ACS 1000 Medium Voltage Drives: 315 - 5000 KW 400 - 6200 HP

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ABB
ACS 1000
Medium Voltage Drives
315 – 5000 kW
400 – 6200 hp
Commissioning Manual
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Document No.: 3HBS210669 ZAB E01 Rev.-

Issued 13-10-2006
ACS 1000 Commissioning Manual 3HBS210669 ZAB E01 Rev.- 1/64
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ABB
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ABB reserves all rights to this document, also in the event of patent issue
or registration of any other industrial property protection right. Misuse, in
particular duplication and forwarding to third parties, is not permitted. This
document has been checked with due care and attention. However,
should the user find any errors, these should be reported to ABB. ABB
aims to maintain the most modern standard, therefore, entries in this
manual may differ from the actual product.
2/64 3HBS210669 ZAB E01 Rev.- ACS 1000 Commissioning Manual
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ABB
Table of Contents
Chapter 1 - Overview .........................................................................................................5
1.1. Safety................................................................................................................................ 5
1.2. Scope of Commissioning .................................................................................................. 5
1.3. Reports ............................................................................................................................. 6
1.4. Related Documents and Parameter References .............................................................. 6
1.5. Tools ................................................................................................................................. 6
Chapter 2 - Precommissioning Check List ......................................................................7

2.1. Office Preparations ........................................................................................................... 7
2.2. Scope of Delivery.............................................................................................................. 8
2.3. Pre-Conditions for Commissioning ................................................................................... 8
Chapter 3 - Inspection of Installation .............................................................................11

3.1. MCB................................................................................................................................ 11
3.2. Transformer (ACS 1000i: N.A.)....................................................................................... 11
3.3. Converter Room ............................................................................................................. 12
3.4. Converter ........................................................................................................................ 13
3.5. Ground Connections....................................................................................................... 14
3.6. Motor...............................................................................................................................14
Chapter 4 - Safety ............................................................................................................15
Chapter 5 - Connecting Auxiliary Supply to the Converter ..........................................17

5.1. EPS Auxiliary Power Supply........................................................................................... 17
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5.2. Phoenix Auxiliary Power Supply ..................................................................................... 18

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5.3. Checking Of Auxiliary Backup Batteries ......................................................................... 21

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Chapter 6 - Commissioning of the Cooling System......................................................23

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6.1. Water-Cooled ACS 1000 ................................................................................................ 23

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6.1.1. Checking the Internal and External Cooling Circuits ...................................................... 23

6.1.2. Filling Up the Internal Cooling Circuit ............................................................................. 24
6.1.3. Functional Test of the Redundant Fan ........................................................................... 24
6.2. Air-Cooled ACS 1000 and ACS 1000i ............................................................................ 24
Chapter 7 - Insulation Resistance Measurements ........................................................27

7.1. Preparations ................................................................................................................... 27
7.2. External MCB.................................................................................................................. 27
7.3. Internal MCB (only ACS 1000i)....................................................................................... 28
7.4. Transformer .................................................................................................................... 28
7.5. Converter (Standard Air- and Water-Cooled ACS 1000)................................................ 30
7.6. Converter (ACS 1000i) ................................................................................................... 33
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Chapter 1 - Overview ABB

7.7. Motor...............................................................................................................................35
7.8. Power Cables..................................................................................................................36
Chapter 8 - Preparing the System.................................................................................. 37

8.1. MCB and Protection Relay..............................................................................................37
8.2. Transformer ....................................................................................................................37
8.3. Converter ........................................................................................................................38
8.3.1. Standard Hardware.........................................................................................................38
8.3.2. Optional Hardware ..........................................................................................................40
8.3.3. Customer Parameters.....................................................................................................40
8.3.4. Motor Parameters in Group 99 And 112 .........................................................................40
8.3.5. Testing of the MCB Control and the Tripping Loop.........................................................43
8.3.6. Testing of I/O’s................................................................................................................45
8.3.7. Testing of Fieldbus-Communication ...............................................................................45
8.4. Motor...............................................................................................................................45
Chapter 9 - Energizing, First Start and Load Test ........................................................ 47

9.1. Energizing the Converter ................................................................................................47
9.2. First Start ........................................................................................................................50
9.3. Load Test ........................................................................................................................51
9.4. Testing of Ride Through and Auto Restart Functions .....................................................51
9.4.1. Main Power Ride Through ..............................................................................................51
9.4.2. Auxiliary Power Ride Through ........................................................................................52
9.4.3. Auto Restart ....................................................................................................................53
Chapter 10 - Final Work ....................................................................................................

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10.1. Spare Parts .....................................................................................................................55
10.2. Customer Training ..........................................................................................................55
10.3. Parameter Backup ..........................................................................................................55
10.3.1. Saving Parameters and System Software using DriveWindow.......................................56
10.3.2. Saving Parameters and System Software using DriveDebug.........................................59
10.4. Customer Approval .........................................................................................................63
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10.5. Customer Documentation ...............................................................................................63

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10.6. Documentation and Back-up Copies for Supportline ......................................................63

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10.6.1. Supportline Contact Information .....................................................................................64

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ABB Chapter 1 - Overview
Chapter 1 - Overview
The purpose of the manual is to assist in commissioning the ACS 1000
frequency converter. It includes necessary instructions, practical hints and
references to related documentation to successfully commission the
converter and the related equipment as needed for the application.
NOTICE!
Commissioning of the converter may only be carried out by personnel
who have been certified at “expert” or “master” level by the Product
Responsible Unit.
1.1. Safety
The safety instructions in this manual, in the User’s Manual and the local
safety regulations must be observed to maintain safety to all those
involved in commissioning the drive system.
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Working on energized equipment can be a life hazard.

Mechanical forces, electric shock and burn can cause severe injuries or
death.
Safety related work practices must be followed at all times.
Take appropriate measures when working on the drive system.
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1.2. Scope of Commissioning

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Normally, the commissioning engineer is only responsible for the

converter. If agreed by contract, the commissioning engineer can take on
the commissioning of:
• Motor,
• Transformer,
• MCB,
• Protection relays,
• External devises (actuators, sensors etc.).
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Chapter 1 - Overview ABB

1.3. Reports
During commissioning, the Commissioning Report and the Field Service

Report and must be filled in. Templates of the documents are available on
the MV AC Drives Portal.
1.4. Related Documents and Parameter References
The following manuals and specifications provide information on the drive

equipment:
• ACS 1000 User’s Manual,
• WCU Operation and Maintenance Manual,
• Signal and Parameter Table,
• Main Circuit Breaker Specification and Application Note,
• Tripping Loop Application Note,
• Power Cable Specification,
• Main Transformer Specification,
• Motor Specification,
• ACS 1000 Service and Maintenance Manual.
When third-party equipment is included in the scope of commissioning
see also:
• Main circuit breaker manual,
• Transformer manual,
• Motor manual.
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1.5. Tools
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• Toolbox with normal tools like screwdrivers, spanners etc.

• Torque spanner 10 - 75 Nm for hexagon head screws M6 to M12
• Personal computer with NDPA-02 PCMCIA-card, NDPC-12 optical
transmitter / receiver, optical fiber cables and DriveWindows or
DriveDebug
• Multimeter with test wires and clips, for example Fluke 87
• 5 kV Megger, for example AVO BM11D
• Water pump equipped with hoses and ISO-R½ female connector, for
example Wolfcraft 2200 3000 L/H (PartsOnline code 09811402)
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ABB Chapter 2 - Precommissioning Check List
Chapter 2 - Precommissioning Check List
2.1. Office Preparations
For an efficient commissioning, make sure that the following items are
completed before travelling to site:
• Copy of field service report
• Copy of commissioning report
• Copy of converter documentation
• Information about the scope of delivery
• Information about SW and EPLD updates 1 and 3
• Special tuning instructions for converter 1

• Information on possible converter upgrades 1
Setting values for motor parameters (equivalent circuit of

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the motor)
• Commissioning program (to be agreed with customer)

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• Needed tools 2
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• Suitable megger for insulation test 2

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• Digital camera
• (Spare parts for commissioning)
1 Contact MV AC Supportline for information, see chapter 10.6.1

Supportline Contact information
2 See chapter 1.5 Tools
3 Preprogrammed EPLD’s have to be ordered from PartsOnline,
delivering of the ordered part can take several days depending on
where it has to be delivered
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Chapter 2 - Precommissioning Check List ABB

2.2. Scope of Delivery
After receiving the converter and related equipment, the customer is

asked to check all items against the bill of material and for shipping
damages. Missing parts should be reported immediately to the carrier and
the project responsible ABB organization. All claims for damage should
be made to the carrier and ABB should be notified.
To avoid unnecessary delay of the commissioning, the commissioning
engineer must assure himself that the equipment is complete and intact.
It is recommended practice to photograph damaged equipment and send
the photographs to ABB and the carrier.
2.3. Pre-Conditions for Commissioning
In order to ensure an uncomplicated and fast commissioning, it is

important that the converter and associated equipment are ready for
commissioning. Reviewing and completing the items in the below list
before the commissioning engineer arrives on site will help to achieve
this.
1. Mechanical Installation of the Converter

www.91HMI.com • Converter is securely fixed to the floor
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• Customer side raw water piping is completed and the pipes

are connected to the converter
• Raw water supply is ready

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2. Electrical Installation of the Converter

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• All control cables going into the converter are connected,

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appropriately labelled and the customer side connections are

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completed
• Types and cross sections of control cables are suitable for

the signal type and signal level
• Types and cross section of power cables are selected

according to the “ABB power cable specification”
• Ground cable of converter is tightened on both ends
• Transformer and motor cables are not fastened at both ends

(cables and converter must be meggered before connection)
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ABB Chapter 2 - Precommissioning Check List
3. Main Circuit Breaker (MCB)

• The MCB is selected as per “ABB MCB specification”
• High voltage power connections are completed
• The MCB is ready to be tested with the converter
• The MCB protection relay settings are set and tested
• Safety devices (door locks etc.) are tested and in operation
4. Converter Transformer
• Grounding is completed
• Transformer auxiliaries (dehydrating breathers, cooling,

protection devices) are ready
• Safety devices (door looks etc.) are tested and in operation
4. Motor
• Motor is installed, aligned and alignment protocol is available
• Grounding is completed
• Motor auxiliaries (bearing lubrication, space heater, cooling

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etc.) are ready

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5. Megger Tests
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• All power cables to converter transformer, between converter

transformer and converter and between converter and motor
are meggered and the measured values are within the
required limits
• Test report of the megger test is available

If the test is carried out by the converter commissioning
engineer, one additional day per converter-motor combination
needs to be reserved. After the test, the mains cables can be
connected, except at the converter end. The test must comply
with the specification (5 kV / 60 seconds).
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Chapter 2 - Precommissioning Check List ABB
6. Power
• Medium voltage is available for start-up of the converter
• Low voltage auxiliary power is available for start-up of the

converter
7. Miscellaneous
Sufficient number and correct type of spare parts are
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available
• Sufficient quantity of deionised water is available
• Air conditioning of drive room is ready for load run of

converter
• Optional equipment (chiller unit etc.) is ready
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ABB Chapter 3 - Inspection of Installation
Chapter 3 - Inspection of Installation

In order to achieve a trouble-free commissioning, it is mandatory that the
installation, including third-party equipment, is inspected.
The status of the installation is checked and it is verified that converter
and related equipment are as specified for the application and have been
installed according to the installation instructions and the applicable
safety regulations.
Checking the installation is performed with the guidance of the
Commissioning Report. Equipment data asked for in the report must be
obtained and noted in the corresponding sections of the report.
If further information on the equipment is required, the applicable
documentation of the manufacturers should be consulted.
3.1. MCB
Check that the main circuit breaker is installed properly according to the
local requirements and according to the instructions in the MCB
documentation. Pay special attention to the following:
• Ambient conditions,
• MCB power circuit connections,

• MCB grounding connections,
• MCB auxiliary voltage supply,
• Interface cabling between the MCB and the ACS 1000,
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Prevention of local control.

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The local control of the MCB must be inhibited; all external controls to
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the MCB must go through the ACS 1000.

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ACS 1000i: N.A. in case the MCB is installed in the converter.

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3.2. Transformer (ACS 1000i: N.A.)

Check that the transformer is installed properly according to local
requirements and according to the instructions in the transformer
documentation. Pay special attention to:
• Ambient conditions,
• Transformer power circuit connections,
• All connections must be done with appropriate ends,
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Chapter 3 - Inspection of Installation ABB

• Cables and busbars must have sufficient cross-sections in
accordance with load current,
• Sharp bends in high-voltage conductors must be avoided,
• Minimum clearances between phase-to-phase and phase-to-earth
parts must always be observed (this includes also the distances from
cables to windings),
• All connections must be tight and mechanically secure, it is
recommended to use a torque-wrench when tightening bolts for
electrical connections (see Table 3-1),
Table 3-1 Recommended tightening torques for different bolt sizes

Bolt size Tightening torque
M6 6…9 Nm
M8 15…22 Nm
M10 30…44 Nm
M12 50…75 Nm
M16 120…190 Nm
• Transformer grounding connections,

• Make sure that transformer secondary power circuit protective shield
connections are made according to recommendations (both ends
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• The transformer frame must be connected to the protective

grounding system,
• Interface cabling between the transformer and the ACS 1000.
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When inspecting the converter room, attention must be paid to the

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following:
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• Building work must be finished in the converter room.

• The converter room must be clean (free of dust) and dry.
• Air filters must be in place.
• Air conditioning must be available latest when the converter will be
operated continuously.
If the condition of the converter room hampers effective commissiong, the
customer and the responsible ABB project engineer must be informed
immediately.
Cleanness of the converter room should be checked several times during
commissioning.
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ABB Chapter 3 - Inspection of Installation
3.4. Converter
The inspection includes the mechanical and electrical installation of the

converter. By visually checking the converter, the commissioning
engineer obtains an overview of the condition of the converter and can
react in time if corrections have to be made.
Useful information on the requirements for the installation site is written in
the User’s Manual of the converter, Chapter 3 - Mechanical Installation
and Appendix C – Mechanical Drawings.
If the installation of the converter has not been carried out as required or
the condition of the converter hampers effective commissiong, the
customer and the responsible ABB project engineer must be informed
immediately.
When inspecting the converter, the checklist below can be used as a
guide. Depending on the configuration of the converter and applicable
options, there might be less or more check items. Always see supplied
parts list, mechanical and electrical drawings for reference.
Check List
• Installation and damages of components.
• Cable openings should be closed to avoid dust entering into the
cabinets.
www.91HMI.com • Foreign parts, dust and moisture must not be present in the converter
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cabinets.
It is very important that there is no dust and moisture inside the
cabinets. Dust and moisture weaken the busbar insulation. Dust
tends to build up on air-cooling elements, thus impairing cooling.
• Converter doors must open and close easily.
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If the doors cannot be opened and closed properly, the alignment of

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the converter must be checked and corrected.

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• Floor fixings must be mounted.

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The mounting holes are indicated in Appendix C- Layout Drawing in

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the User’s Manual of the converter.

• Cooling water connections must be made.
Information on the flange sizes or project specific features are shown
in Appendix C- Layout Drawing in the User’s Manual of the converter.
• Termination and routing of power cables.
All cable connections between converter and transformer and
between converter and motor are shown in Appendix D – Electrical
Drawings in the User’s Manual of the converter. Project specific cable
entries are indicated in Appendix C – Mechanical Drawings in the
User’s Manual of the converter.
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Chapter 3 - Inspection of Installation ABB

IMPORTANT!
Power cables must not be connected at the converter before the
insulation resistance of the converter and the motor have been
measured.
3.5. Ground Connections
Ground connections must be carried out carefully to prevent that high

potentials will occur in any parts, which can be touched easily.
Inspection of ground connections includes the following:
• The converter must be connected to the ground system of the factory
(system ground).
• The shields of all power cables must be connected to the ground
busbar.
• The cross section of the cable shields must be in accordance with the
Power Cable Specification.
3.6. Motor
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be cleaned so that it is safe to run the motor. All
waste that can come in contact with the shaft or the cooling air inlets must
be removed.
The motor installation includes the piping of lubrication and water-cooling
system and the alignment of the motor. An alignment protocol must be
available on site.
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The motor frame must be connected to the ground network of the plant.
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For more details see instructions of the motor manufacturer.

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ABB Chapter 4 - Safety
Chapter 4 - Safety
Before power is applied to the converter, it must be checked that all
covers are back in place so that voltage-carrying parts cannot be touched
accidentally. Interlocks, which prevent that medium and high voltage units
can be accessed accidentally, must be in operation.
• Protection covers inside the converter must be refitted.
If covers have to be removed for measuring purposes, appropriate
safety signs and temporary barriers must be installed and personnel
involved in the commissioning must be informed.
• Cabinet door locks must be checked.
The doors should be kept closed whenever possible. This also helps
to keep the cabinets clean.
Door keys should only be given to persons who take part in the
commissioning.
• All openings of the motor must be closed and shaft covers must be
installed.
The area around the motor must be cordoned off to prevent
accidents during the uncoupled motor tests.
www.91HMI.com • All covers of power cable terminals or terminal boxes in the
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converter, motor, transformer and MCB must be closed.

• Open transformer and motor cable ends must be tied together and
properly grounded.
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Chapter 4 - Safety ABB
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ABB Chapter 5 - Connecting Auxiliary Supply to the Converter
Chapter 5 - Connecting Auxiliary Supply to the Converter

For the next steps, auxiliary voltage is needed.
The auxiliary power supply can be made according to two different
concepts in the ACS 1000.
• With EPS-board (old concept).
• With Phoenix power supply modules (new concept).
5.1. EPS Auxiliary Power Supply
When the ACS 1000 is equipped with EPS-board(s), it is supplied with

one common 3-phase 400, 480 or 575 VAC (other voltages as
engineered option) auxiliary supply for the control electronics and the
cooling system.
Procedure for switching on the auxiliary voltage:
4 Make sure that the protection switches Q1, Q11, Q12, Q13, Q14 and
all optional switches are off.
5 Check the settings of the protection switches Q1, Q11, Q12, Q13 and
Q14 (see Table 5-1 and Table 5-2).
The settings for all other switches are project specific.
Table 5-1 Settings for protection switches (ACS 1000A)

Frame size
A1 A2 / A3
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Supply Frequency [Hz] 50 Hz 60 Hz 50 Hz 60 Hz

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Q1 (control) 0.94 0.94 0.94 0.94

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400 Q11 (fan 1) 4.25 4.25 7.30 6.87

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Q12 (fan 2) 4.25 4.25 7.30 6.87

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Auxiliary Q1 (control) N.A. 0.78 N.A. 0.78

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Supply Voltage 480 Q11 (fan 1) N.A. 3.54 N.A. 5.73

[V] Q12 (fan 2) N.A. 3.54 N.A. 5.73
Q1 (control) N.A. 0.65 N.A. 0.65
575 Q11 (fan 1) N.A. 2.95 N.A. 4.78
Q12 (fan 2) N.A. 2.95 N.A. 4.78
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Chapter 5 - Connecting Auxiliary Supply to the Converter ABB

Table 5-2 Settings for protection switches (ACS 1000W)
Frame size
W1 W2 / W3
Supply Frequency [Hz] 50 Hz 60 Hz 50 Hz 60 Hz
Q1 (control) 1.62 1.62 1.62 1.62
Q11 (pump 1) 4.10 4.50 4.10 4.50
400 Q12 (pump 2) 4.10 4.50 4.10 4.50
Q13 (fan 1) 2.61 3.10 2.61 3.10
Q14 (fan 2) 2.61 3.10 2.61 3.10
Q1 (control) N.A. 1.35 N.A 1.35
Auxiliary Q11 (pump 1) N.A 4.20 N.A 4.20
Supply Voltage 480 Q12 (pump 2) N.A 4.20 N.A 4.20
[V] Q13 (fan 1) N.A 2.59 N.A 2.59
Q14 (fan 2) N.A 2.59 N.A 2.59
Q1 (control) N.A 1.12 N.A 1.12
Q11 (pump 1) N.A 3.50 N.A 3.50
575 Q12 (pump 2) N.A 3.50 N.A 3.50
Q13 (fan 1) N.A 2.16 N.A 2.16
Q14 (fan 2) N.A 2.16 N.A 2.16
6 Check that the voltage selection in the 3-phase auxiliary transformer

T1 is correct selected for each phase.
7 Check that the 3-phase auxiliary voltage supplied from customer side
is within tolerance and write down the value (can be measured from
terminal X10).
8 Switch on the auxiliary voltage to the converter control electronics
with the circuit breaker Q1.
9 Check that the 24 VAC auxiliary voltages at the transformer
secondary are correct in all three phases.
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10 Check that the 32 VAC auxiliary voltages at the transformer

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secondary are correct in all three phases.

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11 Check that the output voltage of the EPS-board(s) are ok (27 VDC,
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27 VAC and +/- 20 VDC).

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12 Check that both the yellow and green LED’s on all subprints on both
GUSP-units (Gate Unit power Supply) are on.
5.2. Phoenix Auxiliary Power Supply
When the ACS 1000 is equipped with Phoenix auxiliary power supplies,
the supply can be arranged different ways. The exact configuration can
be checked from position 18 in the typecode.
A External 3-phase supply and external 1-phase safe line for control.
B External 3-phase supply and internal UPS.
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D Internal 3-phase supply and external 1-phase supply (no safe line) for
control and internal back-up battery.
E Internal 3-phase supply and internal 1-phase supply for control and
internal back-up battery.
F Only available for 575 VAC 3-phase supply.
IMPORTANT!
Configurations A and B are only available for 400 VAC / 480 VAC 3-
phase supply.
Configurations D and E are only available for ACS 1000i with 60Hz
supply network.
Procedure for switching on the auxiliary voltage:

1 Make sure that the switch S5001 (in configration E only) is in position
1 (i.e. the external commissioning auxiliary power supply is used).
2 Make sure that the protection switches Q5051, Q5052, Q5073,
Q5021, Q5022, Q5023, Q5024 and all optional switches are off.
3 Check the settings of all protection switches (see Table 5-3, Table
5-4, Table 5-5 and Table 5-6).
Table 5-3 Settings for protection switches (control hardware supply)
1P- Auxiliary Supply 3P- Auxiliary Supply
Voltage [V] Voltage [V]
120 230 400 480
Q5052 (control) N.A. N.A. 1.6 1.4
Q5073 (aux. trans.) 1 0.5 0.3 / 0.85* 0.25 / 0.7*
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*if ACS 1000i with intergrated contactor and configuration B

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Table 5-4 Settings for protection switches (ACS 1000A)

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Frame size
A1 A2 / A3
Supply Frequency (Hz) 50 Hz 60 Hz 50 Hz 60 Hz
Q5021 (fan 1) 4.25 4.25 7.30 6.87
400
Q5023 (fan 2) 4.25 4.25 7.30 6.87
Auxiliary Supply
Q5021 (fan 1) N.A. 3.54 N.A. 5.73
Voltage 480
[V] Q5023 (fan 2) N.A. 3.54 N.A. 5.73
Q5021 (fan 1) N.A. 2.95 N.A. 4.78
575
Q5023 (fan 2) N.A. 2.95 N.A. 4.78
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Table 5-5 Settings for protection switches (ACS 1000W)
Frame size
W1 W2 / W3
Q5021 (pump 1) 4.10 4.50 4.10 4.50
Q5023 (pump 2) 4.10 4.50 4.10 4.50
400
Q5022 (fan 1) 2.61 3.10 2.61 3.10
Q5024 (fan 2) 2.61 3.10 2.61 3.10
Q5021 (pump 1) N.A 4.20 N.A 4.20
Auxiliary Supply
Q5023 (pump 2) N.A 4.20 N.A 4.20
Voltage 480
[V] Q5022 (fan 1) N.A 2.59 N.A 2.59
Q5024 (fan 2) N.A 2.59 N.A 2.59
Q5021 (pump 1) N.A 3.50 N.A 3.50
Q5023 (pump 2) N.A 3.50 N.A 3.50
575
Q5022 (fan 1) N.A 2.16 N.A 2.16
Q5024 (fan 2) N.A 2.16 N.A 2.16
Table 5-6 Settings for protection switches (ACS 1000i)

Frame size
A1 A2 / A3
Q5021 (fan 1) 3.54 3.54 3.54 3.54
Q5022 (fan 2) 5.73 5.73 5.73 5.73
400
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Auxiliary Supply
Q5024 (fan 4) 5.73 5.73 5.73 5.73
Voltage
[V] Q5021 (fan 1) N.A 3.54 N.A 3.54
Q5022 (fan 2) N.A 3.54 N.A 5.73
480
Q5023 (fan 3) N.A 3.54 N.A 3.54
Q5024 (fan 4) N.A 3.54 N.A 5.73
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• Terminals X11:1 and X11:2 in case of external 1-

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phase auxiliary power supply.

• Terminals X11:3 and X11:4 in case of internal 1-
phase supply (only applicable in ACS 1000i).
• Terminals X10:1, X10:2 and X10:3 in case of
internal (only applicable in ACS 1000i) or external
3-phase auxiliary power supply.
5 Check that the settings of the UPS modules are correct (if
applicable).
• Battery Select: 7.2 Ah
• Tmax: 5 min
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IMPORTANT!
During commissioning the Battery Select switch on the UPS modules
can be set to “Service”. In the service mode, the UPS module will not
keep the control hardware supplyed from the backup batteries and thus
rebooting of the converter is faster.
6 Switch on the auxiliary voltage to the control electronics with the

circuit breakers Q5051 and / or Q5052 (see the drive specific wiring
diagrams).
7 Check that the output voltages of the power supply modules are ok
(27 VDC +/- 0.5 VDC), in case necessary tune the output voltage on
each power supply.
8 Switch on the 24 VAC power supply with the circuit breaker Q5073
and measure the.
9 Check that both the yellow and green LED’s on all subprints on
GUSP1 and GUSP2 (Gate Unit power Supply) are on.
5.3. Checking Of Auxiliary Backup Batteries
If it is more than 6 months from the dispatch of the converter from the
factory in Switzerland, check the charging of the auxiliary backup
batteries and check the function of the auxiliary ride-through function. If
necessary replace the batteries with new ones.
IMPORTANT!
Auxiliary batteries are considered to be wear-and-tear-parts and cannot
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ABB Chapter 6 - Commissioning of the Cooling System
Chapter 6 - Commissioning of the Cooling System
6.1. Water-Cooled ACS 1000
6.1.1. Checking the Internal and External Cooling Circuits
CAUTION!
Do not switch on a cooling pump if the cooling circuit is empty. If a pump
runs dry, the pump seals will be immediately damaged.
Check that the installation is made as described in chapter 2 – Installation

in the WCU Operation and Maintenance Manual.
Check especially:
• Connection of raw water hoses / pipes.
• Direction of raw water flow.
• Requirements for the raw water (temperature, flow, pressure etc.).
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Leakage water connection.
• For bent hoses and visible damages in the internal cooling circuit.
NOTICE!
Especially the hoses on the sinus filter choke can easily be bent during
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Figure 6-1 Hoses on sine filter choke
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Chapter 6 - Commissioning of the Cooling System ABB

• Cleanness of the strainer Z1.
This should be checked again after some days of operation because
during the first time of water flow possible loose particles and dirt
from the water pipes should be flushed out and caught in the strainer.
6.1.2. Filling Up the Internal Cooling Circuit
Fill the internal cooling circuit according to the instructions in chapter 3 –

Starting up the Cooling System in the WCU Operation and Maintenance
Manual.
After filling up the internal cooling circuit, remember to:
• Vent (deaerate) the internal cooling pumps.
• Check the direction of internal water flow (check the direction of
rotation of the pumps).
• Check the direction of rotation of the auxiliary cooling fans.
• Check the water level in the expansion vessel.
6.1.3. Functional Test of the Redundant Fan
In case the converter is equipped with redundant cooling fans, check the
function according to the instruction below.
1 Start pump number 1, fan number 1 (standard fan inside cabinet)
starts rotating, the air-flaps under the redundant fan should be closed
and the air flaps under the internal fan should open.
2 Feel the air flow (how strong does the fan blow).
3 Switch off the motor circuit breaker of the standard fan, the redundant
fan starts rotating, the air flaps under the redundant fan should open
and the air flaps under the internal fan should close.
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of rotation of the redundant fan.

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6.2. Air-Cooled ACS 1000 and ACS 1000i
• Check that the air exhaust box on top of the converter is assembled
according to the instructions (ACS 1000i: N.A.).
• Check that all applicable fans installed on top of the converter are
installed (only ACS 1000i).
• Check that the fan(s) are rotating smoothly and in the right direction.
• In case of redundant fans check that the installation of the fan box is
made according to the instructions.
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ABB Chapter 6 - Commissioning of the Cooling System
• In case of redundant fans check that the air flap limiting device is
functioning properly.
• Check and test the function of the installed differential pressure
switches (see Table 6-1 and Table 6-2).
Table 6-1 Settings for differential pressure sensors (ACS 1000A)

B1 / B5261 B2 / B5824
Sensor
(Fan Supervision) (Filter Supervision)
Setting 150 Pa 280 Pa
Table 6-2 Settings for differential pressure sensors (ACS 1000i)

B5261 B5262 B5264
Sensor
(Fan Gr. 1) (Fan Gr. 2) (Filter Sup.)
Setting 100 Pa 90 Pa
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Chapter 6 - Commissioning of the Cooling System ABB
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ABB Chapter 7 - Insulation Resistance Measurements
Chapter 7 - Insulation Resistance Measurements

Before any of the components in the drive system can be energized, it
must be assured that they are able to withstand the voltage stress. This
can be verified by measuring the insulation resistance. If the measured
insulation resistance value of the motor, transformer or converter is too
low, the reason may be that insulators, windings etc. have moisture in
them and it may be necessary to dry the windings.
It is advisable to compare the test results with the test reports from the
supply factories.
The contractor or customer can make the insulation resistance
measurements on the supply transformer, cables and motor, in that case
a signed test-protocol of all measurements must be attached to the
commissioning report. A certified commissioning engineer must always
make the insulation resistance measurement test on the ACS 1000.
7.1. Preparations
• Make sure that the Main Circuit Breaker is locked in test position
(ACS 1000i: make sure that the external supply breaker is locked in
www.91HMI.com test position).
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• Disconnect the cables between the supply transformer and the

converter and isolate them from ground and the frames of the
transformer and the converter (ACS 1000i: disconnect the supply
cables and isolate them from ground and the frames of the supply
breaker and the converter).
• Disconnect the cables between the converter and the motor and
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isolate them from ground and the frames of the converter and the
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motor.
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7.2. External MCB
The main circuit breaker is commissioned and the insulation tests are
performed according to the documentation of the manufacturer. The
signed MCB commissioning report must be received from the responsible
person.
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Chapter 7 - Insulation Resistance Measurements ABB

7.3. Internal MCB (only ACS 1000i)
All poles should be meggered against each other and against ground.
The absolute value depends on other equipment connected to the
breaker but it should be higher than 1 MΩ per 1 kV.
7.4. Transformer
The following procedure should be used for checking the insulation

resistance measurement of the supply transformer (ACS 1000i: The
internal transformer is tested together with the converter and it is not
necessary to test it separately).
1 Short circuit all windings individually (HV, LV1 and LV2
andadditionally LV3 and LV4 in case of a 24-pulse transformer).
2 Connect all other windings than the one to be measured to ground
(see Figure 7-1).
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+ -
LV1 LV2 LV3 LV4 MΩ

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Figure 7-1 Example of meggering the HV-winding against ground
3 Connect the megger between the winding to be measured and

ground, the test voltage is 5 kVDC for 60 seconds.
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4 Repeat the measurement for the other windings, all individual

windings should be measured against ground, the following
measurements are needed:
• HV – T/E,
• LV1 – T/E,
• LV2 – T/E,
• LV3 – T/E (in case of 24-pulse transformer),
• LV4 – T/E (in case of 24-pulse transformer).
The insulation resistance should normally be several thousand MΩ, the
value is however depending on temperature of the transformer. For
verification of the actual values to the values during normal conditions
(20°C) the following conversion table is valid.
Table 7-2 Correction factors for transformer insulation resistance

measurement
Ambient temperature °C Correction factor
-10 0.13
-5 0.18
0 0.25
5 0.36
10www.PLCworld.cn 0.50
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20 1.0
25 1.40
30 1.98
35 2.80
40 3.95
45 5.60
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60 15.85
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65 22.40
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70 31.75
75 44.70
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7.5. Converter (Standard Air- and Water-Cooled ACS 1000)
1 Connect all medium voltage input and output connections 1U1, 1V1,
1W1, 2U1, 2V1, 2W1, U2, V2, W2 (and 3U1, 3V1, 3W1, 4U1, 4V1
and 4W1 in case of a 24-pulse rectifier) together.
2 Connect the DC-capacitor terminals Plus, Minus and NP together
(the easiest place is the terminals on the grounding switch).
3 Remove the DC-voltage measurement cables from the ADCVI- and
OVVP-boards (terminals X2.1, X2.3 and X2.5) and make sure that
the wires don’t touch the frame or the boards.
4 Remove the door center post in front of the inverter swing frame (only
in water-cooled converters, see Figure 7-3).
5 Remove the ground-connection of resistor RN.
6 Remove the ground-connection of the star point of the output filter
capacitors Cf.
7 Close the doors to the medium voltage cabinets of the converter.
8 Open the grounding switch.
9 Switch off the auxiliary voltage of the converter.
10 Connect the megger between the main connections (1U1, 1V1, 1W1,
2U1, 2V1, 2W1, U2, V2, W2) and ground.
11 Megger the converter main circuit against ground.
The test voltage should be 5000 VDC for 60 seconds. The measured
insulation resistance must be higher than 10 Mohm in a water-cooled
ACS 1000 and higher than 100 Mohm in an air-cooled ACS1000. In
the water-cooled ACS 1000, the result is depending on the actual
water conductivity of internal cooling water, if the conductivity is
below 0,3 uS it is normally possible to get an acceptable result.
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12 Discharge the measured circuit.

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14 Switch on the auxiliary voltage of the converter.

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15 Connect the ground-connection of resistor RN to ground.

16 Connect the ground-connection of the star point of the output filter
capacitors to ground.
17 Connect the DC-voltage measurement cables to the ADCVI- and
OVVP-boards (terminals X2.1, X2.3 and X2.5).
18 Take out all short circuit jumpers that were connected before the
insulation resistance measurement.
19 Install the door center posts (in case applicable, see Figure 7-3).
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Figure 7-3 Door center posts
CAUTION!
Serious damage can be caused on the converter in case it is energized
without removing all short-circuit-jumpers.
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5 KV / 60
seconds
Fs1
Rpre1
Ls1
Chapter 7 - Insulation Resistance Measurements
ACS 1000 converters

Vcl1 V1u V1v V1w
V1a V1b V1c Vs1
Rs1
Rr1
Rdis1
Cr1 V2u V2v V2w
V2a V2b V2c Cdc1 Ccl1
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Lf
V1Nu V1Nv V1Nw
Rsym
Fm
3HBS210669 ZAB E01 Rev.-

Cm
Rm
Rn V3u V3v V3w
V3a V3b V3c Cdc2 Ccl2 V2Nu V2Nv V2Nw Cf

Cr2 Rdis2
Rr2 V4u V4v V4w

Rs2
Vs2
V4a V4b V4c
Vcl2
Ls2
Rpre2
Fs2
Figure 7-4 Modifications on the main circuit for meggering standard

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Disconnect:
1. The star point of the output filter
Open the grounding switch 2. The ground connection on resistor Rn
ABB
ACS 1000 Commissioning Manual
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7.6. Converter (ACS 1000i)
1 Connect the medium voltage input and output connections U1, V1,
W1, U2, V2 and W2 together (in the cable cabinet on the left side of
the converter).
2 Close the MCB by jumpers (if applicable).
3 Short circuit all four 6-pulse rectifiers (AC and DC terminals) and
connect them to the input and output connectors.
4 Connect the auxiliary windings of all transformers together and
ground them.
5 Remove the ground-connection of resistor RN (input section).
6 Remove the ground-connection from the star point of the output filter
capacitors Cf (input section).
7 Disconnect the surge arrestors from ground.
8 Remove the DC-voltage measurement cables from the ADCVI-,
OVVP1- and OVVP2-boards (terminals X2.1, X2.3 and X2.5) and
make sure that the wires don’t touch the frame of the converter or the
board.
9 Open the grounding switch (manual unlocking).
10 Close the doors of the converter.
11 Switch off the auxiliary voltage of the converter.
12 Connect the megger between the main connections (1U, 1V, 1W, U2,
V2, W2) and the ground.
13 Megger the converter main circuit against ground.
The test voltage should be 5000 VDC for 60 seconds. The measured
insulation resistance must be higher than 100 Mohm.
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14 Discharge the main circuit.

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17 Connect the ground-connection of resistor RN to ground.

18 Connect the surge arrestors to ground.
19 Connect the ground-connection of the star point of the output filter
capacitors to ground.
20 Connect the DC-voltage measurement cables to the ADCVI-, OVVP1
and OVVP2-boards (terminals X2.1, X2.3 and X2.5).
21 Take out all short circuit jumpers that were connected before the
insulation resistance measurement.
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CAUTION!
Serious damage can be caused on the converter in case it is energized
without removing all short-circuit-jumpers.
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Figure 7-5 Modifications on the main circuit for meggering ACS

1000i converters
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7.7. Motor
1 The frame and the windings not being tested must be grounded
during the insulation resistance measurement.
2 All resistance temperature detectors (RTD) must be grounded.
The insulation resistance of new motor is normally very high. A thumb
rule can be that if the measured value is one decade or more lower than
the value measured in the factory, check the winding for excess moisture
or dirt. The test report contains the insulation resistance value measured
in the factory.
If the motor star point is reachable, measure each phase separately as
shown in Figure 7-6.
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reachable (3 measuring values)
If the star point is not reachable, measure all phases together as shown in
Figure 7-7.
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Figure 7-7 Insulation resistance measuring when star point is not

reachable (1 measuring value)
If the reading is too low, dry the motor windings according to instructions
in the motor documentation.
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7.8. Power Cables
Measure the insulation resistance of all power cables and write down the
measured results. Measurements have to be made between all phases
(all cables apart from each other) and between all cables and ground (all
cables bound together at one end). Record the lowest value for each
measurement.
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ABB Chapter 8 - Preparing the System
Chapter 8 - Preparing the System

Before the drive system components can be energized they must be
checked and prepared for switching on the main voltage. When
inspecting each of the system components, follow the instructions given
in the documentation for each of the components.
8.1. MCB and Protection Relay
Protection relays in the feeding switchgear must be tested, especially the

relays of the converter transformer. The setting of these relays must be
checked and compared with the project specific values. Relay test
protocols must be available on site.
The correct operation of the MCB will be tested before the MCB is used to
supply the main power to the converter. The test is performed with the
main power supply disconnected from the MCB.
Information on the required control interface to the converter and on the
breaking time of the circuit breaker can be obtained from the Main Circuit
Breaker Specification and the Main Circuit Breaker Application Note.
• Check that the operational mechanisms of the MCB are working
properly (WITHOUT MEDIUM VOLTAGE SUPPLY).
• Check that the MCB interlocking and locking facilities are working
properly.
• Check that the MCB can be racked out properly.
• Check that the MCB cannot be operated locally.
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8.2. Transformer
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performed according to the instructions of the transformer manufacturer.

Checking of the transformer includes the following:
• Rating plate values must correspond to the project data,
• Cleanness of transformer room and equipment,
• Thermal protective devices and other external measurement and
protection devices,
• Oil quantity, in case of oil type transformer,
Oil quantity can be checked on the oil level gauge located on the oil
expansion vessel,
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Chapter 8 - Preparing the System ABB

• Valves between transformer tank and radiator,
All valves must be in open position to allow free oil flow between tank
and radiators,
• Condition of dehydrating breathers,
• Sense of rotation of fans and pumps (if applicable).
IMPORTANT!
The protectice devices from the supply transformer can be connected
either to the ACS 1000 or to some other protection device. If they are
not conncted to the ACS 1000, it is recommended to connect one
common “Transformer trip signal” to the ACS 1000 tripping loop,
connectors X300:7 and X300:8.
8.3. Converter
8.3.1. Standard Hardware
The following things must be checked before the ACS 1000 can be
energized.
• Visually all medium voltage connections (busbars and cables).
• Visually all auxiliary supply cables.
• Visually all fibre optic cables.
• In case of water cooled ACS 1000, the centre post in font of the
inverter must be installed (see Figure 7-3).
• In case of a water-cooled ACS 1000, the shipping brackets securing
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The DIP-switches for configuring the analogue inputs are correct set
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(each IOEC-board has it’s own set of dip-switches).

All analogue inputs can be set to current or voltage range with dip
switches (2 switches / analogue input), see Figure 8-1 and Figure
8-2.
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AI 20mA
AI 10V
ON
OFF
Figure 8-1 DIP Switch configuration for current-signal
AI 20mA
AI 10V
ON
OFF
Figure 8-2 DIP Switch configuration for voltage-signal
In ACS 1000i the Pt100’s are connected directly to the IOEC-board,

for this connection both dip-switches have to be set to OFF, see
Figure 8-3.
AI 20mA
AI 10V
OFF OFF
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Figure 8-3 DIP Switch configuration for temperature

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Calibration of analogue inputs.

Disconnect the terminals –X31 and –X32 on all IOEC-boards and set
the following parameters to “YES” to perform the offset-calibration.
IOEC 1 and IOEC2: Parameter 13.01 Auto Offset Calib.
IOEC 3: Parameter 81.01 Auto Offset Calib.
IOEC 4: Parameter 86.01 Auto Offset Calib.
• Parameters for inverter air and transformer temperature
measurement in ACS 1000i (see
• Table 8-4).
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Table 8-4 Settings for Analogue Inputs for temperature measurement in
ACS 1000i
Parameter Setting
190.28 AI4 Filter IO1 1s
190.27 AI4 Minimum IO1 4mA/2V
190.25 AI4 HighValue IO1 10550
190.26 AI4 LowValue IO1 -13
8.3.2. Optional Hardware
• Check the supply voltage for the motor space heater and write down
the value.
• Check the supply voltage for converter space heaters and write down
the value.
• Check the function of all included options (motor space heater,
converter space heater, motor cooling fan / pump etc.).
8.3.3. Customer Parameters
Set all customer specific parameters. For more information see the Signal
and Parameter table.
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Different software-versions may have different parameters.
8.3.4. Motor Parameters in Group 99 And 112

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equivalent circuit of the motor (see Figure 8-6).

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mot_par-table from the loading package of the used software must

be used.
• Check that the filter capacitance specified with the type code (cell
B45) corresponds with the filter capacitance value in parameter 6.15
FilterCapacity and with the installed sine filter capacitance in the
converter (check the name plates of the installed capacitors).
• Check that the filter inductance specified with the type code (cell
B46) corresponds with the filter inductance value in parameter 6.14
FilterInductance and with the installed sine filter choke in the
converter (check the name plate of the installed choke).
• Check that the filter resonance frequency (cell E70) is less than 380
Hz.
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If the calculated resonance frequency is higher than 380 Hz, check

that the entered motor data and the entered sine filter inductance and
capacitance are correct, if the calculated sine filter resonance
frequency is still too high, the sine filter configuration must be
changed.
• Set the correct motor parameters in group 99.
• Set the correct motor parameters calculated with the mot_par-Excel-
table in group 112, the group can be opened with the password 564.
IMPORTANT!
The sine filter damping parameters in group 112 (older software
versions) or group 115 (newer software versions) must not be modified,
they are automatically set to the correct values by the software loading
package.
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Figure 8-5 Example of motor parameter calculation with the name plate
data
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Figure 8-6 Example of motor parameter calculation with the motor

equivalent circuit
8.3.5. Testing of the MCB Control and the Tripping Loop
Check the function of the MCB and the tripping loop without main voltage.
For more information see the following application notes:
• ACS 1000 Main Circuit Breaker Control
• ACS 1000 Tripping Loop
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The test can be made according to the following procedure:
1 Make sure the MCB is in test-position.
2 Set all appropriate parameters for the MCB Control.
• 21.06 MCB On Control Mode
• 21.07 MCB Feedback Signal
• 21.08 MCB Available Signal
• 21.09 MCB Closing Time Lim
• 21.10 MCB Opening Time Lim
3 In case the MCB Available-function is enabled, check that the
feedback-signals is correct (i.e. the MCB Not Available-alarm is
activated when the MCB is in test-position).
IMPORTANT!
If the MCB Available-function is enabled, it is only possible to operate
the grounding-switch when the MCB is in test-position i.e. when the
MCB Not Available-alarm is active.
4 Temporary disable the MCB Available-function (set parameter 21.08

MCB Available Signal to ‘No’).
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Set the drive to local control.
6 Reset all faults in the converter.
7 Open the grounding switch and make sure that the converter is in
‘RdyForMCBOn-state’ (the state of the converter can be checked
from signal 8.10 Drive Status Word on the CDP-panel).
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converter, the breaker should close and the drive should receive the
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MCB Closed-status-signal.
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9 Wait for 10 to 20 seconds (the exact time depends on the converter

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type), the MCB should be opened by the converter and the fault-
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message ‘Charging’ should be displayed.

10 Reset the fault and close the MCB with On-Line-pushbutton on the
front door of the converter.
11 Wait for about 5 seconds and trip the MCB with the E-stop-button on
the front-door of the converter, the MCB should be opened by the
converter and the fault-message ‘EmergOff’ and ‘TrippLoop’ should
come up.
12 Reset the faults and close the MCB with the On-Line-pushbutton on
the front door of the converter.
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13 Wait for about 5 seconds and open the MCB with the Off-Line-
pushbutton on the front-door of the converter, the breaker should
open and the drive should go to RdyForMCBOn-state.
14 Test all used trip-signals connected to the tripping-loop and make
sure that the converter shows the correct fault for each signal.
15 Set the converter to Remote control and test the remote control of the
MCB.
16 Check the mechanical interlocking of the grounding isolator.
8.3.6. Testing of I/O’s
Check all customer-specific signals. For more information see the

customer specific wiring diagram and the Signal & Parameter-table.
8.3.7. Testing of Fieldbus-Communication
Check that the Fieldbus-communication is working properly. For more

information see the Signal & Parameter-table and the Fieldbus-module
specific Installation and Start-Up guide.
IMPORTANT!
If the Fieldbus is only used for monitoring, parameter 75.04 FBA
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must be set to DSET1 READ.
If parameter 75.04 FBA Comm.Module is set to DSET1 R/W, the bits 2
and 3 in the OCW (Overriding Control Word) must be set to 1 to prevent
the drive to trip to the fault “EmergStop” when the drive is in remote
mode.
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Check that the motor is ready to start (alignment, coupling, lubrication,

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cooling etc.) and make sure that starting the motor does not cause any
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danger. It is recommended to disconnect the motor from the load for the
first start if there is a risk that the load is damaged in case the motor turns
in the wrong direction.
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ABB Chapter 9 - Energizing, First Start and Load Test
Chapter 9 - Energizing, First Start and Load Test
9.1. Energizing the Converter
Charging of the converter for the first time.

• Monitor the DC voltages with the parameters 2.03 DC Voltage Udc1,
2.05 DC Voltage Udc2 and 2.07 DC Voltage Udc1+2.
• Check that the difference between 2.03 DC Voltage Udc1 and 2.05
DC Voltage Udc2 is less than 1 %.
• Check that the protection IGCT’s switches on properly (i.e. that a
small step is visible in the DC voltage in the end of the charging
sequence, see Figure 9-1).
• Check that the DC voltage is as close to 100 % as possible, in case
needed, lower or higher the voltage with the tap-changer on the
supply transformer.
IMPORTANT!
ACS 1000i, with 50 Hz transformer have no tap changers.
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Chapter 9 - Energizing, First Start and Load Test ABB
Figure 9-1 Example of charging of the DC link

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IMPORTANT!
The DC link voltage corresponds to the maximum rated output voltage
(peak voltage), for example for a 3.3 KV drive:
UDC100% = 3300V * 2 *1.045 = 4877V = 100%

And for a 4 kV drive:
UDC100% = 4000V * 2 *1.045 = 5911V = 100%

In the ACS 1000i, the scaling of the DC link voltage is the same as in
the standard ACS 1000 but because the ACS 1000i always is based on
4 KV hardware, the normal DC link voltage is different, see Table 9-2.
Table 9-2 DC voltage scaling for ACS 1000i
Nominal Rated input

UDC1 + UDC2 UDC1 + UDC2
inverter voltage voltage
(V) (%)
(V) (V)
3300 6000 5146 106 %
3300 6300 5404 110 %
3300 6600 5661 116 %
3300 10000 5146 106 %
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3300 11000 5661 116 %
4000 N.A. 5911 100 %
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9.2. First Start
1 Energize the converter according to the instructions in chapter 9.1.

2 After the DC link is charged, the ACS 1000 shows the status “Rdy To
Strt”.
NOTICE!
In software-versions before MSOH4300, the ACS 1000 automatically
asks for an ID Run, by showing the warning “ID RunReqst” when the
MCB is closed for the first time.
To disable the ID Run (as recommended) set parameter 112.20 Manual
First Start to ‘YES’, the ID RunReqst-alarm is deactivated and the ACS
1000 should show the status “Rdy To Strt”.
3 Start the motor from the CDP-panel and make sure that the motor is
running in the correct direction.
4 Check that the converter works ok in the whole speed-range from
both local and remote control.
5 In case needed, tune the speed-controller.
Error
Step
height
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Time
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Required response time

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Figure 9-3 Step response of speed control test
A Undercompensated, short integration time and low gain

B Undercompensated, too low proportional gain
C Normal
D Normal when better dynamich performance is needed
E Overcompensated, short integration time and high proportional gain
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9.3. Load Test
Connect the driven equipment to the motor and go in steps up to rated

power and speed. Monitor the DC voltage, if the DC voltage level at
maximum power is below the nominal value, stop the drive, ground it and
adjust the tapping on the supply transformer.
Monitor the following parameters during the load test:
• 3.02 SpeedRef3,
• 1.02 MotorSpeed,
• 1.07 MotorCurrent,
• 1.09 MotorTorque,
• 2.07 DC Voltage Udc1+2,
• 4.02 InvWtrCoolingTemp (in case of water cooled ACS 1000),
• 2.16 InverterAirTemp (in case of air cooled ACS 1000).
Save the trend from the test run with DriveDebug or DriveWindows and
attach it to the commissioning report.
9.4. Testing of Ride Through and Auto Restart Functions
Check that the main power ride through, the auxiliary power ride through
and the auto restart-functions work properly in case they are required.
Monitor the following parameters during the ride through and the auto
restart tests:
• 1.02 MotorSpeed,
• 2.07 DC Voltage Udc1+2,
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• 9.04 FaultWord4 (RideThrough-fault: b09),

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• 9.13 AlarmWord3 (RideTrough-alarm: b03, AuxRideThrgh-alarm:

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b02),
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• 9.07 FaultWord7 (AutoRestart-fault: b02),

• 9.11 AlarmWord1 (AutoRestart-alarm: b01).
Save the trends from the testswith DriveDebug or DriveWindows and
attach them to the commissioning report.
9.4.1. Main Power Ride Through
The converter’s ability to cope with main power supply breaks depends
mainly on the application. In case of a high inertia application (for
example a fan), the converter should be able to cope with quite long
power dips whilst in case of a low inertia application (for example a
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compressor), the converter can only cope with short power dips (less than
0.5 – 1 seconds).
Test procedure:
1 Enable the main power ride though function with parameter 39.01
RIDE THROUGH ENABLE and make sure that the ride though time
and minimum speed are set correctly with parameters 39.02 RIDE
THROUGH TIME and 39.03 RIDE THROUGH MIN SPEED (it is
usually not necessary to change the values of these parameters).
2 Close the MCB, start the motor and increase the motor speed to the
normal operation point.
3 Open an upper breaker for a short while to make sure the converter
can cope with the power break without tripping.
9.4.2. Auxiliary Power Ride Through
The converter is designed to be able to keep operating through an

auxiliary power ride through by keeping the control electronics supplied
from the backup batteries. During the auxiliary ride through, the alarms
and faults from the cooling unit are suppressed.
In the air-cooled ACS 1000 and in ACS 1000i, the maximum allowed
auxiliary ride through time is set with parameter 39.05 AUX RIDE
THROUGH TIME. In the water-cooled ACS 1000, the maximum allowed
auxiliary ride through time is limited to 1 second.
CAUTION!
Make sure that the backup batteries are charged properly before
performing the auxiliary ride through test.
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Test procedure:
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1 Enable the auxiliary power ride though function with parameter 39.04
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AUX RIDE THROUGH ENABLE and make sure that the ride though
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time is set correctly with parameters 39.05 AUX RIDE THROUGH (it
is usually not necessary to change the values of this parameters).
3 Switch off the auxiliary power supply from a supply contactor for a
short while to make sure the converter can cope with the auxiliary
power break without tripping.
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9.4.3. Auto Restart
The undervoltage auto restart-function is designed to automatically restart

the converter after an undervoltage-faults has occured.
Test procedure:
1 Enable the undervoltage restart enable-function with parameter 31.01
UNDERVOLT RESTART ENABLE and make sure that the
undervoltage restart time is set correctly with parameter 31.02
UNDERVOLT WAIT TIME.
3 Open an upper breaker and wait until the motor has stopped and that
the alarm ‘AutoRestart’ is shown on the CDP-panel.
4 Close the upper breaker within the time specified in parameter 31.01
UNDERVOLT RESTART ENABLE and make sure the DC-link is
charged properly and that the motor starts automatically.
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ABB Chapter 10 - Final Work
Chapter 10 - Final Work
10.1. Spare Parts
Before leaving the site, the customer spare parts are to be checked
against the bill of material. If spare parts have not been ordered at all, the
commissioning report is to be marked accordingly.
Spare parts of the customer containing software (AMC and INT-board)
are to be updated with the software used in the converter and the
customer specific parameters are to be set.
10.2. Customer Training
If not agreed by contract otherwise, the subjects listed below can be used
as a guide when organizing on-site training. The training can be based on
chapter 6 - Operation in the User’s Manual of the converter.
• Safety instructions related to the operation of the converter
• Door interlocking system in conjunction with the grounding switch
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Control panel
• Overview of keypad modes
• Reading and interpreting status, alarm and fault
messages
• Control modes (local/remote)
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• Energizing and starting the converter

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• Stopping and de-energizing the converter

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• Where to get help

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If customer personnel are not trained by the commissioning engineer on

site, the customer should be informed about the training programs offered
by ABB training centers worldwide.
10.3. Parameter Backup
All parameters of the converter must be saved using DriveWindow and

DriveDebug.
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Chapter 10 - Final Work ABB

10.3.1. Saving Parameters and System Software using DriveWindow
The parameters are saved in two steps and the parameters together with
the system software are saved in a third step.
Parameters
Only parameter groups, which are open in DriveWindow, can be saved.
Since the parameter groups above 99 are not open by default, they must
be opened first.
The parameter groups above 99 are opened and all open parameters are
saved in the “drive window parameter” file (“dwp” file) for use with
DriveWindow:
1 If several converters are linked via a DDCS communication link,

select the converter from which parameters will be uploaded or a
software backup will be made.
2 Enter passcode 564 into parameter 16.03.

Parameter groups 1 to 99 and 112 and 190 will be opened.
3 Save the open parameter groups as “dwp” file (see Figure 10-1).
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4 Enter pass code 2289 into parameter 16.03.

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Parameter groups 1 to 99 and all parameter groups above 99 except

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112 and 190 will be opened.

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5 Save the open parameter groups as “dwp” file (see Figure 10-1).
6 Enter pass code 358 into parameter 16.03 to lock the parameter
groups over 100.
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Figure 10-1 Saving the DriveWindow Parameter File
System Software and Parameters

In this step, a complete backup of the AMC flash memory is made
including system software and all parameters and it is stored in a “bpg”
file.
The backup is created and saved according to the following steps:
1 Select the backup package. Nothing will happen, this step does not
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2 Initiate compilation of the backup.
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3 After selecting “Backup”, the following window is displayed.
4 When the “Select Drives” dialog box is displayed, select the item from
which the backup is to be made.
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5 Press “Backup”.
While the backup is executed the following dialog box is displayed.
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6 Save the backup as a “bpg” file.
10.3.2. Saving Parameters and System Software using DriveDebug
Version 2.9 or a higher version of DriveDebug is required to make a

backup of parameters and system software. Lower versions than 2.9
might not be able to upload all parameters.
Check in the “property“ menu of DriveDebug that the path designation in
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Parameters
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1 In the “Target” menu, click on “Open Target List Window…”.
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2 In the target list, select the drive from which parameters will be
uploaded or a software backup will be made.
3 In the “Target” menu, select the “Open Parameter Window” to upload

the parameters.
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5 Save the parameters as a “text” file (extension “txt”) so customers do

not have to rely on the DriveWindow tool for viewing settings.
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6 Save the parameters as a “pac” file. Check that “complete” is

selected in the “Parameter backup/restore mode” window and press
“Backup”.
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System Software and Parameters
In this step, a complete backup of the AMC3 flash memory is made
including system software and all parameters.
1 Save the parameters as a “tar”-file.
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NOTICE!
This step can take up to 10 minutes.
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10.4. Customer Approval
After the test runs have been performed and the commissioning report
has been filled in completely, the representative of the customer is asked
to confirm the end of the commissioning with his / her signature on the
report. Date and signature on the report will indicate the beginning of the
warranty period to the factory.
10.5. Customer Documentation
The following documentation stays with to the customer after the

commissioning:
• Copy of the commissioning report
• Copy of the parameter backup files:
• “txt” file
• “dwp” file
If possible, the parameter files should be stored on a customer PC.
• Complete software backup including system software and parameter
settings
• “bpg” file
• Copy of the signal and parameter table(s):
• In electronic format
• As paper copy (if required)
Note: Make sure that the correct version of the signal and parameter
table stays with the customer.
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10.6. Documentation and Back-up Copies for Supportline

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For revising and archiving of the factory documentation and for later
assistance of the customer send the following to the MV AC Supportline:
• Commissioning report
• Field report
• Parameter and software backup files (files with extensions “txt”,
“dwp”, “tar” and “pac”)
• Photographs of the installation (photographs only to be taken with
permission of the customer)
• Copy of modified mechanical and electrical drawings
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10.6.1. Supportline Contact Information
Lotus Notes address: MV AC Supportline/CHIND/ABB

E-mail address: mv.ac.supportline
Phone:+41 844 845 8
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Document No.: 3HBS210669 ZAB E01 Rev.-

ACS 1000 Commissioning Manual 3HBS210669 ZAB E01 Rev.- 1/64

2/64 3HBS210669 ZAB E01 Rev.- ACS 1000 Commissioning Manual

Chapter 2 - Precommissioning Check List ......................................................................7

Chapter 3 - Inspection of Installation .............................................................................11

Chapter 4 - Safety ............................................................................................................15

Chapter 5 - Connecting Auxiliary Supply to the Converter ..........................................17

5.2. Phoenix Auxiliary Power Supply ..................................................................................... 18

5.3. Checking Of Auxiliary Backup Batteries ......................................................................... 21

Chapter 6 - Commissioning of the Cooling System......................................................23

6.1. Water-Cooled ACS 1000 ................................................................................................ 23

6.1.1. Checking the Internal and External Cooling Circuits ...................................................... 23

Chapter 7 - Insulation Resistance Measurements ........................................................27

ACS 1000 Commissioning Manual 3HBS210669 ZAB E01 Rev.- 3/64

Chapter 1 - Overview ABB

Chapter 8 - Preparing the System.................................................................................. 37

Chapter 9 - Energizing, First Start and Load Test ........................................................ 47

Chapter 10 - Final Work ....................................................................................................

10.5. Customer Documentation ...............................................................................................63

10.6. Documentation and Back-up Copies for Supportline ......................................................63

10.6.1. Supportline Contact Information .....................................................................................64

4/64 3HBS210669 ZAB E01 Rev.- ACS 1000 Commissioning Manual

ABB Chapter 1 - Overview

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Working on energized equipment can be a life hazard.

1.2. Scope of Commissioning

Normally, the commissioning engineer is only responsible for the

ACS 1000 Commissioning Manual 3HBS210669 ZAB E01 Rev.- 5/64

Chapter 1 - Overview ABB

During commissioning, the Commissioning Report and the Field Service

1.4. Related Documents and Parameter References

The following manuals and specifications provide information on the drive

• Toolbox with normal tools like screwdrivers, spanners etc.

6/64 3HBS210669 ZAB E01 Rev.- ACS 1000 Commissioning Manual

ABB Chapter 2 - Precommissioning Check List

Chapter 2 - Precommissioning Check List

2.1. Office Preparations

• Copy of field service report

• Copy of commissioning report

• Copy of converter documentation

• Information about the scope of delivery

• Information about SW and EPLD updates 1 and 3

• Special tuning instructions for converter 1

• Information on possible converter upgrades 1

Setting values for motor parameters (equivalent circuit of

• Commissioning program (to be agreed with customer)

• Suitable megger for insulation test 2

• (Spare parts for commissioning)

1 Contact MV AC Supportline for information, see chapter 10.6.1

ACS 1000 Commissioning Manual 3HBS210669 ZAB E01 Rev.- 7/64

Chapter 2 - Precommissioning Check List ABB

After receiving the converter and related equipment, the customer is

2.3. Pre-Conditions for Commissioning

In order to ensure an uncomplicated and fast commissioning, it is

1. Mechanical Installation of the Converter

• Customer side raw water piping is completed and the pipes

• Raw water supply is ready

2. Electrical Installation of the Converter

• All control cables going into the converter are connected,

appropriately labelled and the customer side connections are

• Types and cross sections of control cables are suitable for