—

MEDIUM VOLTAGE DRIVES

ACS2000
Technical Catalog

+
• High reliability due to proven design and low
parts count
Technical Catalog

• Fuseless design
• Air-cooled
• Application tailored design
• Softstarter
ACS2000

• Arc resistant design

• Direct torque control
—

• Power range up to 4MW

—
ABB Sp. z o.o.
Medium Voltage Drives
Placydowska 27,
95-070 Aleksandrow Lodzki,
Poland

Document name
ACS2000
Technical Catalog

Document number
3BHS511343 ZAB E01 Rev. D

Issue date
2018-03
—
Table of contents

7 List of abbreviations and documents

11 Introduction

17 Applications and drive configurations

25 Hardware design

45 Functional description, operation

59 Control system and process interfaces

67 Options

79 Installation

87 Product life cycle management

91 System integration
—
List of figures

12 Voltage source inverter 31 Example of 1 MVA DFE rectifier

topology module

20 ACS2000, 1-2MVA, AFE, non- 32 Phase module replacement kit

integrated transformer
32 Lifting a phase module
21 ACS2000, 1-2MVA, AFE, direct-
to-line configuration 33 Grounding switch

22 ACS2000, 1-2MVA, AFE, 34 ACS2000 AFE 1MVA, control

integrated transformer compartment

23 ACS2000, 1-4MVA, DFE, non- 35 ACS2000 DFE 2MVA, control

integrated transformer compartment

24 ACS2000, 1-4MVA, DFE, 36 Example of ACS2000 DFE 1MVA,

integrated transformer control compartment

26 ACS2000 AFE, 1 MVA, direct- 37 ACS2000 AFE 1MVA, terminal

to-line configuration compartment

27 ACS2000 AFE, 2 MVA, direct- 39 Safety label examples

to-line configuration
39 Door locks, ACS2000 AFE 1 MVA
28 Example of ACS2000 DFE 1
MVA 41 Cooling, ACS2000 AFE 1MVA

29 Phase module types 41 Cooling, ACS2000 AFE 2 MVA

30 Example of 1 and 2 MVA AFE 41 Cooling, ACS2000 DFE 1 MVA

and INU phase modules
43 Transporting ACS2000 AFE 69 EMC entry plates with conductive
cushions
44 Transporting ACS2000 DFE
69 Roxtec frame with sealing modules
46 DTC control platform for control cables

48 Dynamic speed response with 69 Top cable entry

DTC
70 ACS2000 DFE 4MVA, redundant fan
48 Torque response times with configuration
DTC vs. PWM
72 AF 100 Fieldbus and Modbus RTU
51 Setting the control panel to
local or remote 72 Modbus TCP and Profibus DP / FMS

52 Typical start sequence 76 DriveMonitor

52 Typical stop sequence 76 DriveMonitor touchscreen

55 Signal display on control panel 84 ACS2000 AFE 1 MVA, EMC entry

plates, bottom cable entry
58 Input fuses
84 ACS2000 AFE 2 MVA, EMC entry
60 Typical configuration of plates, bottom cable entry
control system
84 EMC entry plate (bottom cable entry)
61 Location of AMC circuit
boards 85 Drive system with non-integrated
transformer
63 Local control hardware
86 Drive system with integrated
64 Control panel transformer

65 IOEC module 88 ABB life cycle management model

65 IOEC I/O system 89 ABB service portfolio

68 Cable gland 95 Load capacity curves

68 Power cable entry with Roxtec

sealing system
—
List of tables

12 1-1: Available configurations

40 3-1: Measured noise levels for the

different drive configurations

47 4-1: DTC versus current vector control

48 4-2: Typical performance figures for

direct torque control

74 6-1: Output fiter options

List of abbreviations and
documents
8 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
List of abbreviations

Abbreviation Meaning
AC Alternating current
ACS2000 ACS2000 medium voltage AC drive
ADCVI Analog digital conversion for voltage and current
AFE Active front end
AMC Application and motor controller
ANSI American National Standards Institute
CMC Common mode choke
DC Direct current
DDCS Distributed drive control system
DFE Diode front end
DTC Direct torque control
EMC Electromagnetic compatibility
IEC International Electrotechnical Commission
IEEE Institute of electrical and electronics engineers
IFU Input filter unit
IGBT Insulated gate bipolar transistor
IOEC Input and output electronics card
INU Inverter unit
IP Ingress protection
Degree of protection provided by an enclosure against ingress of foreign objects or water
ISO International organization for standardization
MCB Main circuit breaker
MTBF Mean time between failure
MTTR Mean time to repair
NC Normally closed
NEMA National electrical manufacturers association
PC Personal computer
PCB Printed circuit board
PID controller Proportional–integral–derivative controller
Generic control loop feedback mechanism (controller) widely used in industrial control
systems
PPCS Power plate communication system
PTC Positive temperature coefficient
PWM Pulse width modulation
RMS Root mean square
TEU Terminal unit
UPS Uninterruptible power supply
VSI Voltage source inverter
 LIST OF ABBREVIATIONS AND DOCUMENTS 9

—
Related documentation

Document identification Document title

3BHS299605 ZAB E01 Applicable codes and standards
3BHS210587 ZAB E01 Application note, air gap torque pulsation limits
3BHS301179 ZAB E01 Application note, guide to select the correct retrofit drive
3BHS268039 ZAB E01 DriveMonitor user’s manual
3BHS260165 ZAB E01 Line-side circuit breaker specification
3BHS260162 ZAB E01 Main transformer specification
3BHS302295 ZAB E01 MCB engineering guidelines, input circuit breaker control
3BHS104301 ZAB E01 Painting specification
3BHS542290 ZAB E01 Power cables engineering guideline
3BHS260164 ZAB E01 Power cable specification for ACS2000
3BHS824803 ZAB E01 ABB MVD ACS Motor Specification
3BHS824804 ZAB E01 Technical project Specification Motor
3BHS824805 ZAB E01 ABB MVD ACS High Performance Motor Spec
3BHS824806 ZAB E01 ABB MVD ACS High Speed Motor Spec
3AFY 58056685 R0025 Technical guide no. 1, direct torque control
3BHS363184 ZAB E01 Transport arrangements for 1 MVA
3BHS363301 ZAB D01 Transport arrangements for 2 MVA
3BHS348383 ZAB E01 Type code
3BHS196243 Emergency off / stop modes and prevention of operation
3BHS808793 Product life cycle status statement ACS2000
10 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D
Chapter 1
Introduction

12 The standard solution

13 Technical features

13 Direct Torque Control (DTC)

13 Active Front End (AFE)

13 Diode Front End (DFE)

13 Motor-friendly output waveforms

14 Benefits for the customer

14 Compliance with international standards

14 What you need is what you get

14 Low operating and maintenance costs

14 Maximum availability and short repair times

14 Performance features

15 Cyber Security Requirements

15 Cyber Security Disclaimer

15 User Lock
12 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
1.1 The standard solution

The air-cooled ACS2000 is a general-purpose frequency converter for

the control of standard induction motors. The design of the ACS2000
is based on the voltage source inverter (VSI) topology.

— The ACS2000 has been developed with the same

References
— standard components, software tools and design
1-1 Voltage source principles as applied to all members of the medium
inverter topology
voltage drives family. This approach greatly
increases the reliability of the ACS2000 and offers
users a consistent addition to the existing low and
medium voltage ACS product range. Being a highly
standardized product, short delivery times to cus-
tomers and commissioning times are achieved.

The ACS2000 comes with different configurations:

• On the line side, the ACS2000 can be configured
with an integrated or a non-integrated isolation
transformer.
A direct-to-line solution (transformerless) is
available for applications where the line voltage
corresponds to the motor voltage.
The line-side rectifier can either be an Active
Front End (AFE) with IGBT semiconductors or a
Diode Front End (DFE).
• On the motor side, the ACS2000 can be retrofit-
ted to standard induction motors with voltages
between 6.0 and 6.9 kV and power range from
250 to 3200 KW.

—
Table 1-1 Available configurations

Direct-to- Integrated Non-integrated

line transformer transformer
Low harmonic AFE DFE DFE
drives
Regenerative AFE AFE AFE
drives

ACS2000

Power Transformer Rectifier Voltage Inverter Motor

supply source
(DC link)

—
1-1
 CHAPTER 1 – INTRODUCTION 13

—
1.2 Technical features

With its compact footprint, constant power factor and configuration

options, the ACS2000 can be easily integrated into customer's
systems. The various line supply connection options provide perfect
voltage matching and low harmonic distortion.

1.2.1 Direct Torque Control (DTC) 1.2.3 Diode Front End (DFE)
The motor control platform is based on DTC. DTC The diode front end of the drive consists of two
achieves accurate torque and speed performance identical phase modules. The12-pulse diode recti-
and allows the speed of any standard squirrel cage fier bridge of each phase module add up to a net-
induction motor to be controlled without the need work friendly 24-pulse system. The DFE rectifies
for pulse encoder devices for speed feedback. the AC line voltage of the supply network and con-
nects its output to the minus and plus side of the
1.2.2 Active Front End (AFE) DC link. The DFE allows two-quadrant operation of
The drive is available with a 5-level self-commu- the drive.
tated active front end for four-quadrant operation.
Drives with AFE can be used with an input trans- 1.2.4 Motor-friendly output waveforms
former, or for the direct connection to the 6.0 to The inverter (INU) is an active 3-phase unit with the
6.9 kV power supply. same electrical design as the active rectifier (AFE).
The AFE rectifies the AC line voltage of the supply The unit is a self-commutated, 5-level voltage
network and connects its output to the minus, neu- source inverter.
tral point and plus side of the DC link. The INU provides near sinusoidal current and volt-
The AFE maintains the DC-link voltage at the age. This is achieved with ABB’s patented multi-
required level and adjusts the desired input power level topology, that utilizes a DC link enabling an
factor at the point of common coupling (PCC) to output waveform with a minimum number of
near unity. power components. As a result of the multilevel
topology, the drive produces an optimum number
Customer T
Energy flow in driving mode of nine switching levels (phase to phase).
PCC
h Energy flow in braking mode
e
Power 
supply M 10000 V P
A P
P
F INU
5000 V
Transformer IFU AFE DC link EMC filter P
E 
Time

provides a low harmonic signature which meets -5000 V

the most stringent requirements for harmonic dis- P
tortion as defined by the relevant standards. This
-10000 V 
P
avoids the need for harmonic analysis or the instal-
lation of network filters. The resulting waveform makes the drive compati-
ble for standard VSD motors and cable insulation.
Regeneration
For applications with high braking energy, the
drive is available with optional regeneration capa-
bility, which feeds back braking energy to the
power supply. This further reduces the overall
energy consumption.
14 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
1.3 Benefits for the customer

The ACS2000 industrial drive provides high flexibility to customer-

specific needs. Reliable motor control ensures high productivity,
availability and efficiency of operation.

1.3.1 Compliance with international standards 1.3.4 Maximum availability and short repair times
The design of the drive fulfills the requirements of Voltage source inverter (VSI)
international standards listed in ACS2000 - Appli- The benefits of a voltage source inverter (VSI)
cable codes and standards. include excellent availability and reliability.

1.3.2 What you need is what you get Diagnostics system

The flexible design with standard components and A comprehensive self-diagnostic monitoring sys-
the well-proven control platform allows optimum tem generates fault messages with information on
configuration of the drive system. fault type and location. This enables quick and pre-
Standard test procedures for each drive minimize cise localization of disturbances and reduces time
the risk of design errors. spent on fault finding.
Standardized procedures and documentation
reduce installation and commissioning time. Simplicity of power circuit
The simplicity of the power circuit and the modular
Proven ABB control platform design of the hardware lead to high availability and
Configurable application software and standard provide maintenance and repair concept with mini-
interfaces allow optimum integration into the mum outage times. For example, a complete phase
industrial environment. module can be replaced in about 30 minutes.
Interfaces for all common fieldbus types are avail-
able for communication with the higher-level con- 1.3.5 Performance features
trol system. Direct Torque Control (DTC) enables fast and accu-
Standardized control panels and operator inter- rate process control resulting in high and constant
faces, common for all ABB medium voltage drives, production quality and minimum machinery wear.
allow simple and user-friendly operation DTC guarantees:
• Highly dynamic response times without over-
1.3.3 Low operating and maintenance costs shoot
Modular design • Accurate static speed and torque control
The drive is designed to maximize uptime as well • Smooth output current waveforms resulting in
as to facilitate quick repair. The modular design minimum torque ripple.
lends itself to quick and effective replacement of
components, resulting in industry leading mean
time to repair (MTTR).

Reliable components
ABB drive technologies, such as the multilevel VSI
topology, provide a low parts count, increase reli-
ability, extend mean time between failures (MTBF)
and improve availability.

Front access
All drive components are accessible through the
front.

Redundant cooling
Optional redundant cooling fans increase the avail-
ability of the drive.
 CHAPTER 1 – INTRODUCTION 15

—
1.4 Cyber Security Requirements

This product is designed to be connected to and to communicate

information and data via a network interface.

1.4.1 Cyber Security Disclaimer 1.4.2 User Lock

It is Customer's sole responsibility to provide and For better cyber security, it is highly recommended
continuously ensure a secure connection between that you set a master pass code to prevent e.g. the
the product and Customer network or any other changing of parameter values.
network (as the case may be). Customer shall
establish and maintain any appropriate measures ! WARNING
(such as but not limited to the installation of fire-
ABB will not be liable for damages or losses caused by
walls, application of authentication measures,
the failure to activate the user lock using a new pass
encryption of data, installation of anti-virus pro-
code. See 1.4.1 Cyber Security Disclaimer.
grams, etc) to protect the product, the network, its
system and the interface against any kind of secu-
To activate the user lock for the first time, enter
rity breaches, unauthorized access, interference,
the default pass code, 358, into 16.02 Passcode.
intrusion, leakage and/or theft of data or informa-
This will make parameters 16.16…16.17 change-
tion.
able. Then enter the old pass code to 16.16 OldUs-
erPasscode and change user pass code in 16.17
ABB and its affiliates are not liable for damages
NewUserPasscode. In 16.02 Parameter Lock, the
and/or losses related to such security breaches,
user lock functionality can now be enabled.
any unauthorized access, interference, intrusion,
To reopen the lock, enter your pass code into 16.03
leakage and/or theft of data or information.
Passcode. This will again make parameters 16.16
and 16.17 visible.

For further details refer to Signal and Parameter

Table, parameter group 16.
16 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D
Chapter 2
Applications and drive
configurations

18 Drive configurations

19 Fields of application

20 Drive types

20 Non-integrated transformer configuration, ACS2000, 1-2MVA, AFE

21 Direct-to-line configuration, ACS2000, 1-2MVA, AFE

22 Integrated transformer configuration, ACS2000, 1-2MVA, AFE

23 Non-integrated transformer configuration, ACS2000, 1-4MVA, DFE

24 Integrated transformer configuration, ACS2000, 1-4MVA, DFE

18 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
2.1 Drive configurations

Depending on the field of application, the ACS2000 comes with

different drive configurations:

• Input transformer configuration

An input transformer is used if the line voltage
has to be adapted to the motor voltage, or if
the maximum short-circuit current of the main
power supply exceeds 50 kA.

Two installation solutions are available for the

transformer:
- Integrated
Drive and transformer are placed next to
each other and form a single unit. For the
integrated configuration, a dry-type trans-
former is used.
- Non-integrated
The transformer is external to the drive. The
transformer can be an oil-immersed or dry-
type device. The distance between drive and
transformer is determined by the maximum
possible cable length for the transformer
secondary cables. Drives with an external
transformer are equipped with a common
mode choke.

• Direct-to-line (DTL) configuration

For applications where the line voltage corre-
sponds to the motor nominal voltage, the
ACS2000 can be connected direct-to-line by
employing input reactors instead of an input
transformer. The DTL configuration is used for
6 to 6.9 kV line voltages.

• Active front end (AFE) or diode front end (DFE)

The configuration depends on the requirement
to recover energy.
 CHAPTER 2 – APPLICATIONS AND DRIVE CONFIGURATIONS 19

—
2.2 Fields of application

The ACS2000 provides reliable motor control for a wide range of

applications:

Cement, mining and minerals

Crushers, conveyors, mills, mine hoists, fans,
pumps

Chemical, oil and gas

Compressors, extruders, pumps, mixers, blowers

Metals
Fans, pumps

Pulp and paper

Fans, pumps, refiners, vacuum pumps, chippers

Power generation
Conveyors, fans, pumps, coal mills

Water
Pumps

Other applications
Test stands, wind tunnels, sugar mills
20 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
2.3 Drive types

The ACS2000 provides different line supply connections which are

available for regenerative applications with an active front end (AFE) or
for low harmonic applications with a diode front end (DFE).

— 2.3.1 Non-integrated transformer configuration,

References
— ACS2000, 1-2MVA, AFE
2-1 ACS2000, 1-2MVA,
AFE, non-integrated
transformer Legend
1. Main circuit breaker
2. Input transformer
3. Input filter unit
4. Active front end
5. DC link
6. Inverter unit
7. Induction motor

1 MVA 2 MVA

ACS2000

Main
power M
supply

1 2 3 4 5 6 7
—
2-1
 CHAPTER 2 – APPLICATIONS AND DRIVE CONFIGURATIONS 21

— 2.3.2 Direct-to-line configuration, ACS2000,

References
— 1-2MVA, AFE
2-2 ACS2000, 1-2MVA,
AFE, direct-to-line
configuration Legend
1. Main circuit breaker
2. Input reactor
3. Input filter unit
4. Active front end
5. DC link
6. Inverter unit
7. Induction motor

1 MVA DTL 2 MVA DTL

ACS2000

Main
power M
supply

1 2 3 4 5 6 7
—
2-2
22 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

— 2.3.3 Integrated transformer configuration,

References
— ACS2000, 1-2MVA, AFE
2-3 ACS2000, 1-2MVA,
AFE, integrated
transformer Legend
1. Main circuit breaker
2. Integrated input transformer
3. Input filter unit
4. Active front end
5. DC link
6. Inverter unit
7. Induction motor

1 MVA 2 MVA

ACS2000

Main
power M
supply

1 2 3 4 5 6 7
—
2-3
 CHAPTER 2 – APPLICATIONS AND DRIVE CONFIGURATIONS 23

— 2.3.4 Non-integrated transformer configuration,

References
— ACS2000, 1-4MVA, DFE
2-4 ACS2000, 1-4MVA,
DFE, non-integrated
transformer Legend
1. Main circuit breaker
2. Input transformer
3. Diode front end
4. DC link
5. Inverter unit
6. Induction motor

2 MVA 3 MVA

1 MVA

4 MVA

ACS2000

Main
power M
supply

1 2 3 4 5 6
—
2-4
24 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

— 2.3.5 Integrated transformer configuration,

References
— ACS2000, 1-4MVA, DFE
2-5 ACS2000, 1-4MVA,
DFE, integrated
transformer Legend
1. Main circuit breaker
2. Integrated input transformer
3. Diode front end
4. DC link
5. Inverter unit
6. Induction motor

1 MVA 2 MVA

3 MVA 4 MVA

ACS2000

Main
power M
supply

1 2 3 4 5 6
—
2-5
Chapter 3
Hardware design

26 ACS2000 AFE, 1 MVA

27 ACS2000 AFE, 2 MVA

28 ACS2000 DFE, 1 - 4 MVA

29 Phase modules

29 Overview

30 AFE and INU phase modules, 1 and 2 MVA

31 DFE rectifier modules

32 Accessories for maintenance

33 DC link

34 Control compartment

34 ACS2000 AFE 1MVA

35 ACS2000 AFE 2MVA

36 ACS2000 DFE

37 Terminal compartment

38 Cabinet design

38 ACS2000 AFE

38 ACS2000 DFE

38 Color and type of coating

38 Degree of protection

39 Safety labels

39 Doors and door locks

40 Door safety switch

40 Cooling

43 Lifting arrangements
26 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
3.1 ACS2000 AFE, 1 MVA

— Legend
References
— 1. Direct-to-line compartment
3-1 ACS2000 AFE, 1 MVA, 2. Terminal compartment for feeder and motor
direct-to-line
configuration cables
3. Control compartment
4. EMC filter (behind control compartment)
5. Phase modules of inverter unit (INU)
6. DC link capacitor
7. Phase modules of active front end (AFE)
8. Input filter unit (IFU)

4
3

5
2

6
1

—
3-1
 CHAPTER 3 – HARDWARE DESIGN 27

—
3.2 ACS2000 AFE, 2 MVA

— Legend
References
— 1. Direct-to-line compartment
3-2 ACS2000 AFE, 2 MVA, 2. Swing frame of control compartment
direct-to-line
configuration 3. Terminal compartment (behind swing frame)
4. Input filter unit (IFU)
5. DC-link capacitors
6. Phase modules of active front end (AFE)
7. Phase modules of inverter unit (INU)
8. Grounding switch
9. EMC filter
10. Charging transformer

9 7
10

8
3
5

2 4 6
1

—
3-2
28 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
3.3 ACS2000 DFE, 1 - 4 MVA

—
References
Legend —
1. Swing frame of the control compartment
• The principle design and layout,
—
3-3 Example of ACS2000 2. Terminal compartment (behind the swing
DFE 1 MVA
frame) and the arrangement of the
3. EMC filter
4. Common mode choke (CMC) major power electronics com-
5. Option, only present with non-integrated trans- ponents is the same for all out-
former
6. Phase modules of inverter unit (INU) put powers of the ACS2000
7. DC-link capacitor(s) DFE (1-4 MVA).
8. Phase modules of diode front end (DFE)
• The arrangement of the phase
modules is the same for all out-
put powers of the ACS2000
DFE; their weight and dimen-
sions vary based on the output
power.

5
2

3 6

4 7

1 MVA

—
3-3
 CHAPTER 3 – HARDWARE DESIGN 29

—
3.4 Phase modules

The phase modules are the building blocks for the line-side rectifier
unit (DFE or AFE) and the inverter unit (INU) of the drive.

— 3.4.1 Overview
References
— The standardized modules contain the power
3-4 Phase module types semiconductors and the circuit boards (AFE and
INU phase modules) for communication with the
control system of the drive.

DFE rectifier module

1 MVA AFE and INU phase module

2 MVA AFE and INU phase module

3 - 4 MVA INU phase module

—
3-4
30 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
References
3.4.2 AFE and INU phase modules, 1 and 2 MVA —
1. Phase capacitors
above only shows 1 and 2 MVA
—
3-5 Example of 1 and 2 2. Phase INT circuit board below cover 3-5
MVA AFE and INU phase
modules 3. Gate drivers phase modules as an example,
4. Connectors
5. IGBT module, contains two IGBTs but it is applicable also to 3 and 4
6. Heat sink with IGBTs, 1 MVA phase module MVA phase modules.
7. Heat sink with IGBTs, 2 MVA phase module
The arrangement of the major
power electronics components is
the same for all phase modules, 1
to 4 MVA.

1 MVA 2 MVA

4 4

3 3 1 3

2 2

1 1

6
5 7

—
3-5
 CHAPTER 3 – HARDWARE DESIGN 31

— 3.4.3 DFE rectifier modules

References
— Legend
3-6 Example of 1 MVA DFE 1. Snubber capacitors
rectifier module
2. Snubber resistors
3. Diodes
4. Connectors
5. Diode
6. Diode on heat sink

1
3 3 3
2 4
2

2
3 3 3
2 4

5 6

—
3-6
32 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
3.5 Accessories for maintenance
Phase module replacement kit
The following parts are required for the maintenance of the phase
modules. The parts can be order as a kit (standard option), or
separately.

—
References
—
3-7 Phase module
replacement kit
—
3-8 Lifting a phase
module

1 Module rails x2 (indicated for

all inverter modules and
11 22 33 1 MVA rectifier modules)
2 Module tray (indicated for
2 - 3 MVA rectifier modules)
3 Module tray (indicated for
4 MVA rectifier modules)
4 Support tray (for ACS2000
4
4 DFE drives only)
5
5 5 Cantilever (for 2 - 4MVA
7 8 phase modules)
6 6 Lifting hoist

7 Hoisting brackets - 3 arms

(for 2MVA phase modules)
8 Hoisting brackets - 4 arms
(for 3 - 4MVA phase modules)

—
3-7

—
3-7
 CHAPTER 3 – HARDWARE DESIGN 33

— 3.5.1 DC link The grounding switch is electromechanically inter-

References
— The main components of the DC link include: locked with a discharge monitoring circuit to pre-
3-9 Grounding switch • The capacitor(s) vent closing of the switch while the DC-link is 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), press the

pushbutton Grounding Switch Unlocked (1)
located on the control compartment door (the
pushbutton lights up) and - at the same time - turn
the grounding switch to the grounded (2) position.

When the switch is in position grounded, the

• Charging unit power electronics components of the drive are
The unit charges the DC-link capacitor(s) before connected to the PE ground busbar.
the main circuit breaker is closed to connect the
drive to the main power supply. This way, exces-
sive inrush currents are prevented.
• Grounding switch
The grounding switch is a protection device
that enables safe access to the rectifier/
inverter compartment of the drive.

Grounding switch

—
3-9
34 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
3.6 Control compartment

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 hardware.

Depending on the control concept of the drive sys-

tem, the remote control hardware include a higher-
level control system and/or remote operator sta-
tions.

3.6.1 ACS2000 AFE 1MVA

— Legend
References
— 1. AMC circuit boards
3-10 ACS2000 AFE 1MVA, 2. IOEC modules with analog and digital inputs
control compartment
and outputs
3. Circuit breakers, auxiliary relays and contactors
4. Power supply units
5. Air pressure switches

5
1 4 4

2 2
2 2
—
3-10
 CHAPTER 3 – HARDWARE DESIGN 35

3.6.2 ACS2000 AFE 2MVA

— Legend
References
— 1. AMC circuit boards
3-11 ACS2000 DFE 2MVA, 2. Communication interfaces to external devices
control compartment
3. Circuit breakers, auxiliary relays and contactors
4. Air pressure switches
5. IOEC modules with analog and digital inputs
and outputs

4
1

5 5

5 5

—
3-11
36 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

3.6.3 ACS2000 DFE

— Legend
References
— 1. IOEC modules with analog and digital inputs
3-12 Example of ACS2000 and outputs
DFE 1MVA, control
compartment 2. Power supplies, contactors, auxiliary relays
3. AMC circuit board

2 2

1 1

—
3-12
 CHAPTER 3 – HARDWARE DESIGN 37

3.6.4 Terminal compartment

— The terminal compartment provides the terminals
References
— for the feeder and motor cables, and the ground
3-13 ACS2000 AFE 1MVA, busbar for the termination of the ground cable and
terminal compartment
the cable screens.

Cable entry
The cables enter the cabinet through the floor
(standard) or through the roof (option) of the cabi-
net.

Cable transits
The cabinet is prepared for one of the following
cable entries:
• EMC entry plate (standard)
• Roxtec cable transit (option)
• Undrilled entry plate (option)
See Chapter 6 - 6.1 Cabinet, Power cable entry
plates and Top cable entry for information on the
optional cable transits.

—
3-13
38 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
3.7 Cabinet design

The riveted and folded cabinet construction of the drive ensures a

strong, flexible and self-supporting framework.

3.7.1 ACS2000 AFE The outer panels are bolted to the C-shaped pro-
Construction files with self-tapping screws. The panels are also
The construction avoids the need for additional protected by hot-dip zinc-coating.
skeletal support and provides effective protection The outside of the doors and the side panels are
against electromagnetic emissions. painted to enhance the appearance of the cabinet.
EMC has been achieved by applying an EMC sealing
EMC around the doors, the rear and the side panels. The
EMC has been achieved by applying a cabinet inside panels of the compartments are not
design consisting of folded, galvanized sheet painted, because paint tends to reduce the effec-
metal plates (thickness: approximately 2 mm) and tiveness of metallic bonding which is paramount to
minimizing the space between the rivets. The successful EMC.
inside walls of the compartments are not painted,
because paint tends to reduce the effectiveness of 3.7.3 Color and type of coating
metallic bonding which is paramount to successful Standard color
EMC. RAL 7035 (light gray),
Accordingly, only the front of the cabinet is painted
while all other walls are galvanized. However, the Optional colors
cabinet can be ordered optionally with the whole Possible
of the outside painted. EMC performance is further
enhanced by the use of metal cable ducts between Type of coating
different compartments. Powder coating

3.7.2 ACS2000 DFE Layer thickness

The cabinet has been designed using the MNS cab- ≥ 50 µm (standard)
inet system of ABB. The design consists of a skele- Up to 150 µm (option)
tal frame (1) to which the outer panels (2) are
bolted to. Corrosion resistant materials are used 3.7.4 Degree of protection
to protect the cabinet from corrosion. The standard degree of protection for the cabinet
is IP 21.
The basic elements of the frame are C-shaped steel
See Chapter 6 - 6.1 Cabinet for optional IP codes.
profiles with screw holes at a regular distance of 25
mm. The profiles are hot-dip zinc-coated.

2
 CHAPTER 3 – HARDWARE DESIGN 39

— 3.7.5 Safety labels Legend

References
— Safety labels are attached to the cabinet to alert 1. Cover of DTL compartment: bolted
3-14 Safety label personnel of potential hazards when working on 2. Cover of terminal compartment: bolted
examples
— the drive. The standard language of the label text is 3. Door of control compartment: lockable
3-15 Door locks, ACS2000 English. If specified when ordering the drive, the 4. Door of AFE-INU compartment: electromechan-
AFE 1 MVA
labels are provided in the national language of the ically locked
customer. The label design is based on the relevant Door cannot be opened when the main power is
ANSI and ISO standards. connected.
5. Cover of input filter compartment: bolted
3.7.6 Doors and door locks 6. Lock insert of control compartment
To ensure safety and to prevent the doors being 7. Lock insert of AFE-INU compartment
opened unintentionally, all doors are lockable, and 8. Keys
the doors of compartments where medium volt-
ages are present during operation (1, 2, 4 in 3-15)
are bolted or electromechanically 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.

—
3-14

8
8

6 7

3
7

1 2 5 4

—
3-15
40 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

3.7.7 Door safety switch The door of the control compartment is not inte-
The doors of medium voltage compartments are grated into the interlocking circuit and can always
secured by a safety switch. The device is tied into be opened.
an interlocking circuit that operates with the
grounding switch and the interlocks from the main 3.7.8 Cooling
circuit breaker of the drive. The interlocking sys- The drive and the integrated transformer can be
tem ensures that: equipped with a non-redundant (standard) or a
• the main power cannot be connected to the redundant (option) fan configuration.
drive unless the door is securely closed, the
grounding switch is in position not grounded, Function
and the safety switch is in position locked. The fan unit is switched on by the control system
• the door can only be opened when the main cir- of the drive when the DC link has been charged.
cuit breaker has been opened, the DC-link has When the main power has been switched off, the
been discharged, and the grounding switch is in fan continuous to run for a preset time to remove
position grounded. the heat from the cabinet.

Noise level

—
Table 3-1 Measured noise levels for the different drive configurations

Front-End Line Frame Fan Redundancy Sound Pressure Measurement

Connection S: Standard Level Report
R: Redundant
AFE External 1 MVA S
Transformer
R
2MVA S
R
DTL 1 MVA S
R
2MVA S 79.8 dB (A) 3BHS351154 a)
R 80.1 dB (A)
Integrated 1 MVA S
Transformer
R
2MVA S
R
DFE External 1 MVA S 75.2 dB (A) 2UBB017444 b)
Transformer
R
2MVA S 74.8 dB (A) 2UBB017444 b)
R
3 MVA S
R
4 MVA S 79.4 dB (A) 2UBB017444 b)
R 79.0 dB (A)
Integrated 1 MVA S
Transformer
R
2MVA S 76.3 dB (A) 2UBB017462 b)
R
3 MVA S 82.2 dB (A) 2UBB017445
R
4 MVA S
R

a. a. Measurement performed with AC cooling Where not mentioned differently:

fan (previous design) - The measurements were performed in no-
b. b. Measurement not performed strictly load operation.
according to ISO 3746 - The measurements were performed accord-
The main difference between single and redundant ing to ISO 3746.
fan systems regarding noise is the location of the - The fans were running on full speed (100 %).
running fans. Note: As a rule of thumb, the pressure noise level
increases by +3 dB (A) if the number of fans doubles.
 CHAPTER 3 – HARDWARE DESIGN 41

— Air flow monitoring When the filter mats are clogged and the pressure
References
— Air pressure switches in the drive (1 in 3-16, 3-17, 3- drop reaches the specified final pressure loss, the
3-16 Cooling, ACS2000 18) and in the integrated transformer monitor the message Conv1CoolAirFilter is displayed on the
AFE 1MVA
— air flow. control panel of the drive and the alarm/fault lamp
3-17 Cooling, ACS2000 lights up on the control compartment door.
AFE 2 MVA
— Separate air pressure switches in each compart-
3-18 Cooling, ACS2000 ment monitor the air flow through the filter mats
DFE 1 MVA
and the air flow through the compartments.

—
3-16

—
3-17
42 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
3-18
 CHAPTER 3 – HARDWARE DESIGN 43

— 3.7.9 Lifting arrangements

References
— ACS2000 AFE
3-19 Transporting The ACS2000 with AFE is fitted with lifting rails (1)
ACS2000 AFE
on the roof. The cabinet can either be lifted by
crane (2) or forklift (3). Longer drives can be trans-
ported with pallet trucks (4), one on the right and
one on the left side of the drive.

2 3

—
3-19
44 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

— ACS2000 DFE
References
— The cabinet is equipped with lifting brackets on
3-20 Transporting the base frame. A crane or a forklift (only drives
ACS2000 DFE
with 1 MVA output power) can be used for lifting.

Integrated transformer
Integrated transformers are equipped with lifting
brackets on the base frame like the ACS2000 with
DFE and can be lifted by crane or forklift.

—
3-20
Chapter 4
Functional description, operation

46 Control functions

46 Direct Torque Control (DTC)

48 Speed control functions

49 Ride-through functions

49 Control functions

49 Application parameters

50 Control modes and macros

50 Input signal source selection and signal processing

51 Local and remote control

52 Start and stop sequences

54 Main circuit breaker control

55 Diagnostics

56 Protection

56 Alarms and faults

56 Internal protection functions

58 Hardware-based protection functions

46 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
4.1 Control functions

This chapter presents the principles that apply to the standard

functions for drive control, monitoring and protection. It also
describes the basic operation and diagnostic devices.

— 4.1.1 Direct Torque Control (DTC) Performance and benefits

References
— Principle DTC provides excellent speed control accuracy
4-1 DTC control platform DTC is an optimized motor control method for AC even without pulse encoder feedback. It virtually
drive systems that allows direct control of motor eliminates the excitation of any torque resonances
torque and flux. Rather than switching in a prede- on the motor shaft by avoiding explicitly assigned
termined pattern as in conventional pulse width pulse width modulation frequencies. Control of the
modulation drives, DTC determines each switching frequency converter is immediate and smooth
instance separately based on the actual flux and under all conditions and the audible noise of the
torque values. motor is considerably reduced compared to other
control methods.
The measured motor currents and DC-link voltages The torque response times are up to ten times
are inputs to an adaptive motor model that calcu- faster than with conventional control methods
lates exact values of torque and flux every 25 μs. such as current vector control. This results in mini-
Motor torque and flux comparators compare the mum torque ripple and most accurate static speed
actual values to the reference values that are pro- and torque control.
duced by the torque and flux reference controllers.
Depending on the outputs from the hysteresis con-
trollers, the optimum switching logic directly
determines the optimum inverter switch positions
every 50 μs. While switching in conventional pulse
width modulation controlled drives is done only in
predetermined patterns and results in slower
response times, DTC enables switching whenever
required.

Torque reference Torque- Torque Switching

reference flux logic
or controller comparator
Speed reference
Speed
controller
Switch
Actual speed positions
Motor
model Voltage
Current

—
4-1
CHAPTER 4 – FUNCTIONAL DESCRIPTION, OPERATION 47

—
Table 4-1 DTC versus current vector control

DTC (asynchronous motors) Vector control

Motor control variables Switching is based on core motor variables flux and Switching is based on the separate
torque control of magnetic field and torque
producing current components
Requirements for speed Shaft speed and position are not required (only high Mechanical speed is essential. Requires
encoder performance applications as for example in the shaft speed and position (measured or
mining and metal industry require speed encoders) estimated)
Maximum inverter response Each inverter switching process is determined Inverter switching is based on average
time separately (every 25 μs) references to a pulse width modulator
resulting in delays in response and
unnecessary switching
Torque step rise time Torque step rise time is less than 3 ms at 70% speed Torque step rise time closed loop: 10 -
20 ms sensorless: 100 - 200 ms

Other major features and benefits of DTC are: • Low noise and torque ripple
• High-speed accuracy Because it avoids dedicated modulation fre-
Typical speed accuracy is 0.1% of nominal quencies, DTC keeps audible motor noise low
speed (without speed encoder). and torque ripple negligible.
• High torque performance • Minimum inverter switching losses at maximum
DTC provides full torque at zero speed and fast control performance.
torque step response time (typical ~ 3 ms). DTC provides for fast control without requiring
• Robust control method high switching frequency. This is possible
DTC is very robust and compensates distur- because control is not based on a fixed pulse
bances and inaccuracies on supply, motor and width modulation frequency. Instead, switching
load side. This avoids unnecessary shutdowns is only executed when required. Conventional
and increases the reliability of the drive. pulse width modulation control requires >10
kHz switching frequency for equivalent perfor-
mance.

PWM without encoder PWM with encoder DC drive with encoder DTC without encoder
Static speed error ± 1...3% ± 0.01% ± 0.01% ± 0.1...0.5%
Dynamic speed error 3% sec 0.3% sec 0.3% sec 0.4% sec
48 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

— Speed response
References
— 4-2 shows a typical dynamic speed response
4-2 Dynamic speed caused by a load step. —
response with DTC Table 4-2 Typical performance figures for direct torque
— In many applications, there is no need for speed control
4-3 Torque response and position encoders to meet the performance
times with DTC vs. PWM
requirements (see Table 4-1). Torque control Without pulse With pulse
encoder encoder

4-3 shows how torque response times to a set- Linearity error + 4%(1) + 3%

point change can be reduced substantially when Torque rise time < 10 ms < 10 ms
DTC is used instead of pulse width modulation
(PWM). (1) When operated around zero frequency, the error may be
bigger.

! For more information on DTC, see Techni-

cal guide no. 1, Direct torque control Speed and torque performance figures meet or
(3AFY 58056685 R0025). exceed the requirements of IEC 61800-4.

Acceleration and deceleration ramps

4.1.2 Speed control functions
The drive provides user-selectable acceleration
Speed control
and deceleration ramps. It is possible to adjust
The static speed control error is typically +0.1%
acceleration and deceleration times (setting val-
(10% of nominal slip) of the motor nominal speed,
ues: 0 - 1800 s) and to select different ramp
which satisfies most industrial applications.
shapes. The value is selected depending on the
process. Switching between the two ramps can be
Torque control without T
T
(%) controlled via a digital input.
speed feedback
N

T
The available ramps include:
ref
100
The ACS2000 performs 90
T act

precise torque control • S-curve ramps are ideal for applications that
without any speed feed- require a smooth transition from one speed to
back from the motor shaft another.
with torque rise time of • Linear ramps are ideal for drives requiring long
less than 10 ms at 100% 10
acceleration/deceleration periods and where S-
torque reference step. < 10 ms
t (s) curve ramps cannot be used.
T = Rated motor torque
By applying a torque refer- N ..
T = Torque reference
ref .
T = Actual torque
ence instead of a speed
act

reference, the drive maintains a specific motor

torque value; the speed adjusts automatically to
the required torque.

Speed
(rpm) Torque (kNm)

Torque

Speed

Value depends
on process

Time

—
4-2

Typical torque step

Torque:
(response times at 70% speed)
DTC • DTC: 3 ms
• PWM flux vector: 10 – 20 ms
• PWM scalar: > 150 ms

PWM

—
4-3
CHAPTER 4 – FUNCTIONAL DESCRIPTION, OPERATION 49

Motor Motor
speed speed
(rpm)
1560
S1
Linear
1380

S2
690
S3 540

Speed
1 1.25 2 t (s) reference
(rpm)
The ramp shapes can be adjusted via parame- s1 low s1 high
540 690
s2 low s2 high
1380 1560

ters as follows: 4.1.3 Ride-through functions

- S1: Suitable for short acceleration and/or The ride-through function prevents an undervolt-
deceleration times. age fault when short voltage dips of the main sup-
- S2: Suitable for medium acceleration and/or ply voltage occur.
deceleration times.
- S3: Suitable for long acceleration and/or Auxiliary ride-through
deceleration times. The auxiliary ride-through function guarantees cor-
rect fault indication and proper trip sequencing
Constant speeds when the auxiliary power supply of the ACS2000 is
Up to seven constant speeds can be programmed, lost. During ride-through, the power for the control
and selected by digital inputs. If activated, the circuits of the ACS2000 is supplied by internal buf-
external speed reference is overwritten. fer capacitors or batteries.
The ride-through time is 100 ms with the standard
Full torque at zero speed configuration (externally supplied UPS). With the
A motor fed by the ACS2000 can develop short- used of an optional battery the ride-through time
term motor nominal torque at startup without any can be extended to 15 minutes.
pulse encoder feedback. This feature is essential
for constant torque applications. However, if per- Power loss ride-through
manent operation at zero speed is required, a If the supply voltage is lost due to voltage dips or
pulse encoder must be used. other disturbances in the power supply, the
ACS2000 continues to operate in an active but
Flying start non-torque producing mode by utilizing the kinetic
This feature allows the ACS2000 to take over a energy of the rotating motor and load. The
rotating motor (for example, a turbo-pump or a ACS2000 is fully active as long as the motor
fan). With the flying start function, the frequency rotates and supplies energy to the drive.
of the motor is detected by the ACS2000, and the
output is synchronized to the motor speed. From Automatic restart
there the ACS2000 takes the control again accord- The ACS2000 can automatically reset itself after an
ing to the selected reference. undervoltage has occurred. This function is acti-
vated with two parameters. One parameter
Critical speed enables the function, the other parameter selects
The critical speed function is needed for applica- the undervoltage waiting time. If the automatic
tions where it is necessary to avoid certain motor restart feature is activated and an undervoltage is
speeds or speed bands, for example due to detected in the DC link, the waiting time is started.
mechanical resonance problems. The ACS2000 When the voltage recovers within the selected
makes it possible to set five different speeds or time, the fault is reset automatically and the drive
speed bands which are avoided during operation. resumes normal operation. When the waiting time
has elapsed and the voltage has not recovered, the
Each critical speed setting allows the user to drive shuts down and the MCB opens.
define a low and a high-speed limit. If the speed
reference signal requires the ACS2000 to operate 4.1.4 Control functions
within this speed range, the critical speed function 4.1.4.1 Application parameters
keeps the ACS2000 operating at the low (or high) The ACS2000 is configured and customized with
limit until the reference is out of the critical speed application parameters. These parameters can be
range. The motor is accelerated and decelerated altered, either with the integrated control panel, or
through the critical speed band according to the by using a PC and the optional DriveWindow soft-
acceleration or deceleration ramp. ware package.
Control and monitoring functions of the ACS 2000
can be activated by setting parameters one by one.
50 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

Parameter lock Reference signal processing

The user can prevent unwanted parameter The ACS2000 can handle a different speed refer-
changes by activating the Parameter Lock func- ence scheme in addition to the conventional ana-
tion. log input signal and control panel signals.
• The reference value for the ACS2000 can be
4.1.4.2 Control modes and macros given using two digital inputs: one digital input
The control and operating modes consist of pre- increases the speed, the other decreases it. The
programmed parameter sets. The sets offer preset active reference is memorized by the control
signal interfaces for opening and closing the main software.
circuit breaker, starting and stopping the • The ACS2000 can form a reference value out of
ACS2000, and setting reference values. two analog input signals by using mathematical
Depending on the process, the control and operat- functions: addition, subtraction, multiplication,
ing mode can be selected, thus enabling a quick minimum selection, and maximum selection.
and easy startup of the ACS2000.
It is possible to override the actual speed reference
Using a control and operating mode has the advan- with predefined constant speeds (see Constant
tage that the number of individual parameters to speeds for further information).
be set during startup is minimized. All para-meters It is possible to scale the external reference value
have factory-set default values. These default val- so that the minimum and maximum values of the
ues can be left unchanged or they can be set indi- signal correspond to a speed other than the nomi-
vidually according to the needs of the customer. nal minimum and maximum speed limits.
The ACS2000 can be operated with one of the fol-
lowing standard control modes and macros:

Control modes
• Speed control
• Torque control
• PID control
• Master/Follower

Macros
• User 1
• User 2

4.1.4.3 Input signal source selection and signal

processing
Two programmable control locations
The ACS2000 can receive the start, stop and direc-
tion commands, and the reference value from the
integrated control panel, and the closing or open-
ing commands for the main circuit breaker from
the pushbuttons on the control compartment
door.
Alternatively, it is possible to predefine two sepa-
rate external control locations (EXT1 and EXT2) for
these signals. The active external control location
can be changed via the control panel or via a digital
input.
The control panel always overrides the other con-
trol signal sources when switched to local mode.
Optionally, the ACS2000 can be equipped with a
fieldbus adapter module, (see Chapter 6 - Options
for further information).
 CHAPTER 4 – FUNCTIONAL DESCRIPTION, OPERATION 51

— 4.1.4.4 Local and remote control Prevention of local control

References
— The standard drive provides all means for local and To prevent unauthorized local control of the drive,
4-4 Setting the control remote operation. The local control panel on the local control can be enabled and disabled from
panel to local or remote
front door of the control compartments and the remote control via hardwired I/O or by entering a
two LED pushbuttons are provided for local opera- password into the local control panel.
tion and to connect/disconnect the main power Changing the control mode from local to remote
supply. and vice versa can be disabled by setting digital
input disable local.
When in remote control, the operational com-
mands and the reference value are transmitted to Remote control
the drive from a remote control station via fieldbus When the drive is in remote control mode, it is not
or remote I/O. possible to operate the drive locally and the ON/
OFF pushbuttons are disabled. The drive then only
Selecting local or remote operation accepts commands that arrive via the remote con-
Selecting the local control mode is possible if no trol interface.
remote request from the overriding control system
is present. The local control mode is entered by Emergency off
pushing the LOC/REM pushbutton on the control The local emergency-off pushbutton on the front
panel. An L on the panel display indicates local door of the control compartment is active in local
operation. In remote control, the L is not displayed and remote mode.
(see circle in 4-4). The letter R is indicated if the
control panel is used as a remote control place.

(See also Chapter 5 - 5.2 Local control hardware)

Local control
When the drive is in local control mode, it is possi-
ble to operate the drive locally by means the ON/
OFF pushbuttons on the drive front door and from
the control panel. In local control mode, the drive
does not accept any remote command.
It is also possible to block any local control of the
drive.

1 L 600.0 rpm 0 1 600.0 rpm 0 1 R 600.0 rpm 0

StateINU ReadyRun StateINU ReadyRun StateINU ReadyRun
MOTOR SP 0.00 rpm MOTOR SP 0.00 rpm MOTOR SP 0.00 rpm
POWER 0.0 kW POWER 0.0 kW POWER 0.0 kW

—
4-4
52 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

— 4.1.4.5 Start and stop sequences

References
— If all preconditions are fulfilled, it is possible to
4-5 Typical start start and stop the drive via the control panel, the
sequence
— ON/OFF pushbuttons on the drive front door or via
4-6 Typical stop sequence remote control (ON/OFF command).

Not ready on
Ready on conditions:
Auxiliary supply on (400 VAC)
AFE(DFE)-INU door
*AFE Ready on & closed and locked
Drive not grounded
No emergency off
Ready on No fault

On command

Charging

DC link charges
Fan switches on
MCB closes

*AFE Ready ref

Ready run

Start command

INU starts to modulate

Ready ref

*Drives with AFE Operation

—
4-5
 CHAPTER 4 – FUNCTIONAL DESCRIPTION, OPERATION 53

Operation

Ready ref

Stop command

Stopping

Speed ramps down

INU stops to modulate

Ready run

Off command
Stop command to *AFE

MCB opens

DC link discharges
Fan switches off
after a delay

*AFE Ready on

Ready on Actions:

Drive is grounded
AFE (DFE)-INU door
is released for opening
Auxiliary supply is switched off
(400 VAC)
Not ready on
*drives with AFE

—
4-6
54 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

4.1.4.6 Main circuit breaker control • If the drive applies a close command and the
The main circuit breaker (MCB) is a major protec- expected feedback signal does not arrive after
tion device of the drive. If a serious fault occurs in a preset time, the close command is reset and
the drive, the MCB disconnects the main power the MCB is tripped.
supply to the drive immediately to prevent hazard • If the open command from the drive to the MCB
to the personnel and further damage to the equip- is a maintained signal, it is reset after receiving
ment. Therefore the ACS2000 exclusively controls the open feedback signal from the switchgear.
and monitors the MCB. If the feedback signal does not arrive after a
preset time, a trip command to the MCB is
The feedback signals from the MCB upon a close or issued.
an open command from the drive are monitored.
These signals must have the correct status and Note: See always the Note on main circuit breaker
must arrive within a preset time at the drive: design when dimensioning the main circuit
breaker.
 CHAPTER 4 – FUNCTIONAL DESCRIPTION, OPERATION 55

—
4.2 Diagnostics

Diagnostic information can be obtained through the Control panel, the

Black box, the DriveWindow and the DriveDebug tool.

— Actual signal monitoring Data loggers

References
— The control panel allows displaying three signals The ACS2000 provides two data loggers. Each data
4-7 Signal display on simultaneously. The signals are selected from the logger monitors up to six different analog or
control panel
actual signals parameters. binary signals. Sample time and trigger level for
each signal can be adjusted independently.
Examples: The data loggers are set up and their content
• ACS2000 output frequency, current, voltage viewed either using the DriveWindow or DriveDe-
and power bug tool.
• Motor speed and torque • Digital I/O and analog I/O status
• DC-link voltage • PID controller actual values (if the PID control
• Active control location (Local / External 1 / macro is selected)
External 2)
• Reference values Fault logger
• ACS2000 ambient temperature In the event of an alarm or a fault in the ACS2000,
• Operation time counter (h), kWh counter or in the equipment monitored by the drive, a spe-
cific message can be saved in the fault logger.
Black box Information on the 64 most recent alarm and fault
The black box is an additional flash memory (PCB) events can be stored.
that saves fault events and data logs for analysis.
The content of the black box can only be down- The messages can be called up on local control
loaded via a software that is available for autho- panel of the ACS2000, or they can be viewed with
rized service personnel. one of the following PC-based tools: DriveWindow,
See Chapter 5 - Black box for further information. DriveDebug or DriveMonitorTM.

Information
The drive software version and serial number can
be displayed on the control panel.

1 600.0 rpm 0
StateINU ReadyRun
MOTOR SP 0.00 rpm
POWER 0.0 kW

—
4-7
56 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
4.3 Protection

Human life and property are protected from dangerous electric arcs
with the ACS2000’s arc resistant design. Certified functional safety
features and an integrated DC grounding switch make the system safe
and reliable.

4.3.1 Alarms and faults when the first fault of the fault class is active.
The control system continuously monitors all rele- Date and time stamps facilitate fault tracing,
vant system variables. Preprogrammed protection especially when a fault leads to several subse-
functions ensure that these variables remain quent faults.
within certain limits to maintain safe operation of
the drive. These internal functions are predefined 4.3.2 Internal protection functions
and the user cannot change them. Optionally, the Air cooling
drive supports the processing of standard and cus- Air pressure switches monitor the pressure drop
tomer-specific fault signals from external equip- across the phase modules. Additionally, the air
ment. These signals are activated and adjusted flow through the DTL filter compartment and
with parameters. transformer compartment (if present) is moni-
tored.
If an alarm or fault condition occurs in the drive or Separate air pressure switches monitor clogging
related equipment, a message displays on the con- of the filter mats and alert the operator.
trol panel or, as an alternative, in DriveWindow, Dri-
veDebug or DriveMonitor. Cabinet temperature
The temperature inside the drive is measured and
The drive knows two error types: monitored. The drive shuts down when the tem-
• Alarm (Warning) perature exceeds a preset level.
An alarm does not shut down the drive. If an
alarm condition is not corrected in due time Charging fault
however, this can lead to a fault. The intermediate DC-link voltage is monitored
• Fault while the DC link is energized. The drive shuts
A fault always shuts down the drive. The type of down when the voltage does not reach the desired
shutdown depends on the origin of the fault. level after a preset time.
Depending on the type of fault, the main circuit
breaker (MCB) is opened or stays closed: Communication
- Class 1 faults (FC 1) open the MCB. The DDCS communication links of the ACS2000 are
- Class 2 faults (FC 2) do not open the MCB. monitored. The drive shuts down when a link is
interrupted.
Since the MCB is controlled and monitored
entirely by the drive, no external opening com- Ground fault
mand must be given to the MCB when a fault The drive constantly measures the voltage
condition occurs. between the DC link neutral point and the ground
and analyses the voltage harmonics. Using this
In general, a fault condition must be corrected technique, ground faults inside and outside the
and the fault be manually reset before the drive drive can be detected fast and reliably.
can be started again. Additionally, the resultant output currents are
monitored which allows a fast reaction if there is a
The faults are entered into the Fault logger as low-impedance ground fault in the motor (for
they occur and are numbered; the last fault example, a winding insulation failure).
entered always has number 1 assigned to it, and
the first fault always has the highest number in
the fault logger. Information of the fault classi-
fication (for example, FC 1 or FC 2) is also saved
CHAPTER 4 – FUNCTIONAL DESCRIPTION, OPERATION 57

Limit values Overspeed

User selectable values can be monitored for low The motor speed as determined by DTC is moni-
and high limits, for example: tored. The drive shuts down when the motor speed
• Speed value exceeds the maximum user-adjustable limit.
• Current value
• Torque value Overvoltage
• Reference value The positive and negative DC-link voltage is moni-
• Actual value of the PID controller tored for overvoltage.
The limit values are adjustable. The digital status Reason for DC-link overvoltage is typically a feed-
of the active limit appears on the control panel dis- ing network overvoltage. For ACS2000 AFE, this
play and can also be allocated to a digital output. case may occur while braking with a weak network
supplying the drive.
Motor overload The drive shuts down when the voltage exceeds
The 3-phase RMS value of the motor current is the limit value.
monitored and compared with three adjustable
thresholds. A pickup delay for each threshold can Undervoltage
also be set. The drive shuts down when an overload An undervoltage condition occurs when the main
is detected. power supply is lost. The loss of the power supply
Motor phase loss is detected by monitoring the positive and nega-
The phase loss function monitors the status of the tive DC-link voltage. An alarm is initiated and the
motor cable connections. If any of the motor Power loss ride-through is activated (if selected)
phases is not connected, the ACS2000 refuses to when the voltages drop below 70% of their nomi-
start. nal values. The drive shuts down when the voltages
The phase loss function also monitors the motor drop below 65% of their nominal values.
connection status during normal operation. The
motor frequency must be above a minimum level in Short-circuit in the rectifier bridge (only ACS2000
order for this feature to function. The drive shuts DFE)
down when a motor phase is lost. A short-circuit in the rectifier bridge is detected by
monitoring the DC-link voltage. The drive shuts
Motor stall down and the main circuit breaker opens when a
The stall function can be enabled or disabled. The short-circuit is detected.
limits for the stall frequency (speed) and the stall
time are adjustable. The reaction of the ACS2000 Supply phase loss
(alarm or fault) can be selected. The voltage ripple in the DC link is an indication for
a supply phase loss. The drive shuts down when
Torque the ripple rises above a preset level.

Stall region
Tm.a Short-circuit and overcurrent
The inverter phase currents are monitored for this
purpose. This protection is implemented in soft-
ware and hardware. The drive shuts down when
Stall f (Hz)
frequency the preset limit is exceeded.
If selected, the motor stall function is activated
when all of the following conditions are fulfilled:
• The output frequency is below the set stall fre-
quency.
• The actual torque exceeds the stall torque limit.
• The frequency and torque levels of the two pre-
vious conditions have been present for a period
longer than the set stall time.

Motor winding and bearing temperature

The ACS2000 provides inputs for PT100 measuring
devices motor winding and bearing temperature
supervision.
Values for alarm and pick-up values can be set.
58 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

— 4.3.3 Hardware-based protection functions Process stop

References
— Input fuses A process stop button or relay can be connected to
4-8 Input fuses Input fuses in the terminal compartment protect a predefined input of the ACS2000. The actual pro-
the DTL and AFE versions of the ACS2000 against cess stop input must be closed during normal
short-circuit currents from the main power supply. operation. When the digital input opens, the con-
In the DTL versions, the fuses are required for pro- trol system initiates a stop command. The stop
tection because there is no current limiting trans- mode (ramp stop, stop at torque limit, or coast
former impedance if a short-circuit occurs. stop) is selected with a parameter. The main circuit
In the AFE versions, the fuses allow break times of breaker is opened when the motor has come to a
the main circuit breaker as defined in the Note on stop.
main circuit breaker design. Without the fuses, the
break time of the main circuit breaker would have Transformer protection relay
to be shorter. The fuses also allow the use of fused The normally closed (NC) contact of the external
contactors instead of a main circuit breaker protection relay is connected to the Tripping loop
upstream of the input transformer. terminals of the ACS2000. When the contact
opens, the main circuit breaker opens.
External emergency off
The normally closed (NC) contacts of external Tripping loop
emergency-off pushbutton can be connected to The ACS2000 is equipped with a hard-wired trip-
the Tripping loop of the drive. ping loop. Normally closed contacts from external
protection devices (for example, transformer pro-
Motor protection relay tection relay) can be connected to the loop. When
The normally closed (NC) contact of the external the loop is opened, the main circuit breaker is
protection relay is connected to the Tripping loop tripped directly either via the tripping or the open-
terminals of the ACS2000. When the contact ing coil.
opens, the main circuit breaker opens.

Example: ACS2000 1MVA AFE

—
4-8
Chapter 5
Control system and process
interfaces

60 Control system

61 AMC circuit board

63 Local control hardware

63 Control panel

64 Control panel

65 Process interfaces

65 IOEC modules

66 Options
60 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
5.1 Control system

The drive control system is based on ABB's proven ACS frequency

converter control platform.

— The control system incorporates the hardware for The control system is configured, customized, and
References
— the control, monitoring and protection of the drive, tuned with a set of application parameters. The
5-1 Typical configuration the communication interfaces to the local control application parameters are organized in functional
of control system
panel (see 5-3), and to remote control hardware. groups and have factory-set default values. The
Depending on the control concept of the drive sys- default parameter values are adjusted during com-
tem, the remote control hardware include a higher- missioning to the specific application of the drive
level control system and/or remote operator sta- to activate the specific control, monitoring and
tions. protection functions for the driven process, and to
define the signals and data to be transferred
between drive and external equipment.

DriveWare®DriveMonitor®

Higher-level External
control system devices

Control panel
DDCS
DDCS

*Fieldbus IOEC
RS485

adapter I/O modules

DDCS

AFE INU
AMC circuit board AMC circuit board
DDCS

PPCS PPCS PPCS *Pulse

encoder

AFE INU
INT circuit board INT circuit board

PPCS PPCS PPCS PPCS PPCS PPCS

Phase INT Phase INT Phase INT Phase INT Phase INT Phase INT
circuit board circuit board circuit board circuit board circuit board circuit board

Phase module Phase module Phase module Phase module Phase module Phase module

AFE ACS2000 INU

with DFE *Option

ACS2000 with AFE

—
5-1
 CHAPTER 5 – CONTROL SYSTEM AND PROCESS INTERFACES 61

— 5.1.1 AMC circuit board General control tasks

References
— The AMC circuit board is the major component of Each AMC circuit board has specific control and
5-2 Location of AMC the drive control system and performs general closed-loop tasks assigned to it.
circuit boards
drive, motor control, and closed loop functions. • The AMC circuit board of the active front end
The main internal control hardware and the periph- (AFE) handles all rectifier and line-related func-
eral input and output interfaces to the customer tions of the drive.
communicate with the AMC circuit board via opti- • The AMC circuit board of the inverter (INU) pro-
cal fibers. cesses drive and status information, performs
the speed and torque control tasks, and moni-
The circuit board is fitted with a Motorola DSP pro- tors the operation of the drive.
cessor and features two PPCS and eight DDCS All relevant drive variables (for example, speed,
communication channels. The communication torque, current, voltage) are continuously moni-
channels are used for high-speed data transfer via tored by the control system. Pre-programmed
the INT circuit boards to the Phase INT circuit protection functions ensure that these vari-
boards inside the phase modules (see 5-1). ables remain within certain limits to maintain
Active front end (AFE) and inverter (INU) have their safe operation of the drive. These internal func-
own AMC circuit board. tions are not programmable by the user.
Drives with diode front end (DFE) have only one Optionally, the drive offers monitoring of sig-
AMC circuit board. nals from external equipment. These can be
activated and adjusted by parameter settings.
Legend Other general control, protection and monitor-
1. AMC and main INTerface circuit board of the ing tasks regarding the whole drive include con-
INU trol and monitoring of:
2. AMC and main INTerface circuit board of the - Main circuit breaker (MCB)
AFE - Grounding switch
3. INTerface circuit board - Door interlocking system
4. AMC circuit board - Cooling system
5. Flash memory PCB These tasks are implemented in the AMC circuit
board of the INU.
Black box
The AMC circuit board is equipped with an addi- Speed and torque control
tional flash memory PCB (see 5 in 5-5). The PCB The speed and torque of the motor is controlled by
serves as a black box which saves data and fault DTC (Direct Torque Control). DTC is implemented
loggers of the drive for a longer time even if the in the AMC circuit board of the inverter (INU). See
auxiliary power supply has been switched off. Chapter 4 - 4.1.1 Direct Torque Control (DTC) for
detailed information on DTC.

1
4

3
5

2*

* only drives with AFE

—
5-2
62 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

Peripheral I/O modules - DriveWare® software tools

The peripheral input and output devices connected
DriveWare® includes software tools such as
to the AMC circuit board of the INU include:
the commissioning and maintenance tools
• Local control panel
DriveWindow and DriveDebug, and
The AMC circuit board communicates with the
DriveOPC for data transfer between ABB
control panel via an RS-485 link. For further
drives and Windows®-based applications.
information, see section 5.2.2 Control panel.
• I/O modules for parallel signal transfer to exter- - DriveMonitorTM (Option)
nal devices DriveMonitorTM is a monitoring and diag-
• Optional fieldbus adapters for serial data trans- nostics tool that allows access to the drive
fer to a higher-level control system from any location in the world via a secure
• PC-based service tools comprising: Internet connection.
 CHAPTER 5 – CONTROL SYSTEM AND PROCESS INTERFACES 63

—
5.2 Local control hardware

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.

—
References
5.2.1 Control panel • Resets alarm and fault mes-
— — sages
5-3 Local control
hardware Control panel
• Starts and stops the motor
• Displays status messages of
the drive
• Displays alarm and fault mes-
ages

Legend
1. Control panel
2. Main supply on and off pushbuttons
1 3. Alarm-fault lamp
4. Grounding switch unlocked pushbutton
5. Emergency reset pushbutton (option)
6. Emergency off pushbutton

2 2

3 4

—
5-3
64 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

— 5.2.2 Control panel

References
— Features
5-4 Control panel The key features of the control panel include:
• 4-line display
• User-selectable display of actual values
• Fault memory to support maintenance

Functions
The control panel allows the operator:
• to enter startup data into the drive,
• to control the drive by setting reference values
and by giving start, stop and direction com-
mands,
• to display three actual values at a time,
• to display and set parameters,
• to display information on the last 64 fault
events.

Legend
1. Display
2. Keypad
3. Mode selection keys
4. Fast navigation keys, select and/or change a value fast
5. Slow navigation keys, select and/or change a value slowly
6. Enter key, terminates a procedure
7. Local or remote selection key
1 L -> 1242,0 rpm I
8. Reset key
MotCurr 76.00 A 1 9. Reference key
MotSpeed 1242.0 rpm 10. Start key
Torque 86.00 % 11. Forward key
12. Reverse key
13. Stop key
2

4 5 6

9
7 10
8
13
11 12

—
5-4
 CHAPTER 5 – CONTROL SYSTEM AND PROCESS INTERFACES 65

—
5.3 Process interfaces

Analog and binary I/O signals internal and external to the drive are
connected to the control system by IOEC modules.

— 5.3.1 IOEC modules The standard I/O includes one module for control
References
— Location and monitoring functions of the drive (IOEC 1), and
5-5 IOEC module The DIN rail-mounted IOEC modules are installed in one module (IOEC 2) for external signals.
—
5-6 IOEC I/O system the control compartment of the drive. The drive can include the optional IOEC modules 3
and 4 depending on the hardware options of the
Standard/optional modules drive. IOEC 3 is used to monitor optional redun-
The standard I/O includes one module for control dant fan units, the air flow through the cabinet and
and monitoring functions of the drive (IOEC 1), and redundant power supply units of the drive. IOEC 4
one module (IOEC 2) for external signals. includes freely programmable digital and analog
The drive can include the optional IOEC modules 3 inputs and outputs.
and 4 depending on the hardware options of the
drive. IOEC 3 is used to monitor optional redun-
dant fan units, the air flow through the cabinet and
redundant power supply units of the drive. IOEC 4
includes freely programmable digital and analog
inputs and outputs.

Digital outputs Digital intputs Analog

in/outputs
—
5-5

INU
AMC circuit board

IOEC 1 IOEC 2 IOEC 3 IOEC 4

Standard Standard Option Option

—
5-6
66 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

Analog inputs 24 V internal voltage supply

One isolated DC/DC converter supplies an over-
No. of inputs 4 load-protected voltage of 24 VDC (max. output cur-
Signal interface Floating, galvanically isolated rent: 180 mA) to operate digital inputs from
Signal level 0 - 20 mA, 4 - 20 mA, 0 - 10 V, 2 - 10 V passive contacts. The output is protected by a PTC
Individually scalable by parameter resistor against short-circuit and external overvolt-
Resolution 10 bit ages.
Isolation level 350 V (AC)
5.3.2 Options
Each analog input can be adapted individually to See Chapter 6 - Options for the following customer
the type and range of the connected input signal: interfaces:
• Signal type: voltage or current (selectable by • Fieldbus communication interfaces
DIP switches) • Pulse encoder interface
• Signal inversion: if a signal is inverted, the maxi- • Motor temperature monitoring interfaces
mum input level corresponds to the minimum
signal value and vice versa
• Minimum level: 0 mA (0 V), 4 mA (2 V) or by
input tuning function (actual input value is read
and set as minimum)
• Maximum level: 20 mA (10 V) or by input tuning
function (actual input value is read and set as
maximum)
• Signal filter time constant: adjustable between
0.01 to 10 s.
The offset of the analog inputs can be calibrated
automatically or manually.

Analog outputs

No. of I/O 2
Signal range 0 - 20 mA (load impedance: max. 250 Ω)
Resolution 12 bit
Isolation level 350 V (AC)

Digital inputs

No. of I/O 14
Signal level 22 - 150 V (DC), 22 - 250 V (AC)
Logical thresholds < 13 V (AC or DC) ≙ "0", > 16 V (AC or DC)

≙ "1"
Input current 13 mA steady state (14 mA max. inrush)
at 24 V (DC)
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)
Isolation level 1350 V (AC)

Digital outputs

No. of I/O 6
Signal level Maximum: 120 V (DC) or 250 V (AC)
Isolation level 4000 V (AC)
Chapter 6
Options

68 Cabinet

68 Power cable entry plates

69 Control cable entry plates

69 Top cable entry

69 Space Heater

70 Redundant cooling

71 Auxiliary and control supply

72 Control interfaces

72 Pulse encoder

72 Fieldbus adapter modules

73 Manual Emergency Shutdown

74 Output filter options

76 DriveMonitor

77 Internal arc protection

68 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
6.1 Cabinet

The chapter provides an overview of the main options available for the
ACS2000. A complete list of all available options is provided in the
Typecode document of the ACS2000.

Degree of protection 6.1.1 Power cable entry plates

Option: IP 42 Undrilled aluminum plate
Standard: See section 3.7.4 Degree of protection The plate is provided for the use of cable glands.
The aluminum plate has a thickness of 5 mm.
Cabinet color All material for cable entry, EMC requirements and
RAL colors and paint thicknesses other than the degree of protection are provided by the cus-
standard must be specified when ordering the tomer.
drive.
Roxtec frame
— Cabinet paint finish The system seals the cable transits of the drive
References
— Option: the entire cabinet exterior is available with against electromagnetic disturbances and pro-
6-1 Cable gland painted surfaces. vides the required degree of protection.
—
6-2 Power cable entry Standard: See section 3.7.5 Safety labels
with Roxtec sealing The cable entry assembly for the power cables con-
system
sists of a galvanized entry frame. The frame holds
the adaptable EMC sealing modules. The modules
can be adapted to the cable diameter, simply by
peeling off the concentric layers of the module.
Compression wedges ensure that the conductive
foil of the sealing modules tightly enclose the cable
armor or shield in the area of the cable transit.
The sealing modules and installation accessories
are not part of the delivery.

—
6-1

Legend
1. Sealing module
4 5 2. Removable layers to adapt the sealing module
1 to the cable diameter
3. Conductive foil
6 4. Frame
2 5. Compression wedge
6. Sealing module

—
6-2
 CHAPTER 6 – OPTIONS 69

— 6.1.2 Control cable entry plates 6.1.4 Space Heater

References
— EMC entry plates Space heater
6-3 EMC entry plates with EMC entry plates (1) with conductive cushions (2) Indicated for environments with high humidity
conductive cushions
— rate. When the drive is not in operation, the space
6-4 Roxtec frame with Roxtec frame heater heats the whole interior to reduce conden-
sealing modules for
control cables Roxtec frame with Roxtec sealing modules sation.
—
6-5 Top cable entry
6.1.3 Top cable entry Motor space heater control and protection
The drive can optionally be equipped with a power
supply and on/off control for a motor space
heater.This power supply is protected for a current
rating between 2 and 10 A; the voltage is any
between 110 and 240V.

—
6-3

—
6-4

—
6-5
70 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

— 6.1.5 Redundant cooling

References
— All ACS2000 types and integrated transformers
6-6 ACS2000 DFE 4MVA, can be equipped with a redundant fan to ensure
redundant fan
configuration that the operation of the drive system is not inter-
rupted if a fan fails.

—
6-6
 CHAPTER 6 – OPTIONS 71

—
6.2 Auxiliary and control supply

The ACS2000 drive uses auxiliary power for the cooling system, the
charging unit and the control hardware.

Auxiliary supply voltage

440 - 480 VAC, +/- 10%, 3-phase supply, 50 - 60 Hz

Auxiliary supply type

Double 3-phase power supply with automatic swi-
tchover

Single-phase control supply

The following two options are available:
• No externally supplied single-phase control
(supply via 3-phase power supply)
• Customer supplied UPS, double 1-phase power
supply
(2 x single-phase 110 - 240 VAC, 50 - 60 Hz, 90 -
220 VDC)

Power supply
Redundant 24 V power supplies

Control power ride-through

15 minutes control ride-through with an additional
battery.
72 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
6.3 Control interfaces

The ACS2000 can be fitted with all major fieldbus adapters for smooth
integration and controlling of different processes.

— 6.3.1 Pulse encoder 6.3.2 Fieldbus adapter modules

References
— A pulse encoder interface module is available for The following fieldbus adapter modules are avail-
6-7 AF 100 Fieldbus and motor speed feedback. able:
Modbus RTU
— A pulse encoder is advantageous in applications
6-8 Modbus TCP and where the flying start function is used. The actual Temperature monitoring
Profibus DP / FMS
frequency of the rotating motor can be detected The option "temperature monitoring" offers ana-
faster and rapid starting of the drive can be log inputs on the IOEC modules 1, 2 and 4 to moni-
achieved. It is also recommended if a highly accu- tor the motor and transformer winding
rate readout of the speed is required. temperatures.
Another application for a pulse encoder would be The temperature sensors have a 2, 3 and 4-wire
for motors running at speeds below 30 Hz for lon- configuration and are connected to the tempera-
ger periods. ture transducers in the drive.

The requirements for a pulse encoder are as fol- Control I/O expansion
lows: The option includes freely programmable I/Os (DI,
• Supply voltage 12 VDC or 24 VDC (supplied by DO, AO) on IOEC module 2 and 4.
the module)
• Single-ended or differential connection can be Spare terminals
used The option includes 30 non-wired terminals.
• Available signal channels: A, A inverted, B (90°
electric phase shift to A), B inverted (Z (zero MCB interposing relay
channel), Z inverted - optional) The interposing relays enable the high-power cir-
• The encoder should provide 2n pulses/revolu- cuit of the main circuit breaker to be switched by a
tion. The recommended pulse train is 2048 low-power control signal from the IOEC module.
pulses/revolution. Maximum signal frequency The option "MCB interposing relay" also includes a
should not exceed 100 kHz. power supply that provides the control voltage for
The module is fed from the internal control power the tripping loop of the drive.
supply of the drive.

Legend
Legend 1 Modbus TCP
1 AF 100 Fieldbus 2 Profibus DP/FMS
2 Modbus RTU

1 2 11 2
2

— —
6-7 6-8
 CHAPTER 6 – OPTIONS 73

Safety relay Emergency Stop

The safety relay is wired into the tripping loop and Emergency stop (Emergency stop category 1
monitors the hard-wired emergency-off circuit of according to IEC 60204-1) fulfills the safety/perfor-
the drive. The relay complies with the following mance levels SIL3 and PLe.
standards: The Emergency Stop function ramps down the
• IEC/EN 61508, Safety Integrity Level (SIL 3) speed of the motor before it automatically initi-
• IEC/EN 62061, SIL Claimed Level (SIL CL) 3 ates an Emergency Off command to open the MCB.
The additional Emergency Reset button on the
control door serves to reset the relay.

6.3.3 Manual Emergency Shutdown

Emergency Off
Emergency off (Emergency stop category 0
according to IEC 60204-1) fulfills the safety/perfor-
mance levels SIL3 and PLe.
The Emergency Off function immediately opens
the MCB (Main Circuit Breaker).
The Emergency Off function can be enabled from
several independent sources
- Emergency Off push button on the door of the
COU
- External Emergency Off signals from the process
- Other safety functions, for example the Emer-
gency Stop function, if applicable.

1 Emergency reset button

—
6-7
74 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
6.4 Output filter options

Depending on the motor type, cable length and application, several

output filter options are available.

—
Table 6-1 Output fiter options

Drive Filter Extended Motor cable Transformer Area classificationc Comments

Configuration Topology functionality length cable lengthb
DTL Floating EMC None < 300 m n/a 6kV: Safe Area; Motor cable length up to 600m
filter 4kV: Zone 2 possible with Cplusd
AFE Floating EMC None < 300 m < 300 m Safe Area Motor cable length up to 600m
filter possible with Cplusd
Grounded EMC None < 300 m < 30 m Zone 2 Motor cable length up to 600m
filter possible with Cplusd
AFEi Grounded EMC None < 300 m n/a Zone 2 Motor cable length up to 600m
filter possible with Cplusd
DFE/DFEi Grounded EMC None < 300 m < 30 m Zone 2 Transformer cable <100 m for
filter Safe Area
Grounded sine None < 5'000 m < 30 m Zone 1 Standard sine filter configuration
filter Transformer cable <100 m for
Safe Area
Output voltage < 20'000 m < 30 m Zone 1 Suitable for long motor cable
boosting up to 7.5 kVa lengths
Transformer cable <100 m for
Safe Area
Output voltage above >20'000 m < 30 m Zone 1 Suitable for long motor cable
7.5kV by step-up length
transformer Transformer cable <100 m for
Safe Area
Floating sine Operation under < 5'000 m < 100 m Safe Area Suitable for operation under
filter single ground fault single ground fault
Operation under < 20'000 m < 100 m Safe Area Suitable for long motor cable
single ground fault & lengths and operation under
output voltage single ground fault.
boosting up to 7.5 kVa Above 6.9kV with Cplus.

Operation under >20'000 m < 100 m Safe Area Suitable for operation under
single ground fault & single ground fault
output voltage above Above 6.9kV with Cplus.
7.5kV by step-up
transformer
Ground current < 5'000 m < 100 m Safe Area Suitable for underground mining
monitoring applications

a. Only available for 6kV voltage class. rent harmonics less than 5 % at middle speed
b. Not applicable for integrated transformer range, and less than 2 % at rated speed). Motor
or direct-to-line configuration. voltage dv/dt approximately 5 V/us.
c. Guideline for compatibility with motors
installed in hazardous locations. Output voltage boosting
d. Depending on cable and motor type. The output voltage can be boosted up to 7.5kV
(available as engineered option). In this case, the
Output power quality output frequency is limited to 69 Hz.
EMC filter: Motor current THD less than 5 %. Motor
voltage dv/dt less than 500 V/us .
Sine filter: Motor current THD less than 5 % (cur-
CHAPTER 6 – OPTIONS 75

Output voltage boosting with step-up Underground mining applications

transformer Floating sine filter with filter capacitor star point
The output voltage can be boosted above 7.5kV connected to NP with RC and ground current moni-
with a step-up transformer (available as engi- toring is suitable for underground mining applica-
neered option). tions.
Example: with 6kV/20kV step up and 20kV/6kV
step down transformer. EX-proof motor
For more details about ABB ex-proof motors, see
Increased output frequency 3AAM100250 in the ABB library. For non-ABB
The ACS2000 with sine filter can be ordered with motors: The motor supplier always has to approve
an increased output frequency of 82.5 Hz as a max- the converter operation of an ex-proof motor. To
imum (engineered option). To achieve this, the out- avoid problems with non-ABB motors, select a sine
put voltage cannot be higher than 6.3 kV. filter.
In case a motor temperature supervision is needed
ESP applications in an EX application, “PT 100 (hazardous)” has to
Floating sine filter with filter capacitor star point be chosen.
connected to PE with capacitors is suitable for ESP
applications.
76 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
6.5 DriveMonitor

DriveMonitor is an option enabling real-time access to the diagnostic

data of the drive. DriveMonitor allows monitoring of up to 9 drives and
provides an Ethernet port to an external PC, to the Intranet of the
customer or the internet. The internet connection enables service
engineers to monitor the performance of the drive remotely.

— DriveMonitor provides the following functions:

References
— • Acquisition of all available drive data to prevent
6-9 DriveMonitor data loss in the event of a drive failure
—
6-10 DriveMonitor • Fault and alarm notification with causes and
touchscreen hints for rectification
• Automatic reporting on predefined templates
• Automatic recording of parameter changes
• Tracking of operational conditions
• Long-term data logging for monitoring of com-
ponent lifetime
• Remote diagnostics according to the service
and support-line contracts

The available DriveMonitor hardware solutions are:

• Integrated DriveMonitor without screen
• External wall-mounted touchscreen

! See DriveMonitor user’s manual for fur-

ther information.

— —
6-9 6-10
 CHAPTER 6 – OPTIONS 77

—
6.6 Internal arc protection
Arc Guard
The Arc Guard protects the drive against arcs caused by short-
circuitsinside the cabinet.

This option includes the following solutions:

- Reinforced cabinet doors
- Arc Guard System™ for arc fault detection

The Arc Guard System™ consists of optical sen-

sors, installed throughout the drive lineup and con-
nected to the arc monitor device. The sensors
respond to the light caused by an arc inside the
cabinet.

On detection of an arc, the drive performs protec-

tion firing and immediately opens the main circuit
breaker to disconnect the drive from the main
power supply.
78 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D
Chapter 7
Installation

80 Transportation

81 Ambient conditions

82 Installation site requirements

83 Cable entry for auxiliary and control cables

84 Power cable entry

85 Grounding of the drive system

80 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
7.1 Transportation

The drive is shipped in one unit. The fans and the integrated
transformer of the drive are always shipped separately.

See Chapter 3 - 3.7.9 Lifting arrangements for

information on transport units and lifting arrange-
ments.
 CHAPTER 7 – INSTALLATION 81

—
7.2 Ambient conditions

Ambient conditions may require to derate the drive due to the altitude
or the presence of increased ambient temperature.

Sufficient air flow must be available. Other ambi-

ent factors such as relative humidity, air pollution,
shock and vibration must also be in compliance
with the stated maximum permitted levels.

High ambient Temperature

Above 40 °C ambient temperature the converter
output power must be de-rated by 1.5 % per 1 °C .
The maximum allowed temperature with this de-
rating rule is 50 °C.
The necessary considerations and modifications
are handled as an engineered option. The capabili-
ties depend in this case also on parameters like
installation altitude, temperature cycle profile,
application and others and need to be carefully
checked.

Installation altitude
Up to 3000 m (9843 ft).
At locations 2000 m (6600 ft) above sea level, the
reduction of the rated converter output current by
1% per additional 100 m (330 ft) must be
accounted for. Possibly, a converter with a higher
output power must be selected.
82 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
7.3 Installation site requirements

Specific site requirements for the installation of the drive such as floor
levelling, cable ducts and ventilation are presented below.

Foundation floor leveling

The floor must be of non-flammable material, with
smooth and non-abrasive surface, protected
against humidity diffusion, leveled and able to sup-
port the weight of the drive.
The maximum recommended overall unevenness is
≤ 5 mm per 5 m.

Dimensions clearances

! See Outline drawings for information on

cabinet dimensions, position of floor fix-
ing holes and clearances.

Cable ducts
Cable ducts should be of non-flammable material
with non-abrasive surface.
All cable entries and exits should be protected to
prevent dust, humidity and animals entering the
drive.

Ventilation
Besides the main cooling air flow, part of the heat
losses is dissipated into the air. For this reason,
the installation site must be ventilated to fulfill the
requirements for ambient conditions. The heat
losses into the air depend on the power rating of
the drive.

Safety aspects
Suitable fire protection measures should be
applied to prevent fire spreading into the drive.
Sufficient illumination of the electrical room must
be planned for safety reasons.
Local safety regulations must always be consid-
ered (for example, door locks for electrical room).
 CHAPTER 7 – INSTALLATION 83

—
7.4 Cable entry for auxiliary and
control cables

The drive is prepared in the factory for bottom or top (option) cable
entry, with one of the following cable entries:

• Undrilled entry plate (standard)

The plate is provided for the use of cable glands
(see also Chapter 6 - 6-1). The aluminum plate
has a thickness of 5 mm.
All material for cable entry, EMC requirements
and degree of protection are provided by the
customer.
• EMC entry plate with conductive cushions
(option)
• Roxtec cable transit (option)

See Chapter 6 - 6.1.2 Control cable entry plates for

information on the options.
84 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
7.5 Power cable entry

The drive is prepared in the factory for bottom or top (optional) cable
entry, with one of the following cables entries:

— • Undrilled entry plate (standard) The entry holes are equipped with net-like sleeves
References
— • EMC entry plate (option) for EMC protection (1 in 7-3) and rubber grommets
7-1 ACS2000 AFE 1 MVA, • Roxtec frame (option) (2 in 7-3) for sealing.
EMC entry plates, bottom
cable entry
— ! See Chapter 6 - 6.1 Cabinet, Power cable
7-2 ACS2000 AFE 2 MVA, entry plates for information on power
EMC entry plates, bottom
cable entry cable entry with Roxtec frame or with an
— undrilled entry plate.
7-3 EMC entry plate
(bottom cable entry)
EMC entry plates
The entry plate for ground cable, feeder and motor
cables (1 in 7-1 and 7-2) is made of 1.5 mm thick gal-
vanized sheet metal.

—
7-1

1 2

— —
7-2 7-3
 CHAPTER 7 – INSTALLATION 85

—
7.6 Grounding of the drive system

The grounding system of the ACS2000 AFE and DFE are presented in
this section.

— ACS2000 AFE The principal grounding of the drive system is

References
— The drive is equipped with a ground (or Protective shown in the following illustrations:
7-4 Drive system with Earth, PE) busbar that is located in the terminal • 7-4 Drive system with non-integrated trans-
non-integrated
transformer compartment of the drive. The ground cable is con- former
nected to this ground busbar. The connection • 7-5 Drive system with integrated transformer
must be in compliance with local regulations.

Legend
U1 V1 W1 4 1 Input transformer
1 2 Drive

3 Motor

U2 V2 W2 PE 4 Earth electrode

1 2 3
5 5 Ground cable

6 Cable screen
6
7 Cable shield
7 8 Equipotential bonding conductor

8
1 2 3

U1 V1 W1 PE

2
ACS2000 4

U2 V2 W2 PE
5
1 2 3

6
7

8
1 2 3
5
U V W PE

3 M
4
—
7-4
86 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

— ACS2000 DFE
References
— ACS2000 DFE drive also feature a FE (Functional
7-5 Drive system with Earth) busbar.
integrated transformer

Cable shields and cable armor are connected to the

FE (Functional Earth) busbar inside the drive. The
ground cable is connected to the PE (Protective
Earth) busbar of the drive.

Legend
U1 V1 W1 4 1 Input transformer

2 Drive
1
3 Motor

4 Earth electrode

5 Ground cable

6 Cable screen
2 7 Cable shield

8 Equipotential bonding conductor

ACS2000 4

U2 V2 W2 PE
5
1 2 3

6
7

1 2 3

U V W PE
5
3 M
4
—
7-5
Chapter 8
Product life cycle management

88 Product life cycle model

89 Service offering

90 Product design lifetime

90 Preventive maintenance
88 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
8.1 Product life cycle model

The ABB life cycle management model is designed to manage an

orderly transition to new replacement products or to choose from
various lifetime extending services. At the same time, the model
ensures access to continuing support for our customers.

— The model divides a product’s life cycle into four continues to operate at its peak performance.
References
— phases: active, classic, limited and obsolete. Each
8-1 ABB life cycle phase has different implications for the enduser in Limited phase
management model
terms of services provided. In the limited phase the product development has
come to its end. Spare parts are available as long
Active phase as components and materials can be obtained.
The active phase starts when the drive is launched. Towards the end of the limited phase, services
In the active phase the end user benefits from dif- gradually become obsolete. In addition to the
ferent warranty options and other services such as annual life cycle status reviews, ABB issues a life
training and technical support including drive cycle phase change announcement, half a year
adjustment for optimum performance. Complete prior the product becoming obsolete. This is the
life cycle services from spare parts and preventive last opportunity to transfer to new technology
maintenance to retrofits and service contracts are before product services end.
also provided. The active phase ends when the vol-
ume production of the drive ceases. ABB issues an Obsolete phase
announcement of the life cycle phase change. The ABB drive is transferred to the obsolete phase
when it is no longer possible to provide services at
Classic phase reasonable cost, or when ABB can no longer sup-
ABB drive users continue to benefit from complete port the product technically, or the old technology
life cycle services throughout the classic phase. is not available. ABB will adequately inform about
The classic phase is closely aligned with ABB’s life cycle phase transition from active to classic
research and development work to provide con- phase prior to change.
tinuing support for drives while developing future
drive generations. In the classic phase new drive The ACS2000 drive is in the active phase according
hardware and software development may be to the ABB life cycle model outlined above, for more
required to provide the maintenance techniques information see the Product life cycle statement.
and upgrades needed to guarantee that the drive

—
8-1
 CHAPTER 8 – PRODUCT LIFE CYCLE MANAGEMENT 89

—
8.2 Service offering

ABB have the expertise and experience to help our customers to find
and implement the right service throughout the entire lifetime of their
drives.

— The ABB service portfolio consist of wide range of

References
— available service offerings from installation and
8-2 ABB service portfolio commissioning, to upgrades, maintenance etc.

For more information, see http://new.abb.com/

drives/services.

—
8-2
90 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
8.3 Product design lifetime

ABB medium voltage drives have a standard design life of 20 years.

The design life of the products can be extended to more than 40 years
through maintenances and upgrades.

8.4 Preventive maintenance

Drives are maintained according to detailed product specific

schedules (available in the respective product user manual). Regular
preventive maintenance actions allow to control maintenance costs
and to optimize life time performance.

The ABB maintenance schedule is based on ABB’s

extensive experience and know-how in manufac-
turing and maintaining drives is designed to pro-
vide guidance on recommended actions to ensure
reliable operations through predictive actions,
such as visual inspections and measurements and
preventive actions, such as replacements of com-
ponents based on operating hours of the equip-
ment.

For more information, see http://new.abb.com/

drives/services.
Chapter 9
System integration

92 Main circuit breaker

92 Input transformer selection

93 Drive selection and configuration

94 Motor selection

94 Selection criteria

95 Matching drive and motor

95 Retrofit

95 Torsional excitation

96 Selecting cables

96 Power cables

96 Control cables
92 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
9.1 Main circuit breaker

Information about the main circuit breaker can be obtained below.

! See Note on main circuit breaker for

information.

9.2 Input transformer selection

The ACS2000 drive can be configured with an integrated or an external

transformer.

! See ACS2000 main transformer specifica-

tion for information.
 CHAPTER 9 – SYSTEM INTEGRATION 93

—
9.3 Drive selection and
configuration

With the DriveSmart tool, ABB's sales engineers are able to configure
and dimension the drive, according to the customer’s application
specification.

Selection Configuration
In general, the drive is selected according to the The drive configuration depends on the following
rated motor power. The rated output current of factors:
the drive should be checked to ensure that it is • Required output power
higher than or equal to the rated motor current. • Configuration of the main power supply (input
If a motor with two, six or more poles is used, the transformer or direct-to-line connection)
nominal motor current usually increases as com- • Ability to recover energy (active or diode front
pared to a motor with fewer poles. end)

When determining the appropriate size of the drive

for a particular application, the following factors
need to be considered:
• Ambient temperature
• Temperature of the cooling media
• Altitude of the installation site
• Redundant cooling fan
94 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
9.4 Motor selection

ABB's patented multilevel topology provides full compatibility with the

common IEC motor voltages.

9.4.1 Selection criteria Special attention must be paid to the motor cool-
The motor is selected and sized as required by the ing in variable speed applications. If the motor is
driven load. Supplying an additional power margin self-ventilated, long-time operation at low speeds
to compensate for PWM operation is not required usually requires power derating to compensate for
with the drive due to its sinusoidal output wave- the reduced cooling.
form. After the motor has been selected, or if an
existing motor is used, the following parameters Depending on the mechanical configuration of the
are relevant to select the drive and the trans- motor, shaft, gearbox and load, critical speeds may
former: occur. If the critical speeds have to be avoided, the
• Load characteristic appropriate parameter settings must be made.
• Overloadability Special attention must be paid to variable speed
• Motor voltage applications using two-pole motors, since there is
• Number of motor poles usually a critical speed below its rated speed. For
• Shaft power (nominal) more information, see Chapter 4 - Critical speed.
• Shaft speed (nominal)
• Rated current (nominal) ! See also Technical requirement specifica-
• Motor efficiency tion, Motors for ACS2000 frequency con-
• Motor power factor verters.
 CHAPTER 9 – SYSTEM INTEGRATION 95

— 9.4.2 Matching drive and motor

References
—
9-1 Load capacity curves 9.4.3 Retrofit

! See Application note, Guide to select the

correct retrofit drive, for information on
selecting a suitable drive.

9.4.4 Torsional excitation

! See Application note, Air gap torque pul-

sation limits, for information.

T/TN
2.0
1.9 Legend
1.8 p: number of poles
1.7
T: load torque
1.6
1.5 TN: rated motor torque
1.4 n: speed
1.3
f: output frequency of the drive
1.2
1.1
Curve 2
1.0 Curve 1:
0.9 Typical continuous load curve of an
0.8
0.7
IEC34 self-ventilated motor, con-
0.6 trolled by the drive
Curve 1
0.5 Curve 2:
0.4
Load capacity of the drive. The drive
0.3
0.2 is rated for 100% continuous opera-
0.1 tion with rated current, and a short-
0.0
10 f (Hz)
term overload capacity of 110% of
0 20 30 40 50 60 70 80 90 100
p=2 the rated current for 1 min. every 10
0 600 1200 1800 2400 3000 3600 n (rpm)
min.
p=4
0 300 600 900 1200 1500 1800 2100 2400 n (rpm)
p=6
0 200 400 600 800 1000 1200 1400 1600 n (rpm)
p=8
0 150 300 450 600 750 900 1050 n (rpm)

Rated frequency and field weakening point for the motor are based on 50 Hz

—
9-1
96 ACS2000 TECHNICAL CATALOG 3BHS511343 ZAB E01 REV. D

—
9.5 Selecting cables

Cables are used for the connection of the power to the input
transformer, from the transformer to the converter and from the
converter to the motor.

9.5.1 Power cables

! See Power cable specification for infor-

mation on:
• Transformer primary cables
• Transformer secondary cables
• Motor cables

9.5.2 Control cables

! See Control cable specification for infor-

mation.
—
ABB Sp. z o.o.
Placydowska 27,
95-070 Aleksandrow Lodzki,
Poland

Phone: +1 479 648 5912

E-Mail: [email protected]

www.abb.com/drives

—
3BHS511343 ZAB E01 RevD

© Copyright 2018 ABB. All rights reserved.

The information in this manual is subject to change without
notice. This manual and parts thereof must not be
reproduced or copied, or disclosed to third parties, nor used
for any unauthorized purpose without written permission
from ABB Sp. z o.o., Medium Voltage Drives. The hardware
and software described in this manual is provided under a
license and may be used, copied, or disclosed only in
accordance with the terms of such license.