no alarms and faults are present and the drive is ready, the CDP control panel displays
RdyForMCBOn:
1 L -> 0.0 rpm

Status RdyforMCBon
MotorSpeed 0.00 rpm
Power 0.0%
3. Press the MAIN SUPPLY ON push button on the control compartment door to close the
MCB and charge the DC link.
The push button lights up and the status line of the CDP control panel changes to Charging.
1 L -> 0.0 rpm

Status Charging
MotorSpeed 0.00 rpm
Power 0.0 %
After charging has been finished, the protection IGCTs are closed, the status line of the CDP
control panel changes to Rdy to Strt and the motor can be started.
1 L -> 0.0 rpm 0

Status Rdy to Strt
MotorSpeed 0.0 rpm
Power 0.0 %
4. Enter the reference value.

OPERATION
1 L -> [600.0 rpm] 0

Status Rdy to Strt
MotorSpeed 0.0 rpm
Power 0.0 %
5. Start the motor.
1 L -> [600.0 rpm] 0

Status Magnetizing
MotorSpeed 0.00 rpm
Power 0.0 %
After the motor has been magnetized, the motor speed ramps up to the reference value.
While the motor is accelerating, the run status indication on the display blinks. When the
motor speed has reached the reference value, the run status indication lights
up permanently.
The display shows Running to indicate that the drive is operating.
1 L -> 600.0 rpm I

Status Running
Motor Speed 600.0 rpm
Power 75.0 %
9.8. Stopping the drive

1. Press the STOP key on the CDP control panel.
The motor stops according to the preset stop function and the drive stops modulating.
While the motor stops, the status line of the display shows Stopping. The run status
message blinks during the stop sequence.

OPERATION
1 L -> 600.0 rpm I

Status Stopping
MotorSpeed 300.0 rpm
Power 20.0 %
NOTE – As long as the stop sequence is in progress, the drive can always be restarted by
pressing the START key on the CDP control panel.
When the drive has stopped modulating, the CDP control panel displays Rdy to Strt.
1 L -> 600.0 rpm 0

Status Rdy to Strt
MotorSpeed 0.0 rpm
Power 0.0 %
NOTE – As long as the MCB has not been opened, the motor can be started again.

OPERATION
9.9. Emergency-off
The drive is equipped with a hard-wired emergency off circuit. When an emergency situation
occurs during operation, this safety feature ensures that the drive can be disconnected without
delay from the main power supply. If the EMERGENCY-OFF push button has been pressed while
the drive is at standstill, the main power supply cannot be connected to the drive, hence the
drive cannot be started up.
The EMERGENCY-OFF push button of the drive is part of the operator control panel (Fig. 64) and
features a latching switch action.
IMPORTANT! Pressing the EMERGENCY-OFF push button does not disconnect the auxiliary
power supply from the drive.
9.9.1. Initiating an emergency-off

To initiate an emergency off, press the EMERGENCY-OFF push button on the control
compartment door, or an external EMERGENCY-OFF push button (if present) linked to the
emergency-off circuit.
When an emergency-off is initiated during drive operation, the following takes place:
– MCB opens
– Drive coasts down
– Status line of the CDP control panel displays the message Emerg Off
1 L -> 600.0 rpm

ACS 1000
*** FAULT ***
Emerg Off
– The DC link of the drive discharges.

OPERATION
9.9.2. Starting the drive after an emergency-off

1. To start the drive after an emergency-off, unlatch the EMERGENCY-OFF push button.
The EMERGENCY-OFF push button returns to its initial position when turned into the
direction indicated by the arrows on the push button.
2. To reset the emergency-off safety relay of the drive, press the RESET button on the
control keypad.
RESET
After resetting, the status message of the drive changes to RdyForMCBOn.
1 L -> 0.0 rpm

Status RdyforMCBon
MotorSpeed 0.00 rpm
Power 0.0%
The main power supply can be connected to the drive and the drive can be started again.

CDP CONTROL PANEL
10. CDP control panel
10.1. Overview
The panel messages and parameter settings used in this chapter are typical examples to
illustrate the related instructions and display functions and can therefore differ from the actual
messages and parameter settings in the drive.
2 1 L -> 600.0 rpm

p I
Status
St Running
Runniing
3 MotorSpeed 600.00 rpm
Power 30.0 %
5 ACT PAR FUNC DRIVE
11
6 ENTER 12
7 LOC RESET REF 13

8 REM 14
9
15
10 I 0
Key:
(1) Display (9) Forward key
(2) Status line (10) Backward key
(3) Actual signal names and values (11) Slow navigation key for selecting signals or
(4) Keypad fault messages
(5) Mode selection keys (12) Enter key, terminates a procedure
(6) Fast navigation key for selecting the actual (13) Reference key
signals display or the fault memory display (14) Start key
(7) Local / remote selection key (15) Stop key
(8) Reset key
Fig. 65. CDP control panel

CDP CONTROL PANEL
10.2. CDP control panel functions

The CDP control panel serves as the basic user interface for operating and monitoring the drive
when the local operating mode has been selected.
The CDP control panel can be attached to or detached from the drive without having to switch
off the auxiliary power supply first.
You can perform the following tasks with the CDP control panel:
– Enter start-up data
– Control the drive with a reference value, and start, stop and direction commands
– Display actual values (three values can be read simultaneously)
– Display and adjust parameters
– Display information on the most recent forty fault events
– Upload and download complete parameter sets from one drive to another
10.3. CDP control panel modes

The CDP control panel provides the following modes:
– Identification mode, see Section 10.3.1, “Identification mode”, page 114
– Actual signals mode, see Section 10.3.2, “Actual signals mode”, page 115
– Parameters mode, see Section 10.3.3, “Parameters mode”, page 122
– Functions mode, see Section 10.3.4, “Functions mode”, page 128
10.3.1. Identification mode

The identification mode informs the user about the CDP control panel version and the ID
number of the drive. The information appears on the display when the:
– Power supply is switched on
– CDP control panel is connected to the drive and the auxiliary voltage has already been
switched on.
When the CDP control panel is initialized as described before, the display changes as follows:
CDP312 PANEL V5.30
........

CDP CONTROL PANEL
After 2 to 3 seconds, information on the drive (1, and 2) and the drive identification (3) is
displayed.
1 ACS1000 xxxx
2 <Device Name>
3 ID-NUMBER 1
After another few seconds:
1 L -> 0.0 rpm

Status InitSeq....
MotorSpeed 0.00 rpm
Power 0.0 %
After another few seconds, the display changes to the actual signals mode.
1 L -> 0.0 rpm

Status ErthIsoClos
MotorSpeed 0.00 rpm
Power 0.0 %
10.3.2. Actual signals mode
10.3.2.1. Overview
Two displays can be selected in the actual signals mode:
– Actual signals display
– Fault memory display
The actual signals display appears first when entering the actual signals mode. However, when
the drive is in a fault condition, the fault memory display appears instead.
The actual signals display is used to monitor the drive without interfering with its operation. It
continuously displays three selectable actual values.
The CDP control panel automatically returns to the actual signals display from other modes if
no key is actuated within one minute (an exception from this is the fault memory display).

CDP CONTROL PANEL
10.3.2.2. Actual values

The actual values are organized in groups.
Group Description
Group 01 Measured or calculated motor values
Group 02 Measured or calculated drive values
Group 03 Speed and torque reference values
Group 04 I/O values
Group 05 Data values
Group 06 Information: software version, drive and motor nominal values
Group 07 Control words
Group 08 Status words
Group 09 Fault and alarm words
For the complete list of selectable actual signals, see “Appendix G - Signal and parameter table”.
10.3.2.3. Fault memory

The fault memory display provides information on the 64 most recent fault events that occurred
in the drive. It displays the name of the fault and the time it occurred. For instructions on how
to display and reset the fault memory, see Section 10.3.2.5, “Displaying and resetting the fault
history”, page 120.
When the drive generates a fault or alarm, the corresponding message displays immediately.
Changing from the fault memory mode to other modes is possible without resetting the fault
first. When no key is actuated, the fault or warning text is displayed as long as the fault is active.

CDP CONTROL PANEL
Control panel overview
1 1 L -> 600.0 rpm

Status RdyForMCBon
2 MotorSpeed 0.00 rpm
Power 0.0 %
5
4 ENTER
E NT
TER 6
LOC RESET REF
REM
I 0
Key:
(1) Status line
(2) Actual signal names and values
(3) Selection key for actual signals mode
(4) Fast navigation key for selecting the actual signals display or the fault memory display
(5) Slow navigation key for selecting signals or fault messages
(6) Enter key for confirming the selection
Fig. 66. Control panel - Actual signals mode

CDP CONTROL PANEL
10.3.2.4. Opening the actual signals display

– To open the actual signals display, press the ACT key.
ACT
1 L -> 600.0 rpm 0

Status RdyForMCBon
MotorSpeed 0.00 rpm
Power 0.0 %
Toggle between actual signals display and fault history

– To toggle between actual signals display and fault history display, press a fast
navigation key.
1 L -> 600.0 rpm 0

1 LAST FAULT
+ Panel Lost
0707730 12:30:02 3256
Displaying three actual signals

1. To display the full name of three actual signals, press and hold the ACT key.
ACT
1 L -> 600.0 rpm 0

DriveStatusWord
MotorSpeed
Power
2. To return to the actual signals display, release the ACT key.

CDP CONTROL PANEL
Selecting actual signals

1. To select the actual signals display, press the ACT key.
ACT
1 L -> 600.0 rpm I

Status Running
Power 75.0 %
To select a line where the actual signal is to be displayed, press the corresponding slow
navigation key.
A blinking cursor indicates the selected line.
1 L -> 600.0 rpm I

Status Running
Power 75.0 %
2. To enter the actual signal selection function, press the ENTER key.
1 L -> 600.0 rpm

ENTER
1 Actual Signals
10 ShaftPower
0.0 %
3. To select a parameter group, press a fast navigation key.
1 L -> 600.0 rpm 0

2 Actual Signals
01 ControlMode
SPEED-CTRL

CDP CONTROL PANEL
4. To select an actual signal, press a slow navigation key.
1 L -> 600.0 rpm 0

2 Actual Signals
02 DC Voltage Udc1
1000.0 V
5. To confirm the selection and to return to the actual signals mode, press the ENTER key.
1 L -> 600.0 rpm 0

ENTER
Status Rdy to Strt
MotorSpeed 0.00 rpm
DCVoltage Udc1 1000.0 V
6. To cancel the selection and keep the original selection, press any of the mode
selection keys.
The selected CDP control panel mode is entered.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm 0

Status Rdy to Strt
MotorSpeed 0.0 rpm
Power 0.0 %
10.3.2.5. Displaying and resetting the fault history

1. To enter the actual signals mode, press the ACT key.
ACT
1 L -> 600.0 rpm 0

Status Rdy to Strt
MotorSpeed 0.0 rpm
Power 0.0 %

CDP CONTROL PANEL
2. To change to the fault memory display, press a fast navigation key.
1 L -> 600.0 rpm 0

1 LAST FAULT
+ Panel Lost
0707730 12:30:02 3256
3. To display a specific fault, press the slow navigation keys.

The UP key selects the previous, the down key the next fault.
1 L -> 600.0 rpm 0

2 LAST FAULT
+ Panel Lost
0707730 12:21:02.2452
4. To clear the fault memory, press the RESET key.
1 L -> 600.0 rpm 0

1 LAST FAULT
H MIN S
RESET
5. To return to the actual signals display, press a fast navigation key.
1 L -> 600.0 rpm 0

Status Rdy to Strt
MotorSpeed 0.0 rpm
Power 0.0 %

CDP CONTROL PANEL
Displaying and resetting an active fault

1. To display an active fault, press the ACT key.
ACT
1 L -> 600.0 rpm 0

ACS1000
*** FAULT ***
MCB CloseControl
2. To reset the fault, press the RESET key.
1 L -> 600.0 rpm 0

Status Rdy to Strt
MotorSpeed 0.0 rpm
Power 0.0 %
RESET
10.3.3. Parameters mode
NOTICE
Risk of component damage. Running the drive system with incorrect data can result
in improper operation, reduction of control accuracy and damage to equipment.
→ Parameters must only be set by qualified personnel.
→ DO NOT change a parameter if the effects of the change are unclear.
10.3.3.1. Overview
If the parameter lock is disabled or unlocked (see Section 10.3.3.3, “Enabling / unlocking a
parameter lock”, page 127), the parameters mode allows entering the parameter settings for
the required drive configuration depending on the application.
The parameters are organized in functional groups, so called parameter groups.
TABLE 13 Parameter groups

Group Description
Group 07 Control words
Group 08 Status words
Group 09 Fault and alarm words
Group 11 Start, stop, direction, MCB and control
Group 12 Reference selection

CDP CONTROL PANEL
TABLE 13 Parameter groups (continued)

Group Description
Group 13 Basic analog inputs
Group 14 Basic digital outputs
Group 15 Basic analog outputs
Group 16 System control inputs
Group 17 Utilities
Group 18 Process speed
Group 19 Data storage
Group 20 Limits
Group 21 Start, stop and process stop
Group 22 Ramp functions
Group 23 Speed reference
For details about the parameters, their settings and functions, see “Appendix G - Signal and
parameter table”.
When entering the parameter mode for the first time after the auxiliary voltage of the drive has
been switched on, the CDP control panel displays the first parameter of parameter group 99.
The next time the parameters mode is entered, the previously selected parameter displays.
Some parameter values cannot be changed while the drive is running. If tried, the following
warning displays.
** Warning **
Write Access Denied
Parameter Setting
Not Posssible

CDP CONTROL PANEL
Control panel overview
1 1 L -> 600.0 rpm

2 75 OPTION MODULES
3 01 IOEC3 OptionBoard
4 YES
Y ES
7
6 ENTER
E NT
TER 8
LOC RESET REF
REM
I 0
Key:
(1) Status line
(2) Group number and name
(3) Parameter number and name
(4) Parameter value
(5) Selection key for parameters mode
(6) Fast navigation key for selecting a parameter group (and a parameter value)
(7) Slow navigation key for selecting a parameter (and a parameter value)
Fig. 67. Control panel - Parameters mode

CDP CONTROL PANEL
10.3.3.2. Selecting and changing parameters

1. To enter the parameters mode, press the PAR key.
PAR
1 L -> 600.0 rpm 0

12 REFERENCE SELECT
01 KeypadRefSelect
1
2. To select a different group, press the corresponding fast navigation key.
1 L -> 600.0 rpm 0

75 OPTION MODULES
01 IOEC3 OptionBoard
YES
3. To select a parameter, press the corresponding slow navigation key.
1 L -> 600.0 rpm 0

75 OPTION MODULES
NO
4. To enter the parameter setting function, press the ENTER key.
1 L -> 600.0 rpm 0

ENTER
75 OPTION MODULES
[NO]

CDP CONTROL PANEL
5. To change the parameter value, press the:

• Slow navigation key for numbers and text
• Corresponding fast navigation key for numbers only
1 L -> 600.0 rpm 0

75 OPTION MODULES
[YES]
6. To confirm the selection and to return to the actual signals display, press the ENTER key.
1 L -> 600.0 rpm 0

ENTER
75 OPTION MODULES
[YES]
7. To cancel the setting and keep the original selection, press any of the mode selection keys.
The selected keypad mode is entered.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm 0

75 OPTION MODULES
[NO]

CDP CONTROL PANEL
10.3.3.3. Enabling / unlocking a parameter lock

Unwanted parameter entry can be prevented by activating the parameter lock function.
The corresponding parameters are 16.02 PARAMETER LOCK and 16.03 PASSCODE and belong
to parameter group 16 SYSTEM CTRL INPUTS.
Enabling the parameter lock

1. Select parameter 16.02.
2. Set parameter 16.02 to 1 (LOCKED).

3. Confirm the setting and exit the parameters mode.
Unlocking the parameter lock

1. Select parameter 16.03.
2. Set the correct pass code.

3. Confirm the setting and exit the parameters mode.
For more information, see “Appendix G - Signal and parameter table”.
10.3.3.4. User lock
NOTICE
Risk of component damage. ABB is not be liable for damages or losses caused by the
failure to activate the user lock with a new pass code.
Setting the master pass code

ABB recommends that you set a master pass code to lock the control panel to protect the
parameter values.
1. To activate the user lock for the first time, enter the default pass code, ie, 358, in 16.03
Passcode.
You can now edit parameters 16.06…16.07.
2. Enter the old pass code in 16.06 OldUserPasscode.
3. Enter the new pass code in 16.07 NewUserPasscode.
4. In 16.02 Parameter Lock, enable the user lock functionality.
NOTE – To reopen the lock, ie, to edit parameters 16.06 and 16.07, enter the new pass code
in 16.03 Passcode.

CDP CONTROL PANEL
10.3.4. Functions mode

The functions mode is used to set the display contrast.
1 1 L -> 0.0 rpm

UPLOAD <= <=
2 DOWNLOAD => =>
CONTRAST 4
4 ENTER
E NT
TER 5
LOC RESET REF
REM
I 0
Key:
(1) Status line
(2) Selectable functions
(3) Selection key for functions mode
(4) Slow navigation key for selecting a line (and adjusting the contrast)
Fig. 68. Control panel - Functions mode

CDP CONTROL PANEL
10.3.4.1. Adjusting the display contrast

1. To enter the functions mode, press the FUNC key:
FUNC
1 L -> 0.0 rpm 0

UPLOAD <= <=
DOWNLOAD => =>
CONTRAST 4
2. To select the contrast adjustment function, press the slow navigation keys until the
blinking cursor reaches the CONTRAST line.
1 L -> 0.0 rpm 0

UPLOAD <= <=
DOWNLOAD => =>
CONTRAST 4
3. Press the ENTER key.
1 L -> 0.0 rpm 0

ENTER
CONTRAST [4]
4. To change the contrast value, press a slow navigation key.
1 L -> 0.0 rpm 0

CONTRAST [6]

CDP CONTROL PANEL
5. To confirm the selection and to return to the actual signals display, press the ENTER key.
1 L -> 0.0 rpm 0

ENTER
UPLOAD <= <=
DOWNLOAD => =>
CONTRAST 6
6. To cancel the setting and keep the original setting, press any of the mode selection keys.
The selected keypad mode is entered.
ACT PAR FUNC DRIVE
1 L -> 0.0 rpm 0

UPLOAD <= <=
DOWNLOAD => =>
CONTRAST 6

CDP CONTROL PANEL
10.4. Local and remote control

The local-remote feature of the CDP control panel allows selecting the control location of the
drive. Possible are:
– Local control
– Remote control
In this context, remote control is not necessarily equivalent to higher-level control. For more
information, see Section 10.4.2, “Remote control”, page 132.
10.4.1. Local control

In local control mode, full operational control of the drive is enabled from the local operator
panel. Commands from remote have no effect.
Entering local control mode

– To enter the local control mode, press the LOC-REM key.
Local control is indicated by the letter L.
1 L -> 600.0 rpm 0

Status Rdy to Strt
MotorSpeed 0.00 rpm
Power 0.0 %
LOC
REM

CDP CONTROL PANEL
10.4.2. Remote control

In remote control mode, operational commands or reference values come from a higher-level
control system via fieldbus or remote I/O.
However, with the following parameter settings it is possible to start and stop the drive, to set
the motor’s direction of rotation, and to enter reference values from the CDP control panel.
– 11.01 EXT1 START/STOP/DIR = 10 (KEYPAD) or
12.03 EXT REF1 SELECT = 1 (KEYPAD) and
12.02 EXT1/EXT2 SELECT = 1 (EXT1)
– 11.02 EXT2 START/STOP/DIR 10 (KEYPAD) or
12.06 EXT REF2 SELECT = 1 (KEYPAD) and
12.02 EXT1/EXT2 SELECT = 2 (EXT2)
Entering remote control mode

– To enter remote control, press the LOC-REM key.
• Full remote control from a higher-level control system is indicated by a blank space.
1 600.0 rpm 0
Status Rdy to Strt
MotorSpeed 0.00 rpm
Power 0.0 %
LOC
REM
• Partial remote control (some commands enabled locally) is indicated by the letter R.
1R 600.0 rpm 0
Status Rdy to Strt
MotorSpeed 0.00 rpm
Power 0.0 %
LOC
REM

CDP CONTROL PANEL
10.5. Operational commands

For instructions on how to start and stop the drive system from the CDP control panel, see
Section 9.7, “Starting the drive”, page 107 and Section 9.8, “Stopping the drive”, page 109.
10.5.1. Setting the direction of rotation

Setting the direction of rotation from the CDP control panel is possible in:
– Local control mode L
– Remote control mode R
The arrow on the display indicates the direction of rotation:
– When the motor is running, the arrow indicates the actual direction.
– When the motor is not running, the arrow indicates the preselected direction.
Procedure
– To set the direction of rotation, press the forward or backward key.
If you change the direction while the motor is running, the motor automatically ramps down
to zero speed and re-accelerates in the opposite direction to the preset speed. The arrow
changes at zero speed.
• Forward key
1 L -> 600.0 rpm

Status Running
Power 75.0 %
• Backward key
1 L <- 600.0 rpm

Status Running
Power 75.0 %

CDP CONTROL PANEL
10.5.2. Entering a reference value

Entering a reference value from the CDP control panel is possible in:
– Local control mode L
– Remote control mode R
Procedure
1. Press a mode selection key.
ACT PAR FUNC DRIVE
1 L -> 600.0 rpm I

Status Running
Power 75.0 %
2. To enter the reference value input mode, press the REF key.
1 L -> [600.0 rpm] I

Status Running
Power 75.0 %
REF
3. To enter / change the reference value, press the corresponding fast or slow navigation key.
1 L -> [550.0 rpm] I

Status Running
Power 75.0 %

CDP CONTROL PANEL
4. To exit the reference value input mode, press any of the mode selection keys.
ACT PAR FUNC DRIVE
1 L -> 550.0 rpm I

Status Running
Power 75.0 %

PREVENTIVE AND CORRECTIVE MAINTENANCE
11. Preventive and corrective maintenance

11.1. General information
During the warranty period of the drive, all maintenance must be performed exclusively by ABB
service personnel. After the warranty period, maintenance must only be performed by certified
personnel.
11.1.1. Required qualification

To maintain safe and reliable operation of the drive, ABB recommends taking out a service
contract with the ABB service organization.
11.1.2. Maintenance schedule

Perform all maintenance tasks according to the maintenance schedule and the applicable
service instructions, on time and at the intervals stated in the “ACS1000A preventive
maintenance schedule”, 3BHS855276 E01.
11.1.3. Logbook
ABB recommends that you keep track of all troubleshooting and maintenance work in a logbook
including:
– Date and time
– Detailed description
11.1.4. Spare parts

To ensure safe and reliable operation, use only spare parts recommended and approved by ABB.
For information on types and identification codes, see “Appendix E - Parts list”.

11.2. Identifying electrical equipment

This section describes how to identify electrical devices, cables, and wires.
11.2.1. Device identification

To facilitate the identification in wiring diagrams and parts lists, all devices are labeled in
accordance with IEC 81346-1.
Fig. 69. Device identification
11.2.2. Cables and wires

Cables and wires in the drive are equipped with marker sleeves which carry the same
identification number as in the wiring diagrams.
11.2.3. Understanding wiring diagrams

For information on item designation and cross-reference conventions, see “Appendix D -
Wiring diagrams”.

11.3. Alarm / fault indications
11.3.1. Messages
When a failure occurs in the drive or in the equipment monitored by the drive (eg, main circuit
breaker, transformer, cooling system), the CDP control panel displays a corresponding alarm or
fault message.
1 L -> 600.0 rpm 0

ACS1000
*** FAULT ***
MCB CloseControl
The message can be saved and viewed in the fault history of the drive when a PC with the
DriveWindow or DriveDebug is connected to the drive. The fault logger can also be called up on
the CDP control panel.
11.3.2. Error message levels

Two error message levels are used in the drive:
– Alarm: Does not shut down the drive. If the condition causing the alarm is not corrected, a
persisting alarm can lead to a fault. An alarm cannot be reset manually. The alarm message
is deleted from the display as soon as the alarm condition has been corrected.
NOTE – An exception is when an alarm of the cooling system (eg, FanDiffPres, AirFiltSupv) is
not reset automatically. To reset the alarm, set parameter 41.04 FanAlarmReset to RESET.
– Fault: Shuts down the drive. The type of shutdown depends on the origin of the fault.
Depending on the type of fault, the drive opens the main circuit breaker (MCB) or keeps it
closed. A fault condition must be corrected and the fault be manually reset before the drive
can be started again.
11.3.2.1. Alarm / fault messages

If an alarm or a fault occurs, a specific message is saved in the fault buffer of the drive.
Information on the 64 most recent fault and alarm events are saved.
11.3.3. Fault handling

The faults are entered into the fault logger as they occur and are numbered:
– The last fault entered always has number 1 assigned to it.
– The first fault always has the highest number in the fault buffer.
Date and time stamps facilitate fault tracing, especially when a fault leads to several
subsequent faults.

Example:
1) -Fault RESET FAULT 2011-04-26 14:57:56.5370
2) +Fault Undervoltage 2011-04-26 14:47:41.1110
3) +Warn Undervoltage 2011-04-26 14:47:41.1000
4) +Fault MCB Disturb 2011-04-26 14:47:38.0230
In the above example:
4) +Fault MCB Disturb is the reason for the failure of the drive, as it occurred first.
3) +Warn Undervoltage occurred approximately 3 seconds after the first fault.
2) +Fault Undervoltage immediately followed the warning.
1) -Fault RESET FAULT informs that the fault has been reset.
For more information on alarms and faults, see “Appendix G - Signal and parameter table”.
11.3.4. Standard troubleshooting procedure

If a fault shuts down the drive, proceed as follows:
1) DO NOT switch off the auxiliary supply voltage or try to reset a fault message
before all information at the time of the occurrence of the fault condition has
been saved.
2) Select the fault history display on the CDP control panel, but DO NOT clear the
buffer!
For more information, see Chapter 9, “Operation”, page 102.
3) Identify the fault and make a logbook entry.
4) Save the content of the data logger when a PC is available that has the
DriveWindow or DriveDebug tool installed.
The data logger provides information (eg, waveforms of voltage, current, torque)
for efficient troubleshooting.
5) 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
6) After the fault has been rectified, start the drive as described in Chapter 9,
“Operation”, page 102.

11.4. Removing the CDP control panel

IMPORTANT! If the CDP control panel is removed during operation, the drive can only be
stopped by pressing the EMERGENCY OFF button.
1. If the panel is removed while the drive is in operation, check the setting of parameter 31.06
PANEL LOSS SUPERVISION first.
If the parameter is set to NOT USED, the panel can be removed without interrupting
drive operation. For information on setting parameters, see
“Appendix G - Signal and parameter table”.
2. Proceed as illustrated.
The green LED (4) signals that the control voltage has been switched on.
1 2 3

11.5. LEDs and switches on circuit boards

The following section provides an overview on the meaning of LEDs and switches of the main
circuit boards and I/O devices. The LEDs presented in the following section can be checked
easily with the auxiliary voltage switched on and without having to remove covers first. The
LEDs provide information on the status of the devices and can be used for diagnostic purposes.
11.5.1. AMC circuit board

R P T2 S1 S0
F M T1 S3 S2
Status when software Status when software

has loaded has not loaded
LED Color Description Booting ON Booting ON
F Red Fault ON OFF ON ON
R Green Run OFF OFF OFF OFF
M Green ON OFF ON ON
P Green Supply OK ON ON ON ON
Receiving data on
T1 Yellow Flashing ON / OFF Flashing ON / OFF
DDCS channel 0
Receiving data on
T2 Yellow Flashing ON / OFF Flashing ON / OFF
DDCS channel 3
S3 Yellow OFF OFF OFF OFF
S1 Yellow Flashing OFF Flashing OFF
Fig. 70. AMC circuit board

11.5.2. IOEC I/O modules
11.5.2.1. LEDs
1 2 4 5
3
Key: Explanation
(1) Status LED of digital outputs On when output is energized
(2) Link error light Only on when there is a problem with the optical fibers.
(3) Rotary switch Sets the address
(4) Status LEDs of digital inputs On when input is energized
(5) Status LED of the 24 V internal
On when energized
voltage supply
Fig. 71. IOEC module
11.5.2.2. 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, Fig. 71). The factory-set value must
not be changed.
For information on IOEC switch settings, see “Appendix C - Mechanical drawings”.

11.6. Corrective maintenance

Overview on maintenance tasks:
– Section 11.6.6, “Visual checks on the drive”, page 149
– Section 11.6.7, “Cleaning the drive”, page 149
– Section 11.6.8, “Checking wire and cable connections”, page 150
– Section 11.6.9, “Cleaning and replacing filter mats”, page 150
– Section 11.6.10, “Inspecting and replacing batteries”, page 153
– Section 11.6.11, “Replacing the non-redundant fan”, page 155
– Section 11.6.12, “Replacing a redundant fan”, page 158
11.6.1. Safety
DANGER
Hazardous voltages! Before starting to work on the drive, make sure that:
→ Main and auxiliary power supply to the drive is switched off, locked out, and tagged
out
→ Drive is de-energized
→ Safety ground connections are in place
→ Personal protective equipment is provided and used when required
→ Everyone involved is informed
Before energizing the drive again, 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
NOTICE
Risk of component damage. Foreign matter and particularly metallic dust can cause
failure and damage when the drive is energized.
Ensure that foreign matter cannot enter the cabinet:
→ Close the doors and cover openings completely when work is discontinued.
→ Retrieve any foreign matter which accidentally dropped into the cabinet.
WARNING
Risk of electric shock! Contact with a charged capacitor can cause serious injury or
10 min DEATH!
→ After the drive has been de-energized, wait a MINIMUM of 10 minutes for the
capacitors to fully discharge
→ Verify that a capacitor is discharged before you touch it

The IPXXB/IP20 rating of the low voltage compartment is not fulfilled by live parts with
voltages > 50 V AC. If the compartment door is open during drive operation, contact
with these accessible live parts can result in DEATH or serious injury!
→ Work must ONLY be performed by qualified personnel with electrotechnical
expertise

11.6.2. De-energizing the drive locally

The following section describes how to de-energize the drive using the local operator panel of
the drive. If the drive is controlled from remote, follow the established shutdown procedures.
1. Enable the local control mode of the CDP control panel.
For more information, see Chapter 10, “CDP control panel”, page 113
2. Press the stop key.
When the motor has reached zero speed, the display shows Rdy to Strt.
1 L -> 0.0 rpm 0

Status Rdy to Strt
MotorSpeed 0.0 rpm
Power 0.0 %
3. Press the MAIN SUPPLY OFF push button to disconnect the drive from the main
power supply
The following takes place:
• MCB opens
• DC link discharges for approximately five minutes
While the DC link discharges, the display shows the following.
Alternating display message:

1 L -> 600.0 rpm 0 – Discharging
Status Discharging
MotorSpeed 0.00 rpm – CoolOFFDelay
Power 0.0 %
– RdyForMCBon
When the DC link has discharged completely, the status line displays RdyforMCBOn and the
MAIN SUPPLY OFF push button lights up.
1 L -> 0.0 rpm

Status RdyforMCBon
MotorSpeed 0.00 rpm
Power 0.0%
4. Rack-out, lock-out, ground and tag-out the main power feeder.

5. If the grounding switch is equipped with the optional lock (1) that secures the switch in the
ungrounded position, unlock the grounding switch.
6. Wait until the yellow lamp GROUNDING SWITCH UNLOCKED lights up.
The lamp lights up when cooling stops after a delay time.
7. If the yellow lamp is on, continue with Section 11.6.3, “Grounding”, page 146.
8. If the yellow lamp is not on, continue with Section 11.6.4, “Grounding switch is not
released”, page 147.
11.6.3. Grounding
1. If the yellow lamp is on, turn the grounding switch to the grounded position.
When the grounding switch is in the grounded position, the status line of the CDP control
panel displays ErthIsoClos.
(Earth isolator closed = grounding switch is in grounded position).
1 L -> 0.0 rpm

Status ErthIsoClos
MotorSpeed 0.00 rpm
Power 0.0 %
2. To de-energize the drive completely, switch off and lockout all auxiliary voltages from
external sources.
NOTE – To open the doors of medium voltage compartments and additional cabinets of the
drive that are equipped with an electromechanical lock, the auxiliary voltage must be
switched on.
3. If necessary, connect a grounding set.

11.6.4. Grounding switch is not released
CAUTION
Hazardous voltage! Forcing the grounding switch can damage the switch and
short-circuit the DC-link capacitors!
→ DO NOT force the grounding switch when the GROUNDING SWITCH UNLOCKED
lamp is off.
→ If you cannot operate the grounding switch, see Section 11.6.5, “Checking the
release conditions for the grounding switch”, page 148.
NOTE – To identify the components referred to in the checklist, see the wiring diagrams and
Fig. 72.
Key:
(1) Fuses
(2) IOEC1 / -A5191 (standard)
(3) IOEC4 / -A5211 (option)
(4) IOEC2 / -A5201 (standard)
(5) IOEC3 / -A5221 (option)
Fig. 72. Location of I/O modules and fuses

11.6.5. Checking the release conditions for the grounding switch
1) Check that the auxiliary voltage is switched on. 
2) Main power supply is disconnected from the drive.

– Check that the MCB is open. 
When the MCB is open, secure it against closing.

– Check that the feedback signal “MCB is open” arrives at the drive, ie, if the following
indicators are lit:
• LED of digital input DI08 of I/O module -A5201 (-A2) 
– (LED is not lit) Check the control-signal wiring between switchgear and drive as 
per applicable wiring diagram.

• MAIN SUPPLY ON push button -S5152 (-S2) 
When the LED and the push button are lit, the feedback signal MCB is open has
arrived at the drive.
– (Push button is not lit) Check if the 24 V blade-type fuse (X27_P2:14) is blown. 
The fuse protects the control circuit of the pushbutton.

3) Discharge level of the DC link.
– Check if the value of parameter 2.06 DC VOLTAGE is below 50 V. 
When the value is below 50 V, the DC link is regarded as discharged. For information
on reading actual values on the CDP control panel, see Section 10.3.2, “Actual signals
mode”, page 115.
4) GROUNDING SWITCH UNLOCKED lamp and the wiring of the lamp.
– Check if the CDP control panel displays a fault. 
A fault prevents the lamp GROUNDING SWITCH UNLOCKED from lighting.

• If a fault is present, follow the instructions in Section 11.3.4, “Standard
troubleshooting procedure”, page 139, before you reset a fault.
• If a fault cannot be rectified and reset, contact the ABB service organization.
– If the CDP control panel does not display a fault, check that digital output DO04 of 
I/O module -A5191 (-A1) is energized.

• DO04 releases the grounding switch and lights the lamp
GROUNDING SWITCH UNLOCKED (–H5152).
• When the LED of DO04 is lit and the control voltage is present at terminals X24:2
and X24:3 of DO04, DO04 is energized.
– If digital output DO04 of the I/O module is not energized, check the I/O module - 
A5191 (-A1).
To do this, check if the auxiliary voltage is present at the supply terminals of the I/O
module.
• X6:1.....24 V (DC)
• X6:2.....0 V

– Check that LED V726 and LED V740 of the I/O module -A5191 are lit. 
The LEDs monitor the control voltages of the I/O module (Fig. 71).
When the LEDs are lit, the I/O module functions properly.
• LED V726.....24 V (DC)
• LED V740.....5 V (DC)
– If digital output DO04 I/O module -A5191 is energized, check that the control voltage 
is present at the terminals of the lamp GROUNDING SWITCH UNLOCKED.

• If the control voltage is present but the lamp is not lit, the lamp is burnt out and
must be replaced.
• If the control voltage is not present, check the wiring of the lamp. Correct the
wiring if necessary.
5) Check that hazardous voltages from the motor cannot be fed into the drive. 
IMPORTANT! When the checklist has been completed, carefully try to turn the grounding switch
to the grounded position. If you cannot turn the grounding switch but doors of medium voltage
compartments have to be opened, call the ABB service organization.
11.6.6. Visual checks on the drive

Check the drive and its immediate vicinity visually at the intervals stated in the maintenance
schedule and pay attention to the following items:
– Humidity inside the drive
– Permitted range of ambient air temperature and humidity of the drive
– Dust built-up inside the drive
– Appropriate fastening of cables and wires and connections of cable screens
– Integrity of cable insulation
– Signs for overheated components, wires, cables or busbars
– Corrosion on circuit boards, connectors or busbars
– Correct type of signal and power cables
For more information, see the applicable cable specifications.
11.6.7. Cleaning the drive
NOTICE
Risk of component damage! The drive contains components which are sensitive to
electrostatic discharge.
→ Apply ESD handling precautions before handling these devices.
Dust on electrical components and wiring can cause failure and damage the
components. Dust and moisture can build up in loose connections and cause loss of
low-level signals.
→ Check the cabinet regularly for signs of dust and humidity and clean if necessary -
alcohol and solvents can damage the components.
→ Use appropriate and recommended cleansing agents.

When cleaning the drive, mind the following:

– To prevent dirt falling into equipment, cover the equipment.
– Clean circuit boards with special care. To prevent the components being damaged, use
antistatic brushes and a vacuum cleaner with a soft nozzle.
– 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 recesses.
– Clean the outside of the cabinet with a vacuum cleaner and cleaning cloths.
11.6.8. Checking wire and cable connections
NOTICE
Risk of component damage. Capacitor bushings are damaged when excessive force
is applied.
→ DO NOT exceed the maximum tightening torque; the tightening torque value is
printed on a label which is attached to the capacitor.If not specified, the maximum
torque must not exceed 20 Nm.
Vibration can loosen electrical connections and cause occasional malfunction or
equipment failure.
→ Inspect all power and control cable connections and tighten them if necessary.
→ Inspect that all plugs and connectors are tight.
11.6.9. Cleaning and replacing filter mats

The filter mats are in the control as the inverter compartments.
For information on inspection and replacement intervals, see the “ACS1000A preventive
TABLE 14 Filter mat specifications

Drive compartment ABB ID Dimensions Filter class Filter type
(L × W) (EN779)
Control 3BHL001134P0001 132 × 320 mm G4 T15/350
Inverter 3BHL001141P0001 818 × 1228 mm G3 T15/150

11.6.9.1. Control compartment filter mat
NOTICE
Risk of component damage! Dust can damage components and cause failure when
the drive is energized.
→ Always clean the filter mat at a safe distance from the open cabinet door.
1. Open the door of the control compartment.

NOTE – You can open the door when the drive is running.
2. Pull the filter out of the sleeve at the bottom.
3. Depending on its condition, clean or replace the filter mat:
• Clean the filter mat with compressed air or a vacuum cleaner and slide the filter mat back
into the sleeve.
• Slide a new filter mat (see Table 14) into the sleeve.
11.6.9.2. Rectifier and inverter compartment filter mat
WARNING
Hazardous voltage! Removing the filter mat while the drive is running can cause
serious injury or DEATH. Foreign objects can be sucked into the exposed air intake and
cause FATAL short-circuits.
→ Keep long, thin objects, such as wires and screwdrivers, away from the exposed air
intake.
→ DO NOT stop work for long periods while the air intake is exposed.
NOTICE
Risk of component damage! Dust can damage components and cause failure when
the drive is energized.
→ Always clean the filter mat at a safe distance from the open cabinet door.

Referring to Fig. 73:

1. Set parameter 41.47 FILTER MAT
CHANGE FUNCTION to ENABLE.
The monitoring of differential air pressure
is disabled for the time that is defined in
parameter 41.48 FILTER MAT CHANGE
TIME (default 30 minutes).
NOTICE The drive might trip if the filter
mat is not replaced before the time 1 2 1228 mm
elapses.
2. Remove the 6 screws (circles) from the
louvered panel (1, Fig. 73).
NOTE – Depending on your drive, you 818 mm
might need a slot or Torx screwdriver.
3. Remove the louvered panel.
4. Starting at the top, roll the filter mat
(2, Fig. 73) down to remove it.
T30
5. Depending on its condition, clean or
replace the filter mat. Fig. 73. Filter panel (1) and filter mat (2) on
• Clean the filter mat with compressed rectifier and inverter compartment
air or a vacuum cleaner.
• Replace the filter mat with a new one
(see Table 14).
6. Reinstall the louvered panel (1, Fig. 73)
with the 6 screws (circles).

11.6.10. Inspecting and replacing batteries
Key:
(1) Power supply unit for battery pack 1
(2) Alarm LED
(3) Battery pack 1
Fig. 74. Control compartment – battery location
11.6.10.1. Checking and replacement indications

The end of the battery life is indicated as follows:
– CDP control panel displays an alarm message.
– Alarm LED on the power supply unit for the battery lights up (2, Fig. 74).
When the end of the battery life is indicated, the drive continues to operate until the time set
with parameter 145.26 Batt-Alm.Tim-out has elapsed.
ABB recommends replacing all of the batteries when one battery is at end-of-life.
11.6.10.2. Replacing a battery
CAUTION
Heavy object. A battery weighs approximately 10 kg!

2 2
Fig. 75. Control compartment - replacing the batteries
1. When the drive is in operation, disable the battery monitoring function first. To do this, set
parameter 31.05 DISABLE BATTERY TEST to ON.
Parameter 31.05 is automatically set to OFF after 1 hour.
2. Disconnect the wires (1, Fig. 75).
3. Unbolt the battery from the plate at the front (2, Fig. 75) and at the back.
4. Install the new battery in reverse order of removal.
5. Record the date of battery replacement in the logbook.

11.6.11. Replacing the non-redundant fan
CAUTION
Heavy object. The fan weighs approximately 100 kg.
774 mm
868 mm
469 mm
Fig. 76. Fan location, dimensions and weight
1 4 5
Key:
(1) ¼”
(2) ~70 mm
(3) 10 mm and 13 mm
(4) Trolley
(5) Lift truck
Fig. 77. Fan - tools and devices
1. Disconnect all power supplies to the drive and ground the drive according to Section 11.6.2,
“De-energizing the drive locally”, page 145.
2. Switch off the motor starter of the fan.

The fan is now isolated from the auxiliary power supply.
3. Measure to confirm the absence of voltage.
4. Unplug the power supply cable (1, Fig. 78) of the fan.
5. Remove the bolts (2, Fig. 78).
IMPORTANT! DO NOT drop washers and bolts into the cabinet.
6. Move the fan onto the lift truck by one of the following methods:

7. Place the lift truck or height-adjustable trolley in front of the fan and pull the fan onto
the platform.
8. Unplug the optical fibers (V3001:A1, V3002:A1) from the protection IGCTs (3, Fig. 78) and
stow the optical fibers in a position where they cannot be damaged when the
fan is replaced.
2 3
Key:
(1) Power supply cable (4) ¼”
(2) Bolts (5) ~70 mm
(3) Optical fiber cables (6) 13 mm
Fig. 78. Replacing the non-redundant fan
9. Push the lift truck under the fan, ensure that the lift truck does not catch cables
and components and lift the fan a little and remove it from the cabinet while avoiding
sudden movements.

11.6.11.1. Installing the non-redundant fan

1. Check the mounting supports (1, Fig. 79).
2. If they are damaged, replace them.

3. If they can be re-used, attach them to the new fan.
4. On both sides of the fan, orientate the groove of the mounting supports (2, Fig. 79)
towards the back of the cabinet.
2
3
1
4
Key:
(1) Mounting supports
(2) Groove
(3) ¼”
(4) 10 mm
Fig. 79. Installing the non-redundant fan
5. Check that all screws are properly fastened.

6. Install the new fan in reverse order of removal.

11.6.12. Replacing a redundant fan

For information on inspection and replacement intervals, see “ACS1000A preventive
The estimated working time to replace a redundant fan is approximately 1 hour.
CAUTION
Heavy object. The fan weighs approximately 100 kg.
774 mm
868 mm
469 mm
Fig. 80. Redundant fans – location, dimensions, and weight

3
8
5
6
Key:
(1) ¼”
(2) ~70 mm
(3) 13 mm and 17 mm
(4) 13 mm
(5) T 30
(6) Cordless drill
(7) 3 × M10×20
(8) Height-adjustable platform
(9) Lift truck
Fig. 81. Redundant fans - tools and devices
Procedure
1. Disconnect all power supplies to the drive and ground the drive according to Section 11.6.2,
“De-energizing the drive locally”, page 145.
2. Switch off the motor starter of the fan.

The fan is now isolated from the auxiliary power supply.
3. Measure to confirm the absence of voltage.
4. Remove the panels.
5. If the fan is removed towards the front of the cabinet, the top panel can stay on the cabinet.
6. If the rear panel is not accessible, remove the sound absorbing panels on the side where the
fan is replaced.

T 30
Fig. 82. Redundant fan unit – removing the panels
7. Unplug the power supply cable.
Fig. 83. Redundant fan unit – Unplugging the power supply cable
8. Remove the fixing bolts.

NOTE – If the bolt at the back (1, Fig. 84) is not accessible from the back of the cabinet,
remove the cover (2, Fig. 84), reach through the opening and unscrew the mounting support
(3, Fig. 84) from below.

5 1
7 2
3
Key:
(1) Bolt
(2) Cover
(3) Mounting support
(4) ¼”
(5) 13 mm
(6) 13 mm
(7) Cordless drill
(8) T 30
Fig. 84. Redundant fan unit – removing the fixing bolts

9. Remove the fan by one of the following methods:

• Crane: replace 3 of the fixing bolts with eye bolts, attach the lifting gear to the eye bolts
and then lift the fan off the cabinet.
Key:
(1) ¼”
(2) 17 mm
(3) 3 × M10 × 20
Fig. 85. Redundant fan unit – using a crane
• Height-adjustable platform: place the platform as close as possible to the fan and then
pull the fan onto the platform.
Fig. 86. Redundant fan unit – using a platform
10. Remove the mounting supports from the fan housing to be replaced and attach the
mounting supports to the new fan housing.

11. If the new fan housing does not have screw holes for the mounting supports, drill holes into
the underside of the fan housing.
For information on the exact hole positions, see drawing number 3BHS128478 E01 in
“Appendix C - Mechanical drawings”.
1 2
12. Check that all screws are properly fastened.

13. Install the new fan in reverse order of removal.

—
ABB Switzerland Ltd.
Bruggerstrasse 66
CH-5400 Baden
Switzerland
new.abb.com/drives/medium-voltage-ac-drives
3BHS213401 E01 Rev. L 2023-09-13
—
© Copyright 2011 ABB. All rights reserved.
The information in this document is subject to change without notice.

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OWNING ORGANIZATION DATE STATUS SECURITY LEVEL

Copyright © 2011 ABB.

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6.3.2. Cabinet roof........................................................................................................................... 71

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9.6.1. Start sequence of the drive .............................................................................................105

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11.6.7. Cleaning the drive ............................................................................................................. 149

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Fig. 72. Location of I/O modules and fuses .................................................................... 147

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1. About this manual

1.1. Equipment covered by this manual

1.2. Structure of the user documentation

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1.3. Terms and abbreviations

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1.4. Related documents

1.4.2. Technical data

Technical data from DriveSmart 1 (configuration software for medium

1.4.4. Specifications and guidelines

1.4.5. Serial communication interfaces

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1.5. Target groups and required qualification

1.5.2. Mechanical installation

1.5.3. Electrical installation

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1.6. User’s responsibilities

1.7. Intended use of equipment

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1.8. Quality certificates and applicable standards

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1.9. Items covered by delivery

Fig. 1. Delivered items

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1.10. Identifying the delivery

1.11. Document conventions

 Prerequisite for a task

1. Sequential procedural steps in a task

Explanation for callout keys in legend under an illustration or refers to a

Underlined text Identifies a hyperlink

Courier font Identifies software file names and file paths

Cursor Represents blinking text on a screen

1 2 3 Callout keys on an illustration

These pictograms refer to the subject matter of the text.

See Section 2.1.2, “Safety signs”, page 21.

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2. Important safety information

2.1. Safety messages and safety signs in this document

2.1.1. Safety messages

2.1.2. Safety signs

Electrostatic discharge susceptible

Hazardous voltage warning