acs 1000 fault tracing manual

If an alarm or a trip is registered by the converter control, the operator must be able to decide whether to shut down the converter for troubleshooting or repair or to reset the fault message and restart the drive. This chapter includes the safety instructions that must be complied with when installing, operating and servicing the ACS 1000. If neglected, physical injury and death may follow, or damage may occur to the frequency converter, the motor and the driven equipment. The contents of this chapter must therefore be studied before attempting any work on, or with the unit. Responsibilities It is the owners responsibility to insure that each person involved in the installation, commissioning, operation or maintenance of the ACS 1000 has received the appropriate training or instructions and has thoroughly read and clearly understood the safety instructions in this chapter. When installing the frequency converter as well as during commissioning and maintenance, all personnel involved must observe the relevant general safety regulations and standards for electrical works in medium and low voltage equipment which are in force at the place of installation. Furthermore personnel must make strict compliance with the instructions given in this manual. ABB Industrie AG declines all liability for any possible damage resulting from failure or negligence to observe this warning. ACS 1000 User’s Manual, Rev. C 3BHS102769 1-1 (of 6) Chapter 1 - Safety Instructions Safety Labels Several levels of safety instructions and notes are used in this manual to highlight a potentially dangerous situation. They are marked with one of the following labels: Danger: This symbol indicates an imminent danger resulting from mechanical forces. A non-observance may lead to life-threatening physical injury or death. Danger: This symbol indicates an imminent danger resulting from high voltage. A nonobservance may lead to physical injury or cause serious damage to the converter.

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Discover everything Scribd has to offer, including books and audiobooks from major publishers. Start Free Trial Cancel anytime. Report this Document Download Now Save Save ACS 1000 Faults Alarms Classic0.1 For Later 88% (8) 88% found this document useful (8 votes) 4K views 189 pages ACS 1000 Faults Alarms Classic0.1 Uploaded by AbhishekDutta Description: fault code acs 1000 Full description Save Save ACS 1000 Faults Alarms Classic0.1 For Later 88% 88% found this document useful, Mark this document as useful 13% 13% found this document not useful, Mark this document as not useful Embed Share Print Download Now Jump to Page You are on page 1 of 189 Search inside document Browse Books Site Directory Site Language: English Change Language English Change Language. Layout and Description of Assembly Cabinet Design Cabinet Sections Door Locks Lifting Arrangements Cooling Circuit Control and Monitoring Equipment CDP 312 Control Panel ACS 1000 User’s Manual, Rev. C 3BHS102769 9 (of 10) Appendix H - Part List Appendix I - Recommended Spare Parts List Appendix J -Dummy Appendix K - Signal and Parameter Table Appendix L - Inspection and Commissioning Record Appendix M - Parameter Setting List Index 10 (of 10) 3BHS102769 ACS 1000 User’s Manual, Rev. C Chapter 1 - Safety Instructions General The ACS 1000 is a high voltage device and when misused it can cause damage to personnel and property. When located, installed and connected in accordance with the instructions given in this Manual, the device is safe. Personnel involved in installation, commissioning and maintenance work on the ACS 1000 must be electrical professionals who are fully acquainted with medium voltage (MV) equipment. Operating the drive does not require special knowledge of frequency converters. However, the user must understand the meaning of the messages on the control panel of the converter.

Do not access the main power circuit nor the motor as long as the system is not grounded. When switching off the mains, always allow the intermediate circuit capacitors to discharge before grounding and starting work on the frequency converter, the motor or the motor cable. The ACS 1000 and adjoining equipment must be properly grounded and the auxiliary supply voltage must be switched off prior to starting with any work. Danger: Some loads may apply a mechanical torque on the motor shaft. If the motor can rotate due to such a load, always disconnect, short-circuit or mechanically block the motor before you start work. 1-4 (of 6) 3BHS102769 ACS 1000 User’s Manual, Rev. C Chapter 1 - Safety Instructions Danger: There can be dangerous voltages inside the ACS 1000 from external control circuits (measurement inputs from PT’s etc.) even if the ACS 1000 mains power and auxiliary power are shut off. Danger: This converter can influence the working of heart pacemakers. Install a corresponding warning sign at the entrance to the converter room. C 3BHS102769 1-5 (of 6) Chapter 1 - Safety Instructions 1-6 (of 6) 3BHS102769 ACS 1000 User’s Manual, Rev. C Chapter 2 - Introduction Overview This manual provides you with detailed information on the installation and start-up of the ACS 1000 frequency converter, including detailed descriptions of the functions, installation and start-up of the unit. Fault tracing information, technical data and dimensional drawings are included as well. Range of Application of the ACS 1000 The ACS 1000 is a standard, medium-voltage AC drive, rated according to the technical specifications in Appendix A - Technical Data. The ACS 1000 has been designed as converter drive for squirrel cage induction motors. The customized engineering content is minimal. Thanks to its outstanding performance, the ACS 1000 is ideally suited for retrofit applications. Figure 2-1 The ACS 1000. Air Cooled Type ACS 1000 User’s Manual, Rev.

Note: This symbol emphasizes important information. A non-observance may cause damage to the converter. Safety Concept The design and the specific safety devices of the ACS 1000 allow safe installation, commissioning, operation and maintenance of the equipment when used as intended. C Chapter 1 - Safety Instructions The ACS 1000 is operating in a medium voltage environment usually consisting (besides the converter) of a power transformer, a motor, cabling, the driven process and a superimposed control system. The safety concept for the ACS 1000 takes into account the embedding of these components in the sense that no additional threat arises from their interaction with the ACS 1000. However, the safety considerations for the individual external components and for the overall process are not part of the ACS 1000 safety concept. Figure 1-1 Residual danger areas of the ACS 1000 Never remove rear cover when converter is energized or before grounding isolator is closed Even after pressing EMERGENCY STOP the converter will not be voltage-free immediately. Discharging will take about 5 minutes. Do not attempt to close the grounding isolator by force or to open the converter doors earlier Keep air intake free from dirt and obstacles Fan is coasting down after shut-down Do not attempt to open doors by force when drive is energized or before grounding isolator is closed Control section: Danger from auxiliary voltage when front door is open General Safety Regulations The safety instructions in this chapter generally apply when working on the ACS 1000. You will find additional instructions and warnings related to particular topics or actions throughout the manual where relevant. Warning: All electrical installation and maintenance work on the ACS 1000 must be carried out by qualified electricians. Danger: Never work on a powered ACS 1000. The main circuit breaker and the input isolators must always be opened and locked in “OPEN ” position.

It includes special requirements for storage and conservation together with instructions for periodical inspections. In addition, information on disposal and recycling of material as well as on temporary shut-down and decommissioning of the ACS 1000 is given. Chapter 10 - Installation specifies the mechanical and electrical requirements to the foundation, cabling and other equipment, gives instructions for mounting (drawings and descriptions), cable routing and termination for power, auxiliary and signal connections (incl. EMC requirements). Chapter 11 - Commissioning includes an installation checklist and and preconditions for commissioning. In addition, the various commisioning steps are described. Appendix A - Technical Data lists the ACS 1000 technical specifications. Appendix B - The CDP 312 Control Panel explains all panel push-buttons and all panel functions. Appendix C - Customer Specific Options is a documentation of all customer specific options including descriptions and drawings. Appendix E - Applicable Codes and Standards is a list of all applicable codes and standards for the ACS 1000. Appendix F - Layout and Mechanical Drawings is a collection of mechanical outline drawings showing all relevant information for floor mounting, cable entries, water flanges etc. Appendix G - Wiring Diagrams is a collection of electrical schematics and terminal diagrams. Appendix H - Part List is a list of all major components including the parts in the repair tool kit. Appendix I - Recommended Spare Parts List is a converter specific list of recommended spare parts. Those parts, which have to be exchanged as part of the regular maintenance program, are listed as well. Appendix K - Signal and Parameter Table includes a complete description of all control parameters. Appendix L - Inspection and Commissioning Record contains all records from factory testing. Commissioning test records and a provisional acceptance certificate shall also be included in this Appendix.

C 3BHS102769 2-1 (of 4) Chapter 2 - Introduction Intended Audience for this Manual This manual is intended for electrical field professionals who are responsible for installing, commissioning and servicing the ACS 1000 frequency converter. What this Manual Contains Chapter 1 - Safety Instructions: In this chapter, which is placed at the beginning of the manual, the various safety instruction levels used in this manual are explained. This chapter also provides general instructions on safety which must be respected during all work on the ACS 1000. Chapter 3 - Design and Functional Description contains a short technical overview of the ACS 1000 and a short description of its features and control functions. Chapter 5 - Operation describes safety considerations, preconditions for energizing and operation of the ACS 1000. Furthermore, remote and local control, starting and stopping, changing setpoints, monitoring of actual process values, de-energizing the ACS 1000 and the emergency stop function are described. Chapter 6 - Parameter Viewing and Editing describes how to view and modify start-up data, how to select application macros and edit other parameters using the CDP 312 control panel. Some ancillary parameter and macro editing features are described as well. Chapter 7 - Preventive Maintenance includes the maintenance schedule and specific descriptions of all preventive maintenance procedures. A list 2-2 (of 4) 3BHS102769 ACS 1000 User’s Manual, Rev. C Chapter 2 - Introduction of fault codes and messages on the CDP 312 control panel as well as explanations of all alarm messages and trip functions is included. The procedure for restarting the converter is described. Chapter 9 - Transportation, Storage, Disposal and Recycling provides information about environmental conditions to be maintained during transportation and storage, together with instructions for packing, unpacking, lifting and moving.

C Chapter 3 - Design and Functional Description Figure 3-2 Voltage and current waveforms at converter output ACS 1000 Output voltage: 4.16kV Output frequency: 60Hz The precharge resistors limit the current in the main DC-link when the converter is energized. They are bypassed with the protection IGCT’s as soon the DC voltage reaches 79%. The main function of these protection IGCT’s is to open in case of a fault in order to prevent the rectifier to feed into the fault. Common mode currents from the inverter are limited with the common mode choke and damped with the common mode damping resistor. Due to its special construction the common mode choke provides full reactance for the common mode currents flowing through transformer secondary cabling, DC-link, output filter and internal grounding bus of the converter. For the main DC-current, on the other hand, the choke forms practically no reactance thus enabling the main current to pass unhindered. Power Circuit Interface Input Circuit The standard version of the ACS 1000 is equipped with a 12-pulse diode rectifier input (see Figure 3-1). This is adequate for most supplying networks and normally the harmonic requirements as demanded by standards such as IEEE 519 can be met. For operation in particularly sensitive networks, the ACS 1000 can optionally be equipped with a 24-pulse rectifier. Output Circuit As a standard the ACS 1000 is equipped with a low pass LC sine filter in its output stage. Current feedback is used to actively control filter operation. The low pass frequency is designed to be well below the lowest switching frequency used by the inverter output stage. This greatly enhances the purity of both the voltage and current waveforms applied to the motor. The drive may be used to supply standard medium voltage motors (existing or new) without applying ACS 1000 User’s Manual, Rev. Control System Direct Torque Control DTC Direct torque control (DTC) is a unique motor control method for AC Drives.

The inverter switching is directly controlled according to the motor core variables flux and torque. The measured motor current and DC link voltage are inputs to an adaptive motor model which produces exact actual values of torque and flux every 25 microseconds. Motor torque and flux comparators compare actual values with the reference values produced by the torque and flux reference controllers. Depending on the outputs from the hysteresis controllers, the pulse selector directly determines the optimum inverter switch positions. Typical performance figures for the speed and torque control are given in Standard Control and Monitoring Functions, page 3- 12. 3-4 (of 30) 3BHS102769 ACS 1000 User’s Manual, Rev. Inverter switching based on average references to a PWM modulator. This results in delays in response and wasted switchings. Torque Step Rise Time (open loop) is less than 10 msec. Torque Step Rise Time Closed Loop 10 to 20 msec. Sensorless 100 to 200 msec. For more information on DTC, please refer to the Technical Guide No. 1 Direct Torque Control (3AFY 58056685 R0025). Layout and Description of Assembly Cabinet Design The riveted cabinet construction of the ACS 1000 provides extremely effective protection against electromagnetic emissions compared to traditional frames. In addition, this construction technique provides a solid, yet ACS 1000 User’s Manual, Rev. C 3BHS102769 3-5 (of 30) Chapter 3 - Design and Functional Description flexible and self-supporting framework which avoids the need for additional skeletal support. The design fulfils the requirements of international standards like UL 347A. EMC (Electromagnetic Compatibility) has been achieved by minimizing the spacing between the rivets and avoiding the use of paint on the cabinet’s inside walls. Paint tends to reduce the effectiveness of metallic bonding which is paramount to successful EMC. As standard, only the front of the ACS 1000 cabinet is painted while all other walls are galvanized.

Appendix M - Parameter Setting List is a customer specific parameter list ACS 1000 User’s Manual, Rev. C 3BHS102769 2-3 (of 4) Chapter 2 - Introduction with all parameter settings after commissioning. The Index contains an alphabetical list of topics treated in this manual with reference to the corresponding page numbers. 2-4 (of 4) 3BHS102769 ACS 1000 User’s Manual, Rev. C Chapter 3 - Design and Functional Description Overview The ACS 1000 is a three phase frequency converter for squirrel cage induction motors. Sophisticated microprocessor circuitry is used for monitoring the motor electromagnetic status. These data and Direct Torque Control enable state-of-the-art sensorless motor control. Additional pulse encoder feedback can be employed in applications where precision speed control is required, or in case of long-time operation near zero speed. The nearly sinusoidal converter output voltage makes the ACS 1000 ideally suited for retrofit applications with existing standard induction motors without the need for derating. Fuseless Design The ACS 1000 features a fuseless protected medium voltage drive. This patented design uses the new power semiconductor switching device, IGCT, for circuit protection. The IGCT, which is placed between the DC link and the rectifier, can, unlike conventional fuses, directly isolate the inverter of the drive system from the power supply side within 25 microseconds, making it 1000 times faster than the operational performance of fuses. The ACS 1000 is fitted with hardware and software protection features to safeguard against faults and damages due to improper operating conditions and equipment malfunction. Control Equipment The ACS 1000 frequency converter is equipped with advanced features for local and remote control.

Control equipment is integrated in the converter cabinet and provides fully digital and microprocessor based process control, protection and monitoring functions, supplemented with hardware protection circuits as a back-up. The CDP 312 Control Panel is the basic local user interface for monitoring, adjusting parameters and controlling the ACS 1000 operation. Technical Specifications Technical Data Standards Fulfilled See Appendix A - Technical Data See Appendix E - Applicable Codes and Standards ACS 1000 User’s Manual, Rev. C 3BHS102769 3-1 (of 30) Chapter 3 - Design and Functional Description Description of the ACS 1000 Functional Description The 3-phase AC line voltage is supplied to the rectifier bridges through the 3-winding converter transformer (see Figure 3-1). Therefore one secondary is wyeconnected while the other is delta-connected. The two fuseless rectifier bridges are connected in series, such that the DC-voltages are added up. Therefore, the full DC-bus current flows through both bridges. Figure 3-1 Elementary diagram - ACS 1000 ACS1000 Frequency Converter 3 M NP Main Circuit Breaker Medium Voltage Switchgear Converter Input Transformer Diode Rectifier Protection Intermediate IGCTs DC-Link Three Level Inverter Output Sine Filter Squirrel Cage Induction Motor Each leg of the 3-phase inverter bridge consists of a combination of 2 IGCT’s for 3-level switching operation: with the IGCT’s the output is switched between positive DC voltage, neutral point (NP) and negative DC voltage. Hence both the output voltage and the frequency can be controlled continuously from zero to maximum, using Direct Torque Control. At the converter output a LC filter is used for reducing the harmonic content of the output voltage. With this filter, the voltage waveform applied to the motor is nearly sinusoidal (see Figure 3-2 ). Therefore, standard motors can be used at their nominal ratings.

The cabinet can be entirely painted outside as an option. EMC performance is further enhanced by the use of metal cable channels, which are an integral part of the folded cabinet construction. 3-6 (of 30) 3BHS102769 ACS 1000 User’s Manual, Rev. C Chapter 3 - Design and Functional Description Figure 3-4 The ACS 1000. Air cooled type Control section Rectifier section Inverter section Cabinet Sections The ACS 1000 is designed with the inverter unit as one complete section including output filter capacitors and DC link capacitor. This section, located on the right hand side, experiences maximum air flow which is advantageous for the temperature sensitive capacitors. Construction allows easy exchange of IGCT’s using a special tool. The middle section houses the cooling fan, the rectifier stack, protection IGCT’s and filter reactor. The construction is such that the fan can be exchanged easily. The third section, on the left hand side, includes control equipment and also provides space devoted exclusively to cable termination. Customer signal terminals are also located in this area. See Figure 3- 5 and Figure 3-6. C 3BHS102769 3-7 (of 30) Chapter 3 - Design and Functional Description Figure 3-5 Front view of ACS 1000 Cooling air exhaust Inverter stacks VLSD boards Common mode damping resistor Rcom Gate unit power supply (GUSP) Ground isolator Rectifier and protection IGCT’s Common mode choke Lcom ADCVI board Cooling fan Drive control swing frame Electronic power supply (EPS) board IOEC2 board AMC3 control board Interface board IOEC1 board ?p transmitters (optional) IOEC3 board (optional) IOEC4 board (optional) Motor start and circuit breakers Batteries Aux.The design is such that the swing frame can be opened without dangerously exposing the power terminals. The standard ACS 1000 cabinet is rated IP21. Higher IP ratings are optionally available. The ACS 1000 cabinet system provides the flexibility to add cabinet sections to the drive at any time.

Sections can be added in widths of 600, 800 and 1000 mm (resp. 24, 32 and 39 Inches). 3-8 (of 30) 3BHS102769 ACS 1000 User’s Manual, Rev. The power section of the drive (multiple doors) includes an electromechanical interlock system that operates in conjunction with the safety grounding switch and electrical interlocks from the main circuit breaker (external). This interlock system insures that none of the power cabinets can be opened until the main source of power is disconnected, the safety grounding switch is closed and the DC link capacitors are discharged. Additionally the same interlock system insures that power cannot be initialized to the drive unless the doors are closed and the safety grounding switch has been opened. The control section can always be opened. Lifting Arrangements The cabinets are fitted with lifting lugs as standard. Channels are provided at the base of the unit for lifting by forklift vehicles. Cooling Circuit The ACS 1000 Type ACS1014-A2 is equipped with forced air cooling as mentioned above. The air intake is located in the front door of the inverter section. The standard grid can optionally be equipped with an air filter ACS 1000 User’s Manual, Rev. C 3BHS102769 3-9 (of 30) Chapter 3 - Design and Functional Description system to minimize air pollution in the converter. The air filter can be replaced from outside while the system is running. Figure 3-7 Cooling fan inside the converter cabinet (standard) Control Box Rectifier Inverter From the front door intake, the air flows through the heat sinks of the vertical inverter stacks and is then routed to the central section where the fan is located. After passing the fan, the air is blown through the rectifier diode stacks, followed by the motor filter reactor. The exhaust is located on top of the cabinet and provides a natural stack effect in order to direct the air flow after the fan. The exhaust is covered in order to protect the equipment inside mechanically.

For further details please refer to Appendix B - The CDP 312 Control Panel. C 3BHS102769 3-11 (of 30) Chapter 3 - Design and Functional Description Standard Control and Monitoring Functions General The ACS 1000 control and protection system is configured and customized through a set of application parameters. These parameters can be programmed by the user, either with the CDP 312 control panel supplied with the converter or with a PC and the DriveWindow software package. Parameters can be defined by setting them one by one or by invoking a predefined set of parameters which is optimized for a particular application. Such predefined parameter sets are called application macros. Therefore part of the functions described in this chapter will automatically be configured by selecting an application macro. In the remainder of this chapter you will find the description of the standard control, monitoring and protection functions with references to the related parameters. This and the following chapter are intended to be used as a reference for obtaining quick information on a specific function. Configuring the ACS 1000 is a task that requires a professional background going far beyond the knowledge needed for system operation. Warning: Never change any parameters if you are not thoroughly familiar with the meaning of each parameter and with the consequences resulting from the modification. Running the ACS 1000, the motor and the driven equipment with incorrect data can result in improper operation, reduction in control accuracy and damage to equipment. Motor Control Features Motor ID Run With the standard motor identification run (ID run) (input of nameplate data is always required), a quick motor identification is automatically done the first time the Start command is given. During this first start-up the motor is run at zero speed for several seconds to allow a basic motor model to be created. This model is sufficient to allow normal operation.

The unbeatable performance of direct torque control (DTC) is based on an accurate motor model. The parameters of this model are automatically 3-12 (of 30) 3BHS102769 ACS 1000 User’s Manual, Rev. C Chapter 3 - Design and Functional Description determined during the enhanced ID run. Basic motor nameplate data (power rating, speed, etc.) must first be entered manually. Then the drive is instructed to perform a motor ID run. For optimum parameter determination the load should be disconnected from the motor during the ID run. The ACS 1000 operates the motor under a predetermined set of running conditions for a few minutes. For each running condition motor and inverter feedback responses are measured. Based on these measurements the motor model parameters are calculated and optimized. The final result is an enhanced mathematical model of the motor which functions to provide the DTC controller with accurate flux, torque, and motor speed information. If no ID run is selected, the converter will be stopped due to ID run fault. Motor ID run can be selected upon entering the so-called start-up parameters of parameter group 99 (parameter 99.12). For further details please refer to Chapter 6 - Parameter Viewing and Editing, Start-Up Parameters, page 6- 7. Filter ID Run Filter ID run is used to verify output filter data. It is carried out with decoupled motor. Filter ID run is not required for normal operation, its purpose is to facilitate trouble shooting in the output filter circuit. Full Torque at Zero Speed A motor fed by the ACS 1000 can develop short-term motor nominal torque at start-up without any pulse encoder or tachogenerator feedback. This feature is essential for constant torque applications. However, if longterm operation at zero speed is required, a pulse encoder has to be applied. Enhanced Flying Start The enhanced flying start function of the ACS 1000 is an improved version of the flying start and ramp start features normally found in frequency converters.

The ACS 1000 can detect the state of the motor within a very short time. Hence, rapid starting is possible under all conditions. This feature allows easy starting of turbine pumps or windmill fans, for example. Flux Optimization Flux optimization of the ACS 1000 reduces the total energy consumption and motor noise level when the drive operates below the nominal load. The total efficiency (motor and the drive) can be improved by 1.10%, depending on the load torque and speed. Flux optimization is activated with parameter 27.01, Flux Control. For further details see Appendix K - Signal and Parameter Table. Power Loss Ride- Through If the incoming supply voltage is cut off the ACS 1000 will continue to operate in an active but non-torque producing mode by utilizing the kinetic energy of the rotating motor and load. The ACS 1000 will be fully active as long as the motor rotates and generates energy to the ACS 1000. The controller keeps the voltage steady as long as the main power is absent. The ACS 1000 runs the motor in generator mode. The motor speed falls but the drive is fully ac- tive as long as the motor has enough kinetic energy. Power loss ride through is set with parameter group 39, Ride Through Function. For further details see Appendix K - Signal and Parameter Table. Acceleration and Deceleration Ramps ACS 1000 provides two user-selectable acceleration and deceleration ramps. Switching between the two ramps can be controlled via a digital input. S1 Linear S2 S3 1 1.25 2 t (s) Acceleration and deceleration ramps are set with parameter group 22, Ramp Functions. For further details see Appendix K - Signal and Param- eter Table. 3-14 (of 30) 3BHS102769 ACS 1000 User’s Manual, Rev. C Chapter 3 - Design and Functional Description Critical Speed There is a Critical Speed function available for applications where it is necessary to avoid certain motor speeds or speed bands, for example due to mechanical resonance problems.