ABB ACS 600, ACS 800 Users Manual

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ACS 600, ACS 800

User’s Manual

This manual includes

•Safety

• Commissioning of the Supply Section with ISU

• Functional Description

• Parameters

• Fault Tracing

• Technical Data

ACA 635 IGBT Supply Sections

260 to 4728 kVA

ACS 800-17 Line-side Converter

120 to 1385 kVA

ACS 600 MultiDrive Manuals (Air-cooled Units, English Originals)

GENERAL MANUALS

*Safety and Product Information EN 63982229

• Complete general Safety Instructions

• Technical data for DSU and TSU supplies and Drive Sections: ratings, power losses, dimensions, weights, fuses etc.

*System Description EN 63700151

• General description of ACS 600 MultiDrive

*Hardware Manual EN 63700118

• General Safety Instructions

• Hardware description of the Drive Section

• Cable selection

• ACS 600 MultiDrive mechanical and electrical installation

• Hardware commissioning of the Drive Section

• Preventive maintenance of ACS 600 MultiDrive

ACS 600 MultiDrive Control Electronics LED Indicators

EN 64289721

• LED descriptions

**Modules Product Catalogue EN 64104268

• Supply Unit components

• Drive Unit components

• Dynamic Braking Units

•DriveWare information

• Dimensional drawings

• Single line diagrams

• Auxiliary power consumption

• Master component tables

**Modules Installation Manual EN 64119010

• Cabinet assembly

• Wiring

**Grounding and Cabling of the Drive System EN 61201998

• Grounding and cabling principles of a variable speed drive system

**EMC Compliant Installation and Configuration for a Power Drive System EN 61348280

* Included with cabinet-assembled systems only ** Included in Modules deliveries only

SUPPLY SECTION MANUALS (depending on the supply type one of these manuals is included in the delivery)

Diode Supply Sections User’s Manual (DSU) EN 61451544

• DSU specific Safety Instructions

• DSU hardware and software descriptions

• DSU commissioning

• Earth fault protection options

Thyristor Supply Sections User’s Manual (TSU) EN 64170597

• TSU operation basics

• TSU firmware description

• TSU program parameters

• TSU commissioning

IGBT Supply Sections User’s Manual EN 64013700

• ISU specific Safety Instructions

• Main components of ISU

• ISU ratings

• ISU power losses

• ISU dimensions and weights

• ISU fuses

• ISU program parameters

• Earth fault protection options

FIRMWARE MANUALS FOR DRIVE APPLICATION PROGRAMS (appropriate manual is included in the delivery)

System EN 63700177

• Commissioning of the System Application Program

• Control Panel use

• Software description

• Parameters of the System Application Program

• Fault tracing

•Terms

Application Program Template EN 63700185

• Commissioning of the Drive Section

• Control Panel use

• Software description

• Parameters

• Fault tracing

•Terms

Standard EN 61201441

• Control Panel use

• Standard application macros with external control connection diagrams

• Parameters of the Standard Application Program

• Fault tracing

• Fieldbus control Note: a separate Start-up Guide is attached

Crane Drive EN 3BSE 011179

• Commissioning of the Crane Drive Application Program

• Control Panel use

• Crane program description

• Parameters of the Crane Drive Application Program

• Fault tracing

CONTROL SECTION MANUALS (delivered with optional Control Section)

Advant Controller 80 User’s Manual EN 64116487

• AC 80 hardware and connections

• AC 80 software

• Programming

• Diagnostics

Advant Controller 80 Reference Manual PC Elements EN 64021737

• Description of PC and DB elements

Advant Controller 80 Reference Manual TC Elements EN 64331868

• Description of TC elements

BRAKING SECTION MANUAL (delivered with optional Braking Section)

ACA 621/622 Braking Sections User’s Manual EN 64243811

• Installation, Start-up, Fault tracing,Technical data

• Dimensional drawings

MANUALS FOR OPTIONAL EQUIPMENT (delivered with optional equipment)

Fieldbus Adapters, I/O Extension Modules, Braking Choppers etc.

• Installation

• Programming

• Fault tracing

• Technical data

ACA 635 IGBT Supply Sections

260 to 4728 kVA

ACS 800-17 Line-side Converter

120 to 1385 kVA

User’s Manual

This manual concerns the ACS 600 MultiDrive supply sections (ACA 635) equipped with an IGBT Supply Unit and ACS 800-17 drives.

3BFE 64013700 REV D

EFFECTIVE: 07.07.2003

Safety Instructions

Overview

Installation and Maintenance Safety

The complete safety instructions for the ACA 6xx in Safety and Product Information (EN code: 63982229) and for the ACS800-17 in Hardware Manual (EN code: 64638505) must be followed when installing,

operating and servicing the drives. Study the complete safety instructions carefully.

These safety instructions are intended for all who work on the ACA 6xx or the ACS 800-17. Ignoring these instructions can cause physical injury or death.

WARNING! All electrical installation and maintenance work on the drive should be carried out by qualified electricians.

Any installation work must be done with power off, and power is not to be reconnected unless the installation work is complete. Dangerous residual voltages remain in the capacitors when the disconnecting device is opened. Wait for 5 minutes after switching off the supply before starting work. Always ensure by measuring that the voltage between the terminals UDC+ and UDC- and the frame is close to 0 V and that the supply has been switched off before performing any work on the equipment or making main circuit connections.

If the main circuit of the inverter unit is live, the motor terminals are also live even if the motor is not running!

Open switch fuses of all parallel connected inverters before doing installation or maintenance work on any of them. These switch fuses are not included in the the ACS 800-17.

When joining shipping splits, check the cable connections at the shipping split joints before switching on the supply voltage.

If the auxiliary voltage circuit of the drive is powered from an external power supply, opening the disconnecting device does not remove all voltages. Control voltages of 115/230 VAC may be present in the digital inputs or outputs even though the inverter unit is not powered. Before starting work, check which circuits remain live after opening of the disconnecting device by referring to the circuit diagrams for your particular delivery. Ensure by measuring that the part of the cabinet you are working on is not live.

ACA 635 IGBT Supply Sections, ACS800-17 iii

Safety Instructions

The control boards of the converter unit may be at the main circuit potential. Dangerous voltages may be present between the control boards and the frame of the converter unit, when the main circuit voltage is on. It is critical that the measuring instruments, such as an oscilloscope, are used with caution and safety as a high priority. The fault tracing instructions give special mention of cases in which measurements may be performed on the control boards, also indicating the measuring method to be used.

Live parts on the inside of doors are protected against direct contact. Special safety attention shall be paid when handling shrouds made of sheet metal.

Do not make any voltage withstand tests on any part of the unit while the unit is connected. Disconnect motor cables before making any measurements on motors or motor cables.

WARNING! Close switch fuses of all parallel connected inverters before starting the drive.

Automatic Resets

Do not open the drive section switch fuses when the inverter is running.

Do not use Prevention of Unexpected Start for stopping the drive when the inverter is running. Give a Stop command instead.

CAUTION! Fans may continue to rotate for a while after the

disconnection of the electrical supply.

CAUTION! Some parts like heatsinks of power semiconductors and toroidal cores on motor cables inside the cabinet remain hot for a while after the disconnection of the electrical supply.

WARNING! If an external source for start command is selected and it is ON, the drive will start immediately after fault reset.

iv ACA 635 IGBT Supply Sections, ACS800-17

Dedicated Transformer

Safety Instructions

WARNING! Frame size R11i and above must be supplied with a transformer dedicated to drives and motors or equipment of equal or higher power, or with a transformer equipped with two secondary windings, one of which is dedicated to drives and motors. Resonances might occur if there is capacitive load (e.g. lighting, PC, PLC, small power factor compensation capacitors) in the same network with the drive. The resonance current might damage some unit in the network.

Medium voltage network

Supply transformer

Neighbouring network

Low voltage

Other load than

drives and motors

Medium voltage network

Other load than

drives and motors

Low voltage

Other drives and motors

Motors

Other drives

Supply transformer

Drive

Low voltage

Drive

ACA 635 IGBT Supply Sections, ACS800-17 v

Safety Instructions

vi ACA 635 IGBT Supply Sections, ACS800-17

Table of Contents

ACS 600 MultiDrive Manuals (Air-cooled Units, English Originals)

Safety Instructions

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Installation and Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Automatic Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Dedicated Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Table of Contents

Update Notice for ACA 635 IGBT Supply Sections 260 to 4728 kVA ACS 800-17 Line-side Converter 120 to 1385 kVA

ACS 800-17 Line-side Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Chapter 1 - About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Chapter 2 - Operation Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Chapter 3 - Hardware Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Chapter 8 - Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Appendix A - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Appendix B Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Chapter 1 – About this Manual

What this Chapter Contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Parameter Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

To which Products this Manual Applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

ISU-related Information in Other Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Chapter 2 – Operation Basics

Operation of ISU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Main Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Voltage and Current Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

DC Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Spectrum of the Voltage DIstortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Spectrum of the Line Current Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Chapter 3 – Hardware Description

Main Components of a Drive with ISU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

ACA 635 IGBT Supply Sections User’s Manual vii

Supply Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Auxiliary Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Incoming Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Filter Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

IGBT Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Main Circuit Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Basic Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Parallel Connected Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Braking Chopper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Chapter 4 – Commissioning the Supply Section with ISU

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Checks with No Voltage Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Connecting Voltage to Auxiliary Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Checks with Voltage Connected to Auxiliary Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Connecting Voltage to IGBT Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Checks with ISU Supply Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Controlling the ISU with an Overriding System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Fieldbus Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

On-load Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 5 – Earth Fault Protection

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Floating Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Insulation Monitoring Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

System-earthed Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Chapter 6 – Firmware Description

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Control Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Identification Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Starting Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Start by the Starting Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Start via Fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Missing Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Control Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

DC Voltage Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Reactive Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

viii ACA 635 IGBT Supply Sections User’s Manual

Chapter 7 – Fault Tracing

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Fault Tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Fault Resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Fault and Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

What to Do in Case of an Earth Fault Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Flowchart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Chapter 8 – Parameters

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1 Actual Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

2 Actual Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

3 Actual Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

4 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

7 Control Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

8 Status Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

9 Fault Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

11 Reference Selects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

13 Analogue Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

14 Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

15 Analogue Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

16 System Control Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

18 LED Panel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

19 Data Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Trend Monitoring with Drive Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Sending a value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

19 Data Storage Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

21 Start/Stop Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

23 DC Bus Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

24 Reactive Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

30 Fault Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

51 Communication Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

70 DDCS Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

71 DriveBus Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

90, 91 Data Set Receive Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

92, 93 Data Set Transmit Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

98 Option Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

99 Start-up Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Appendix A – Technical Data

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Ratings 380...690 V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

ACA 635 IGBT Supply Sections User’s Manual ix

Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Harmonic Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Switching Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

IGBT Supply Section AC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

IGBT Supply Unit DC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Power Cable Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Tightening Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

IGBT Supply Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Drive Control Unit NDCU-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

NIOC Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

NIOC Board Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Drive Control Unit RDCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Motor Control and I/O board RMIO-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

RMIO board specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

CE Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Compliance with the EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Appendix B – Circuit Diagrams

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

x ACA 635 IGBT Supply Sections User’s Manual

Update Notice for

ACA 635 IGBT Supply Sections 260 to 4728 kVA

ACS 800-17 Line-side Converter 120 to 1385 kVA

The notice concerns The translation (DE revision C) of the ACA 635 IGBT Supply Sections

260 to 4728 kVA, ACS 800-17 Line-side Converter 120 to 1385 kVA User’s Manual: code 3BFE 64495062

The notice is in use from 28.07.2003

The notice contains Updates to the REV C translation.

ACS 800-17 Line-side Converter

Chapter 1 - About this Manual

Chapter 2 - Operation Basics

CHANGED: ACS/ACC 617 line-side converter has been replaced by

the ACS 800-17 line-side converter.

Page 1-2, User Interface CHANGED: The user interface of the IGBT Supply Unit is a CDP 312 Control Panel or a PC, which is equipped with a DDCS board and DriveWindow.

Page 2-3 CHANGED: Voltage and current distortion

Spectrum of the Voltage Distortion

1,5

0,5

THD 11 21 31 41 51 61 71 81 91 101 111 121 131 141 151 161 171 181 191

Update notice 1

Update Notice

Spectrum of the Current Distortion

3,5

2,5

1,5

0,5

THD 11 21 31 41 51 61 71 81 91 101 111 121 131 141 151 161 171 181 191

Chapter 3 - Hardware Description

Current THD [%]

Page 3-2, Incoming Unit CHANGED: Frames R6i to R9i: switch fuse (including AC fuses) and main contactor. Frames R11i and above: air circuit breaker.

Page 3-3 CHANGED: Current and voltage distortion

Current Distortion (up to 200th) Generated by the Supply Unit at

PCC (Point of Common Coupling)

4.5 4

3.5 3

2.5 2

1.5 1

0.5 0

0 102030405060708090100

Rsc (Short-circuit Ratio) at PCC

2 Update notice

Voltage THD [%]

Update Notice

Voltage Distortion (up to 200th) Generated by the Supply Unit at

PCC (Point of Common Coupling)

0 102030405060708090100

Rsc (Short-circuit Ratio) at PCC

Page 3-5 Basic Configuration CHANGED: The hardware of the IGBT supply unit is similar to the hardware of the

ACS 600 MultiDrive inverter. One NAMC/RMIO board controls the converter module. It is located inside the Drive Control Unit (NDCU/ RDCU) box. The supply section is equipped with an LCL filter, DC fuses and AC fuses/switch fuse OESA. AC fuses are used with a breaker and a switch fuse is used with a contactor.

ISUICU

OESA

FIU

Converter Module

AC fuses DC fuses

Charging circuit

230/115 V

NAMC/

RMIO

NDCU/RDCU

ACU

Update notice 3

Update Notice

Chapter 8 - Parameters

Page 8-2 CHANGED:

Code Parameter Range/Unit Description Integer Scaling

1 ACTUAL

SIGNALS

1.19 AI1 [V]

0...10 Non-scaled value of analogue input AI1. See Par. 13.01 AI1 HIGH VALUE and 13.02 AI1 LOW VALUE.

10000 = 10 V or 20 mA

Page 8-4 CHANGED: The software version (Parameters 4.01 and 4.03) is expressed as

follows:

Character noExample Meaning

1 I I = Input bridge software 2 X Product: X= ISU 3 X Software type:

A = application software (Parameter 4.03) 4 G Control board: G = NAMC-51, R = RMIO 5 to 8 6000 Software version number: 6000 = NAMC-51,

7000 = RMIO

Page 8-9 ADDED:

Code Parameter T

13 ANALOGUE

INPUTS

13.12 MINIMUM AI1

Default Alternative

y p e

I0 V (1) 0 V

Settings

( ) Fieldbus Equivalent

(2) -10 V

Description Integer

Scaling

This value corresponds to the minimum reference from analogue input AI1.

4 Update notice

Page 8-22 CHANGED:

Update Notice

Code Parameter

70 DDCS

CONTROL

70.20 CH3 HW CONNECTION

Default Alternative

y p e

STAR This parameter is used for

Settings

( ) Fieldbus Equivalent

(0) RING Regeneration enabled. Select

(1) STAR Regeneration disabled.

Description Integer

enabling or disabling regeneration of channel CH3 optical transmitter. In regeneration mode any message received by the channel is echoed back.

RING if the CH3 channels on the NAMC boards / RDCO modules are connected to a ring configuration.

Select STAR with a star configuration such as DriveWindow (PC) – NDBU95 optical branching unit(s) – NAMC board / RDCO module (RMIO board).

Scaling

1=1

Page 8-23 CHANGED: D SET 10 VAL 1 denotes the receive address of data set 10 value 1.

Page 8-24 CHANGED: D SET 11 VAL 1 denotes the transmit address of data set 11 value 1.

Update notice 5

Update Notice

Appendix A Technical Data

Page A-9 ADDED: Drive Control Unit RDCU has been added to the manual. The RDCU unit replaces the NDCU-51 unit. The Drive Control Unit RDCU containing an RMIO-01 board is shown in the pictures below.

Interface for CDP312 Control Panel

X20

X34

X21

X31

X22

X23

X25

X26

X27

X32

X33

X68 X57

6 Update notice

Update Notice

Update notice 7

Update Notice

External control cable connections (non-US) to the RMIO board for the ACS 800 Standard Application Program (Factory Macro) are shown below. For external control connections of other application macros and programs, see the appropriate Firmware Manual.

Terminal block size:

cables 0.3 to 3.3 mm2 (22 to 12 AWG)

Tightening torque:

0.2 to 0.4 Nm (2 to 4 lbf in.)

Only effective if par. 10.03 is set to REQUEST by the user.

0 = open, 1 = closed

DI4 Ramp times according to 0 parameters 22.02 and 22.03 1 parameters 22.04 and 22.05

See par. group 12 CONSTANT

SPEEDS.

DI5 DI6 Operation 0 0 Set speed through AI1 1 0 Constant speed 1 0 1 Constant speed 2 1 1 Constant speed 3

See parameter 21.09 START INTRL

FUNC.

rpm

Fault

X20 1 VREF- Reference voltage -10 VDC, 2 GND

1 kohm <

RL< 10 kohm

X21 1 VREF+ Reference voltage 10 VDC, 2GND

1 kohm <

RL< 10 kohm

3 AI1+ Speed reference 0(2) ... 10 V,

> 200 kohm

4AI1-

5 AI2+ By default, not in use. 0(4) ... 20 mA,

= 100 ohm

6AI2-

7 AI3+ By default, not in use. 0(4) ... 20 mA,

= 100 ohm

8AI39 AO1+ Motor speed 0(4)...20 mA 0...motor nom. 10 AO111 AO2+ Output current 0(4)...20 mA 0...motor 12 AO2-

speed, R

< 700 ohm

nom. current, R

< 700 ohm

X22 1DI1 Stop/Start 2 DI2 Forward/Reverse

3 DI3 Not in use 4 DI4 Acceleration & deceleration select 5 DI5 Constant speed select 6 DI6 Constant speed select

7 +24V +24 VDC max. 100 mA 8 +24V 9 DGND Digital ground 10 DGND Digital ground 11 DIIL Start interlock (0 = stop)

X23 1 +24V Auxiliary voltage output, non-isolated, 2GND

24 VDC 250 mA

X25 1 RO11 Relay output 1: ready 2RO12 3RO13 X26 1 RO21 Relay output 2: running 2RO22 3RO23 X27 1 RO31 Relay output 3: fault (-1) 2RO32 3RO33

External control cable connections (US) to the RMIO board for the

8 Update notice

Terminal block size:

cables 0.3 to 3.3 mm

(22 to 12 AWG)

Tightening torque:

0.2 to 0.4 Nm (2 to 4 lbf in.)

Only effective if par. 10.03 is set to REQUEST by the user.

0 = open, 1 = closed DI4 Ramp times according to 0 parameters 22.02 and 22.03 1 parameters 22.04 and 22.05

See par. group 12 CONSTANT

SPEEDS. DI5 DI6 Operation 0 0 Set speed through AI1 1 0 Constant speed 1 0 1 Constant speed 2 1 1 Constant speed 3

See parameter 21.09 START INTRL

FUNC.

Update Notice

ACS800 Standard Application Program (Factory Macro US version, +N665) are shown below. For external control connections of other application macros and programs, see the appropriate Firmware Manual.

X20 1 VREF- Reference voltage -10 VDC,

RL< 10 kohm

> 200 kohm

= 100 ohm

< 700 ohm

rpm

Fault

2 GND

1kohm<

X21 1 VREF+ Reference voltage 10 VDC, 2GND

1kohm<

3 AI1+ Speed reference 0(2) ... 10 V, 4AI1-

5 AI2+ By default, not in use. 0(4) ... 20 mA, 6AI2-

7 AI3+ By default, not in use. 0(4) ... 20 mA, 8AI3-

9 AO1+ Motor speed 0(4)...20 mA 0...motor nom. 10 AO1-

speed, R

11 AO2+ Output current 0(4)...20 mA 0...motor 12 AO2-

nom. current, R

X22 1DI1 Start () 2 DI2 Stop ( ) 3 DI3 Forward/Reverse 4 DI4 Acceleration & deceleration select 5 DI5 Constant speed select 6 DI6 Constant speed select 7 +24V +24 VDC max. 100 mA 8+24V 9 DGND Digital ground 10 DGND Digital ground 11 DIIL Start interlock (0 = stop) X23 1 +24V Auxiliary voltage output, non-isolated, 2GND

24 VDC 250 mA

X25 1 RO11 Relay output 1: ready 2RO12 3RO13 X26 1 RO21 Relay output 2: running 2RO22 3RO23 X27 1 RO31 Relay output 3: fault (-1) 2RO32 3RO33

Update notice 9

Update Notice

RMIO Board Specifications

Analogue inputs With Standard Application Program two programmable differential current inputs

(0 mA / 4 mA ... 20 mA, R input (-10 V / 0 V / 2 V ... +10 V, R

The analogue inputs are galvanically isolated as a group.

Isolation Test voltage: 500 VAC, 1 min Max. common mode voltage between the channels: ±15 VDC Common mode rejection ratio: > Resolution: 0.025% (12 bit) for the -10 V ... +10 V input. 0.5% (11 bit) for the 0 ... +10

V and 0 ... 20 mA inputs. Inaccuracy: ± 0.5% (Full Scale Range) at 25 °C. Temperature coefficient: ± 100 ppm/

°C, max.

Constant voltage output Voltage: +10 VDC, 0, -10 VDC ± 0.5% (Full Scale Range) at 25 °C. Temperature

coefficient: ± 100 ppm/°C (± 56 ppm/°F) max

Maximum load: 10 mA Applicable potentiometer: 1 kohm to 10 kohm

Auxiliary power output Voltage: 24 VDC ± 10%, short circuit proof

Maximum current: 250 mA (without any optional modules inserted onto slots 1 and

Analogue outputs Two programmable current outputs: 0 (4) to 20 mA, R

Resolution: 0.1% (10 bit) Inaccuracy: ± 1% (Full Scale Range) at 25 °C (77 °F). Temperature coefficient:

± 200 ppm/°C (± 111 ppm/°F) max.

Digital inputs With Standard Application Program six programmable digital inputs (common ground:

24 VDC, -15% to +20%) and a start interlock input. Group isolated, can be divided in two isolated groups (see Isolation and grounding diagram below).

Thermistor input: 5 mA, < 1.5 kohm “1” (normal temperature), > 4 kohm “0” (high temperature), open circuit “0” (high temperature).

Internal supply for digital inputs (+24 VDC): short circuit proof. An external 24 VDC supply can be used instead of the internal supply.

Isolation test voltage: 500 VAC, 1 min Logical thresholds: < 8 VDC “0”, > 12 VDC “1” Input current: DI1 to DI 5: 10 mA, DI6: 5 mA Filtering time constant: 1ms

Relay outputs Three programmable relay outputs

Switching capacity: 8 A at 24 VDC or 250 VAC, 0.4 A at 120 VDC Minimum continuous current: 5 mA rms at 24 VDC Maximum continuous current: 2 A rms Isolation test voltage: 4 kVAC, 1 minute

DDCS fibre optic link With optional communication adapter module RDCO. Protocol: DDCS (ABB

Distributed Drives Communication System)

The RMIO board as well as the optional modules attachable to the board fulfil the Protective Extra Low Voltage (PELV) requirements stated in EN 50178.

= 100 ohm) and one programmable differential voltage

> 200 kohm).

60 dB at 50 Hz

< 700 ohm

10 Update notice

Update Notice

Page A-12 CHANGED:

• EN 61800-3: 1996, Amendment A11: 2000 (IEC 61800-3). EMC product standard including specific test method

Page A-13, Second Environment CHANGED:

The ACA 635 supply sections comply with the EMC Directive in industrial low-voltage network, and IT networks (unearthed mains) with the following provisions. For ACS800-17 units, refer to ACS800-17 Hardware Manual (EN code 64638505).

1. The motor and control cables are selected as specified in the

Hardware Manual.

2. The drive is installed according to the instructions given in the

Hardware Manual.

3. Maximum cable length is 100 metres.

WARNING! The drive may cause radio interference if used in a residential or domestic environment. The user is required to take measures to prevent interference, in addition to the requirements for CE compliance listed above, if necessary.

Note: It is not allowed to use EMC filters on an unearthed mains supply network, unless the filters are able to withstand the unearthed network. (EMC filters are used to minimise the RFI emission of the unit.)

Note: With cables longer than 100 metres, the ACA 635 supply sections comply with the EMC Directive in restricted distribution mode when the installation is described in an EMC plan (a template is available from the local ABB representative).

Table A-1 The EMC cabinet option is marked in the type code as follows. 0 = No EMC cabinet, 1 = EMC cabinet (does not include RFI filters)

ACS 600 Type

ACA 635

Character no. Options ACA635xxxxxxxxxxxx...

Type Code

0,1

Update notice 11

Update Notice

Appendix B Circuit Diagrams

Page B-4 ADDED: Circuit diagram including the Drive Control Unit RDCU

12 Update notice

Chapter 1 – About this Manual

What this Chapter Contains

Intended Audience

Parameter Setting

To which Products this Manual Applies

Contents

This chapter describes the intended audience and contents of this manual. It contains a table referring to tasks described in other manuals.

This manual is intended for people who plan the installation, commission, use and service the drive equipped with an IGBT supply. Read the manual before working on the drive. You are expected to know the fundamentals of electricity, wiring, electrical components and electrical schematic symbols.

The parameters of the IGBT Supply Unit (ISU) Program listed in this manual need not be set in a normal start-up procedure or in normal use. However, the ISU parameters can be viewed and

changed using the Control Panel.

This manual applies to the ACA 635 supply sections and ACS 800-17 drives which contain the IGBT Supply Unit.

The control program of the IGBT Supply Unit is described in the following chapters: Chapter 6 – Firmware Description, Chapter 7 –

Fault Tracing and Chapter 8 – Parameters.

Safety Instructions contain installation and maintenance safety

instructions.

Chapter 2 – Operation Basics describes the operation of the IGBT

Supply Unit.

Chapter 3 – Hardware Description describes the hardware of the

ACA 635 supply sections including descriptions of the LCL filter and the IGBT supply unit which are parts of the ACS 800-17 as well.

Chapter 4 – Commissioning the Supply Section with ISU describes the

commissioning of a supply section that is equipped with the IGBT Supply Unit (ISU).

Chapter 5 – Earth Fault Protection describes the earth fault protection

solutions available for a drive equipped with an IGBT supply unit.

Appendix A – Technical Data contains technical data for the ACA 635

giving information on ratings, fuses, cooling requirements, power losses etc.

ACA 635 IGBT Supply Sections User’s Manual 1-1

Chapter 1 – About this Manual

ISU-related Information in Other Manuals

Task See

Appendix B – Circuit Diagrams contains some example circuit

diagrams of the ACA 635.

Mechanical and Electrical Installation of the Drive

Installation of Optional Modules and DriveWindow

Preventive Maintenance

Technical Data for the ACS 800-17

Associating ISU with DriveWindow

ACS 600 MultiDrive Hardware Manual (EN code: 63700118) or ACS800-17 Hardware Manual (EN code: 64638505)

ACS800-17 Hardware Manual (EN code: 64638505)

DriveWindow Start-up Guide (EN code: 36458585) When associating DriveWindow 1.3 and 1.4 with the ISU proceed as follows:

System Configuration Messages What to do

Error: Encountered target ‘ISU600-xxxx-x’ is unknown. Do you wish to associate it?

Associate ‘ISU600-xxxx-x’ With Choose ACS600 MultiDrive

Do you wish association ‘ISU600-xxxx-x’ = ACS600 MultiDrive be permanent?

Click OK.

from the list.

Click Yes.

User Interface Firmware Manual (for System, Standard or Crane Drive Application Program)

The user interface of the IGBT Supply Unit is a CDP 312 Control Panel or a PC, which is equipped with a DDCS board and DriveWindow.

1-2 ACA 635 IGBT Supply Sections User’s Manual

Chapter 2 – Operation Basics

Operation of ISU

Main Circuit Diagram

Supply network

The ISU is a four-quadrant switching-mode converter, i.e., the power flow through the converter is reversible. The AC current of the ISU is sinusoidal at a unity power factor. As a default, the ISU controls the DC link voltage to the peak value of the line-to-line voltage. The DC voltage reference can be set also higher by a parameter.

A diagram of the main circuit of the IGBT supply is shown below.

Control and Gate Drivers

Common DC bus

LCL Filter

Control

Converter

The control and modulation is based on the Direct Torque Control (DTC) method typically used in ACS 600 motor control. Two line currents and DC link voltage are measured and used for the control. The control boards are similar to the boards of the inverter.

ACA 635 IGBT Supply Sections, ACS800-17 2-1

Chapter 2 – Operation Basics

Voltage and Current Waveforms

The high frequency switching and high du/dt slightly distorts the voltage waveform at the input of the converter. The depth of the voltage notches depends on the ratio of network inductance to total line inductance (network + LCL filter inductance).

Typical line current (i

(A, V)

1200

800

400

02468101214161820222426283032343638

-400

-800

) and voltage (uUV) waveforms are shown below.

t (ms)

-1200

DC Current A typical DC current (i

(A)

500

450

400

350

300

250

200

150

100

100 102 104 106 108 110 112 114 116 118

) waveform is shown below.

t (ms)

2-2 ACA 635 IGBT Supply Sections, ACS800-17

Chapter 2 – Operation Basics

Distortion

Spectrum of the Voltage

DIstortion

IGBT supply unit does not generate characteristic current/voltage overtones llike a traditional 6- or 12-pulse bridge does, because of the sinusoidal waveform of the line current. The Total Harmonic Distortion (THD) in voltage depends slightly on the Short Circuit Ratio in the Point of Common Coupling (PCC), refer to Appendix A – Technical Data.

A typical spectrum of the voltage distortion at the output of the transformer is shown below. Each harmonic is presented as a percentage of the fundamental voltage. n denotes the ordinal number of the harmonic.

1,5

0,5

Spectrum of the Line

Current Distortion

THD 11 21 31 41 51 61 71 81 91 101 111 121 131 141 151 161 171 181 191

A typical spectrum of the line current distortion is shown below. Each harmonic is presented as a percentage of the fundamental current. n denotes the ordinal number of the harmonic.

3,5

2,5

1,5

0,5

THD 11 21 31 41 51 61 71 81 91 101 111 121 131 141 151 161 171 181 191

ACA 635 IGBT Supply Sections, ACS800-17 2-3

Chapter 2 – Operation Basics

2-4 ACA 635 IGBT Supply Sections, ACS800-17

Chapter 3 – Hardware Description

Main Components of a Drive with ISU

Auxiliary Control Unit

ACU

NDCU/RDCU

NAMC, NIOC / RMIO

ACT PAR FUNC DRIVE

ENTER

LOC

REF

RESET

DIN rail

REM

DIN rail

24 V

230/115 VAC

The main components of a drive equipped with an IGBT supply unit are shown below. Two drive sections are drawn in the diagram, in reality the number of them varies. The control panels are optional. This chapter describes the supply section.

Supply Section

Incoming Unit

ICU

Filter Unit and

FIU

charging resistor

with IGBT supply

IGBT Supply Unit

Supply

Unit

Braking Sections

Braking Unit (optional)

Common DC Bus

Chopper

Resistor

Drive Sections

Inverter

ACT PAR FUNC DRIVE

ENTER

LOC

REF

RESET

REM

Inverter

ACT PAR FUNC DRIVE

ENTER

LOC

REF

RESET

REM

Supply Section

The supply section consists of the units listed below:

• Auxiliary Control Unit (ACU)

• Incoming Unit (ICU)

• Filter Unit (FIU)

• IGBT Supply Unit (ISU).

ACA 635 IGBT Supply Sections 3-1

Chapter 3 – Hardware Description

Auxiliary Control Unit The following components are located in the Auxiliary Control Unit:

• Drive Control Unit (NDCU), which includes an Application and Motor Controller (NAMC) Board and a standard I/O (NIOC) Board; or Drive Control Unit (RDCU), which includes a Motor Controller and standard I/O Board (RMIO).

• Optical Branching Unit (NPBU) with parallel connected IGBT Supply Units (frames 2 or 4 times R11i and R12i). NPBU is connected between NAMC/RMIO and NINT boards (inside the converter module).

• Control voltage supply (fuses and transformer)

• On/off switch on the cabinet door and relays

• Optional CDP 312 Control Panel and NLMD-01 Monitoring Display

• Optional voltage and current meters

• Control wiring and relays

• Auxiliary voltage filter for sensitive equipment (I

= 17 A, 230/115 V)

• Optional emergency and earth fault protection components

• Other options (fieldbus adapter modules, man/machine interfaces etc.)

Incoming Unit The following components are located in the Incoming Unit:

• Terminals for the input power (AC supply) connection

• Frames R6i to R9i: switch fuse (including AC fuses) and main contactor. Frames R11i and above: air circuit breaker.

• Optional earthing switch

• Charging fuses and contactor

• Current transformer of optional ammeters

Filter Unit The following components are located in the Filter Unit:

• LCL filter

• Cooling fan for filter

• Charging resistors

• AC fuses (frames R11i and above)

LCL Filters An LCL filter suppresses voltage and current distortion across a wide

frequency range.

3-2 ACA 635 IGBT Supply Sections

Chapter 3 – Hardware Description

Short-circuit ratio (Rsc) describes the strength of the supply network. The diagrams below show the estimated voltage and current distortion as a function of short-circuit ratio.

The short-circuit ratio can be calculated as shown in chapter Appendix A – Technical Data / Harmonic Distortion.

Please note that the curves are merely a visualisation of the effect of the LCL filter and supply network characteristics on the distortion, not a specification.

Current Distortion (up to 200th) Generated by the Supply Unit at

PCC (Point of Common Coupling)

4.5 4

3.5 3

2.5 2

1.5

Current THD [%]

0.5 0

0 102030405060708090100

Rsc (Short-circuit Ratio) at PCC

Voltage Distortion (up to 200th) Generated by the Supply Unit at

PCC (Point of Common Coupling)

Voltage THD [%]

0 102030405060708090100

Rsc (Short-circuit Ratio) at PCC

ACA 635 IGBT Supply Sections 3-3

Chapter 3 – Hardware Description

IGBT Supply Unit The IGBT Supply Unit includes the parts listed below:

Converter The converter consists of an IGBT bridge which forms controlled dc

• Converter (ACN 634 xxxx)

• Converter cooling fans

• DC fuses

• the following control boards inside the converter:

- Thick-film Hybrid Board (NRED) in 690 V units only for limiting the maximum voltage

- Power Supply Board (NPOW)

- Main Circuit Interface Board (NINT)

- Control Distribution Board (NXPP) in frame sizes R10i to 4 x R12i

- Gate Driver Power Supply Board (NGPS) in frame sizes R12i and up for supplying power to NGDR boards

- Gate Driver Board (NGDR)

voltage from the supply network ac voltage. The bridge is capable of delivering braking energy back to the network.

Frame Size A converter (ACN 634 xxxx) consists of

R6i to R9i one converter module

R11i to R12i three phase modules (ACN 644 xxxx) = one converter

⇒

2 x R11i, 2 x R12i two times three phase modules (ACN 644 xxxx) = two phase

module blocks ⇒ one converter

No. 1

4 x R11i, 4 x R12i four times three phase modules (ACN 644 xxxx) = four phase

module blocks ⇒ one converter

No. 1

No. 2

⇒

No. 3

⇒

No. 4

3-4 ACA 635 IGBT Supply Sections

Chapter 3 – Hardware Description

Main Circuit Construction

The converter consists of six insulated gate bipolar transistors (IGBT) with free wheeling diodes and DC capacitors. Frames R8i and R9i are equipped with parallel connected IGBTs for each phase located on three power plates. Frame size R11i includes six power plates and frame size R12i nine power plates.

Configurations

The sections below describe possible configurations of ISU modules.

Basic Configuration The hardware of the IGBT supply unit is similar to the hardware of the

ACS 600 MultiDrive inverter. One NAMC/RMIO board controls the converter module. It is located inside the Drive Control Unit (NDCU/ RDCU) box. The supply section is equipped with an LCL filter, DC fuses and AC-fuses/switch fuse OESA. AC fuses are used with a breaker and a switch fuse is used with a contactor.

ISUICU

OESA

FIU

Converter Module

AC fuses DC fuses

Parallel Connected

Modules

Charging circuit

230/115 V

NAMC/

RMIO

NDCU/RDCU

ACU

Parallel connected IGBT supply converter module configuration is similar to parallel connected inverter module configuration of the ACS 600 MultiDrive. One NAMC/RMIO board controls all parallel connected modules. Each module is equipped with an LCL filter and AC and DC fuses. If one module fails, it can be disconnected by removing the fuses on both sides of it. The whole supply has a common disconnecting device. Full redundancy is not possible. The modules cannot supply the DC link separately, with independent NAMC/RMIO boards.

ACA 635 IGBT Supply Sections 3-5

Chapter 3 – Hardware Description

NDCU/RDCU

NAMC/ RMIO

NPBU

ICU

Braking Chopper A braking chopper can be connected in parallel with an IGBT supply

unit. The configuration is beneficial when the braking is continuous and the drive is not allowed to stop if the supply network trips for a short time.

FIU

ISU

Braking Resistor

3-6 ACA 635 IGBT Supply Sections

Braking Chopper

Chapter 4 – Commissioning the Supply Section with ISU

Overview

This chapter describes the commissioning of a supply section that is equipped with the IGBT Supply Unit (ISU).

WARNING! Only qualified electricians are allowed to commission the drive. The Safety Instructions on the first pages of this manual must be followed. Ignoring the safety instructions can cause injury or death.

Installation Checklist

The installation must be checked before commissioning the supply section. This table refers to the more detailed instruction.

Action Information

Check that the mechanical and electrical installation of the frequency converter is inspected and OK.

Ensure that the insulation resistance of the assembly is checked according to instructions given in the Hardware Manual.

Ensure that the surroundings and inside of the cabinet are free from dust and loose objects (like cable trimmings and other waste left from the installation).

See ACS 600 MultiDrive Hardware

Manual (EN code: 63700118) or ACS800-17 Hardware Manual (EN code: 64638505). Refer to Installation Checklist and Insulation Checks.

After the start, the cooling air fans may suck nearby loose objects into the unit. This might cause failure and damage the unit.

ACA 635 IGBT Supply Sections, ACS800-17 4-1

Chapter 4 – Commissioning the Supply Section with ISU

Checks with No Voltage Connected

This table is a commissioning checklist for the supply section with no voltage connected.

Action Information

WARNING! Ensure that the disconnector of the supply transformer is locked to open

position, i.e. no voltage is, or can be connected to the drive inadvertently. Check also by measuring that there actually is no voltage connected.

1. Air Circuit Breaker, Relays, Switches

If the supply section is equipped with an air circuit breaker, check the current trip levels of the air circuit breaker.

Check the settings of the relays for the emergency stop circuit.

Check the settings of the time relays.

Check the settings of other relays.

Check the settings of the breakers/switches of the auxiliary circuits.

The trip levels have been preset at the factory. In most applications there is no need to change these settings.

See the circuit diagrams delivered with the device.

Check that all breakers/switches of the auxiliary circuits are open.

2. Supply Tripping Circuit

Check the operation of the supply transformer tripping option.

3. Auxiliary Control Voltage Transformer

Check the wirings to the primary and secondary side terminals of the auxiliary control voltage transformer.

This is an optional feature. See the circuit diagrams delivered with the device.

See the circuit diagrams delivered with the device for the correspondence between the wirings and the voltage levels.

4-2 ACA 635 IGBT Supply Sections, ACS800-17

Chapter 4 – Commissioning the Supply Section with ISU

Connecting Voltage to Auxiliary Circuits

WARNING! When voltage is connected to the input terminals of the supply section, the voltage will also be connected to the auxiliary control unit and to auxiliary circuits

- also to the ones wired to drive sections.

Make sure that it is safe to connect voltage to the input terminals. Ensure that while the voltage is connected:

• Nobody is working with the unit or circuits that are wired from outside into the cabinets.

• The cabinet doors are closed.

Disconnect the 230 VAC cables that lead from the terminal blocks to the outside of the equipment and have not yet been checked, and the connections which may not yet have been completed.

Make sure that the main contactor/air circuit breaker cannot inadvertently be closed by remote control, e.g. by temporarily opening some connection in its control circuit.

This table describes how to connect voltage to the supply section input terminals and to the Auxiliary Control Unit (ACU) for the first time.

Action Information

Be ready to trip the main breaker of the supply transformer in case anything abnormal occurs.

Ensure that all cabinet doors are closed.

Close the main breaker of the supply transformer.

Close the main disconnecting switch of the supply section.

Close the main disconnecting switch of the auxiliary circuit.

ACA 635 IGBT Supply Sections, ACS800-17 4-3

Chapter 4 – Commissioning the Supply Section with ISU

Checks with Voltage Connected to Auxiliary Circuits

This table is a commissioning checklist for the supply section with voltage connected to the input terminals, and Auxiliary Control Unit (ACU).

Action Information

WARNING! This section includes instructions for checking/measuring circuits under

voltage. Only a qualified person is allowed to do the work. An appropriate and approved measuring instrument must be used.

IF IN DOUBT, DO NOT PROCEED!

Ensure the actions described in section Connecting Voltage

to Auxiliary Circuits are completed.

Measure phase voltages by using the switch and meter on the cabinet door.

Check the secondary side voltage of the auxiliary voltage transformer. Close the protection switch on the secondary side.

Close the breakers of the auxiliary circuits one by one. Check each circuit by

• measuring for correct voltage at terminal blocks

This is an optional feature. If included, see the circuit diagrams delivered with the device.

See the circuit diagrams delivered with the device.

Note: The cooling fans of the IGBT supply unit will start after the main contactor is closed.

• checking the operation of the devices connected to the circuit.

Check the connection from all external auxiliary voltage sources (e.g. from an Uninterrupted Power Supply, UPS) to the auxiliary control unit.

This is an optional feature. If included, see the circuit diagrams delivered with the device.

4-4 ACA 635 IGBT Supply Sections, ACS800-17

Chapter 4 – Commissioning the Supply Section with ISU

Connecting Voltage to IGBT Supply Unit

This table describes how to connect voltage to the IGBT supply unit and the DC busbars for the first time.

Action Information

WARNING! When connecting voltage to the IGBT supply unit, the DC busbars will

become live, as will all the inverters connected to the DC busbars.

Make sure that it is safe to connect voltage to the IGBT supply unit. Ensure that:

• Nobody is working with the unit or circuits that are wired from outside into the cabinets.

• All cabinet doors are closed.

1. First Voltage Switch-on for the IGBT Supply Unit

If the supply section is equipped with an air circuit breaker, set the air circuit breaker current settings to 50% of the onload values.

Ensure that all cabinet doors are closed.

Be ready to trip the main breaker of the supply transformer if anything abnormal occurs.

It is recommended to set relatively low current values at the first voltage switchon.

Close the main disconnecting switch of the supply section. Close the main contactor / air circuit breaker of the supply section.

2. Air Circuit Breaker Current Settings

Increase the air circuit breaker current settings to the onload values.

ACA 635 IGBT Supply Sections, ACS800-17 4-5

Chapter 4 – Commissioning the Supply Section with ISU

Starting

This procedure instructs how to start the IGBT supply unit.

Action Information

WARNING! When starting the IGBT supply unit, the DC busbars will become live, as

will all the inverters connected to the DC busbars.

Make sure that it is safe to start the IGBT supply unit. Ensure that:

• Nobody is working with the unit or circuits that are wired from outside into the cabinets.

• All cabinet doors are closed.

• The covers of the motor terminal boxes are on.

Ensure the actions described in subsections Checks with No

Voltage Connected and Checks with Voltage Connected to Auxiliary Circuits are completed.

Be ready to trip the main breaker of the supply transformer if anything abnormal occurs.

Close the main disconnecting switch of the auxiliary circuit.

Close the main disconnecting switch of the supply section.

Start the ISU:

• reset the starting logic by the RESET button on the cabinet door

• turn the starting switch on the cabinet door from position 0 to 1 and

• turn the starting switch to the START position and release it.

4-6 ACA 635 IGBT Supply Sections, ACS800-17

Chapter 4 – Commissioning the Supply Section with ISU

Checks with ISU Supply Started

This table is a list of checks to be done after the IGBT supply unit is started and the DC busbars are live.

Action Information

WARNING! This section includes instructions for checking/measuring circuits under

voltage. Only a qualified person is allowed to do the work. An appropriate and approved measuring instrument must be used.

IF IN DOUBT, DO NOT PROCEED!

1. Basic Checks

Check that the cooling fan in the supply section rotates freely in the right direction, and the air flows upwards.

FLOATING NETWORK (IT NETWORK)

1. Earth Fault Protection Based on an Insulation Monitoring Device

Check the setting of Parameter 30.04 EXT EARTH FAULT, and the connection to DI4.

Check the tuning of the insulation monitoring device for the earth fault protection (Bender).

The insulation monitoring device is tuned at the factory. If further tuning is required, see the IRDH265 Operating Manual by Bender (code: TGH1249).

A paper sheet set on the lower gratings stays. Fan runs noiselessly.

This is an optional feature (IRDH265-x). If included, see the circuit diagrams delivered with the device. For information on the protection principle, see Chapter 5 – Earth Fault Protection and the IRDH265 Operating Manual by Bender (code: TGH1249).

SYSTEM EARTHED NETWORK (TN NETWORK)

1. Earth Fault Protection Based on Internal Current Measurement

Check the setting of Parameter 30.02 EARTH FAULT.

Parameters

The parameters of the ISU need not be set in a normal start-up procedure or in normal use.

This is a programmable feature. For information on the protection principle, see Chapter 5 – Earth Fault Protection.

ACA 635 IGBT Supply Sections, ACS800-17 4-7

Chapter 4 – Commissioning the Supply Section with ISU

Controlling the ISU with an Overriding System

This procedure instructs how to control or monitor the IGBT supply unit from an overriding system by using data sets 1 and 2 or 10 to 33 with DDCS and DriveBus communication protocols.

The communication works via fibre optic cables connected to channels CH0 to CH3 on the NAMC board. When the RMIO board is used, channels CH0 to CH3 are provided by the DDCS communication option module (RDCO) which is inserted into the optional module slot marked “DDCS” on the RMIO board.

Action Parameter

Set this parameter to MCW if the ISU will be controlled with an overriding system. Set to I/O if the ISU is only monitored.

Set this parameter to FBA DSET1 or FBDSET 10 depending on what datasets the overriding system uses.

Connect the fibre optic cables to channel CH0.

Set the node address and communication mode for channel CH0 as follows:

Controller Node Address Par. 71.01 CH0

DDCS DriveBus Module-

Bus

APC2 1 - - NO AC70 - - 17...125 NO AC80 - 1...12 17...125 YES FCI (CI810A) - - 17...125 NO

DRIVEBUS MODE

98.01 COMMAND SEL

98.02 COMM MODULE

70.01 CH0 NODE ADDR

71.01 CH0 DRIVEBUS MODE

Note: Setting of Par. 71.01 is valid after the next power-up.

Check that the communication is working.

Set the delay time for a communication fault indication. 70.04 CH0 TIMEOUT

Select the action upon a communication fault on channel

70.05 CH0 COMM LOSS CTRL

CH0.

Select RING, if channels CH0 are connected in a ring. The

70.19 DDCS CH0 HW CONN default setting STAR is typically used with DDCS branching units NDBU-85/95.

If a PC is used for control/monitoring, set the node address

70.15 CH3 NODE ADDR for channel CH3. Addresses 1...75 and 126...254 are allowable. The rest of the addresses are reserved for branching units NDBU-85/95 (see NDBU-85/95 User’s Manual, code: 64285513).

Note: If the channels CH3 of several supply units have been connected in a ring or in a star (via a branching unit), give each converter a unique node address. The new address becomes valid only on the next NAMC board power-on.

4-8 ACA 635 IGBT Supply Sections, ACS800-17

Chapter 4 – Commissioning the Supply Section with ISU

Action Parameter

Select RING, if channels CH3 have been connected in a ring. The default setting STAR is typically used with DDCS branching units NDBU-85/95.

Select the addresses for the data to be received from the overriding system and for the data to be transmitted to the overriding system. Note the different updating intervals.

Test the functions with received and transmitted data.

Fieldbus Adapters

Action Parameter

Set the communication with these parametes. See the appropriate fieldbus adapter manual.

On-load Checks

This table is a commissioning checklist for the loaded supply section.

Action Information

70.20 CH3 HW CONNECTION

Groups 90 and 91 DATASET RECEIVE ADDRESSES Groups 92 and 93 DATASET TRANSMIT ADDRESSES

Group 51 COMMUNICATION MODULE

Check the correct operation of the current meters.

Check the correct operation of the emergency-stop circuits.

This is an optional feature. See the circuit diagrams delivered with the device.

ACA 635 IGBT Supply Sections, ACS800-17 4-9

Chapter 4 – Commissioning the Supply Section with ISU

4-10 ACA 635 IGBT Supply Sections, ACS800-17

Chapter 5 – Earth Fault Protection

Overview

Floating Network

Insulation Monitoring

Diagram This diagram shows earth fault protection implemented with an

Device

This chapter contains descriptions of the earth fault protection solutions available for a drive equipped with an IGBT supply unit. The settings required at the start-up are given in Chapter 4 – Commissioning the

Supply Section with ISU.

This section describes the earth fault protection principle in a floating network.

insulation monitoring device.

L1 L2 L3

Transformer Supply Unit

DC Busbar

Inverter Units

BENDER Insulation Monitoring Device

IL > 0, Leakage Current

M 3~

Description The monitoring device is connected between the unearthed system

and the equipotential bonding conductor (PE).

A pulsating AC measuring voltage is superimposed on the system (measuring principle Adaptive Measuring Pulse, AMP is developed by BENDER, patent pending). The measuring pulse consists of positive and negative pulses of the same amplitude. The period depends on the respective leakage capacitances and the insulation resistance of the system to be monitored.

The setting of the response values and other parameters can be carried out via the function keys. The parameters are indicated on the display and they are stored in a non-volatile memory after setting.

ACA 635 IGBT Supply Sections 5-1

Chapter 5 – Earth Fault Protection

With Bender’s insulation monitoring device it is possible to set up two response values: ALARM1 and ALARM2. Both values have an own alarm LED, which illuminates if reading is below these selected response values.

In Case of an Earth Fault An earth fault closes the measuring circuit. An electronic evaluation

circuit calculates the insulation resistance which is indicated on an LC display or an external ohmmeter after the response time.

The alarm actions depend on the electric connection: for example ALARM1 can be wired to give a warning, and ALARM2 can be wired to trip the device.

Further Information Further information about the insulation monitoring device is available

in IRDH265 Operating Manual (code TGH1249) published by the manufacturer, BENDER companies.

System-earthed Network

Diagram This diagram shows earth fault protection implemented with internal

Description The line current unbalance is calculated from measured currents I

In a system-earthed network, the neutral point of the supply transformer is earthed solidly. This section describes an internal earth fault protection principle in a system-earthed network.

current transducers in the ACA 635.

L1 L2 L3

Transformer

IGBT Supply Unit

Inverter Units

DC Busbar

and I

IL > 0, Leakage Current

, IV

In Case of an Earth Fault In normal operation the current sum is zero. An earth fault leads to an

unbalance in the 3-phase system and therefore to a current sum different from zero. If the current unbalance exceeds the limit set in Par. 30.03 EARTH FAULT LEVEL, an alarm is given or the device is tripped.

5-2 ACA 635 IGBT Supply Sections

Chapter 6 – Firmware Description

Overview

Control Principle

This chapter describes the IGBT supply unit control program. Note:

The parameters listed in this chapter need not be set in normal use. They are mentioned for explaining the control principle only.

The following symbols are used:

1.10

113.05

, 11.11

Actual signal or parameter (see Chapter 8 – Parameters).

Parameter above 100. These parameters are not visible to the user unless the passcode is entered for the Parameter Lock in Parameter 16.03 PASS CODE. These parameters are not allowed to be changed without ABB’s permission.

The fundamental theory of line converter operation can be represented by an equivalent circuit with an AC choke and vector diagrams (below), where

____ motoring _ _ _ generating

network voltage vector

line converter voltage vector

AC choke voltage vector

“network flux” vector

“line converter flux” vector

“AC choke flux” vector

δ power transfer angle.

2gen

jωL

jωLi = U

gen

ACA 635 IGBT Supply Unit Program 6-1

Chapter 6 – Firmware Description

The primary function of the ISU is to control the power transfer between the network and the DC link. The purpose of the AC choke (represented by reactance X = jωL) is to smooth the line current and to act as an energy storage for the switch-mode supply. Power transfer equation between the network and the ISU is presented below:

P =

sin

Real power is being transferred only if an angle difference exists between the two voltage vectors. Reactive power transfer equation is presented below:

Q −=

cos

For the desirable magnitude and the direction of the power and reactive power flow, the length of the converter voltage vector and its phase angle δ (with respect to the line voltage vector) must be controlled. The DC voltage is controlled by keeping the power (energy) equilibrium between the line and the drives in the DC link constant. The sign of the angle determines the direction of the power flow.

The output AC voltage is controlled by setting the length of the flux reference to correspond to the desired output voltage level producing cosfii = 1.0.

The ISU control needs measurements of the DC link voltage and two line currents. The “stator flux” (integral of the voltage vector of the ISU) is calculated by integrating the voltage vector used to generate the output voltage of the ISU. This is due to the fact that the existing voltage in the network can be thought to be generated by a rotating magnetic flux encircled by coils. Each of these coils is one of the line voltage phases. The voltage in the coils can be expressed by the formula below:

The virtual torque generated by the ISU is calculated as a cross product of flux and current vectors:

IxTψ=

Power can also be expressed as a product of torque and angular velocity:

P ωT=

6-2 ACA 635 IGBT Supply Unit Program

Chapter 6 – Firmware Description

If the network frequency is constant, power is directly proportional to the torque. By controlling torque, power transferred between the ISU and the network can be set to a value that keeps the DC link voltage constant. These basic facts enable the use of the DTC method which relies on control of flux and torque.

The main difference between DTC and conventional PWM is that the torque is controlled at the same time level as power switches (25 ms). There is no separate voltage and frequency controlled PWM modulator. All selections of the switches are based on the electromagnetic state of the ISU. This kind of control method can be realised only by using a high speed signal processing technology. The digital signal processor Motorola 56xxx is used in the ACS 600 product family to achieve sufficient speed.

Identification Routine

The ISU adapts itself to the supply network and no data concerning the network conditions is to be set. The converter rating plate data is downloaded in the software package.

When the ISU is connected to the network for the first time, an identification routine must be completed. The identification routine is executed each time after the NAMC/RMIO board is powered and the line-side converter is started provided that Parameter 99.08 AUTO LINE ID RUN is set to YES.

The identification routine can be executed manually also after the next start (without power up of the NAMC/RMIO board) by setting the Parameter 99.07 LINE SIDE ID RUN to YES and pressing the Control Panel Start key. This can be done if there is doubt that the automatic identification routine has failed, or an automatic routine is not desirable as it takes approximately 5 seconds and requires that the line-side converter is not loaded.

During ID Run voltage level in the supply network is estimated based on DC voltage measurement. The value is indicated by Parameter 2.07 DC REF INITIALIZ. If If the value of Parameter 2.07 DC REF INITIALIZ is within allowed limits (see Par. 9.11 bit 9 NET VOLTAGE fault), the procedure goes on further to define the frequency of the network (50 Hz or 60 Hz) and the phase order.

ACA 635 IGBT Supply Unit Program 6-3

Chapter 6 – Firmware Description

The parameters concerning the identification routine are presented below.

Code Parameter Unit Description

99.07 LINE SIDE ID RUN Manual identification run

99.08 AUTO LINE ID RUN Automatic identification run after power up of the NAMC/RMIO board and next start

2.07 DC REF INITIALIZ V Nominal DC reference

Fault

9.11 bit 9 NET VOLT FLT Supply voltage is not valid

Charging

Synchronization

When the control has received a start command, the charging contactor is closed. When the DC link voltage is high enough, the main contactor/breaker is closed and the charging contactor is opened. This procedure is controlled by the NAMC board via NIOC board digital outputs RO1 and RO3 (or by the RMIO board via digital outputs RO1 and RO3).

If the charging is not completed, i.e. the DC link voltage has not exceeded the value of Parameter 30.12 DC UNDERVOLT TRIP or the charging current is not below 5% of I

10s/60s

, a fault bit is set (Parameter

9.11 SUPPLY FAULT WORD bit 0 CHARGING FLT).

The ISU is synchronized to the network by three-phase short-circuits. On the basis of the short-circuit current, the ISU can identify the phase order of the supply network and the starting point for the flux/voltage vector. The phase order of the supply can be changed without performing the identification routine again.

The synchronization can also be done without phase order check by setting Parameter 99.06 FAST SYNC to YES.

If a synchronization trial fails, the ISU makes up to 9 additional trials if the supply has not been disconnected. One reason for a failed synchronization is too low a short-circuit current due to the high impedance of the network.

The synchronization parameters are listed below.

Code Parameter Unit Description

99.06 FAST SYNC One short-circuit pulse is used.

Fault

9.02 SUPPLY PHASE Synchronization failed, phase(s) missing.

9.11 SYNCHRO FLT Synchronization failed, short-circuit current

below limit.

6-4 ACA 635 IGBT Supply Unit Program

Chapter 6 – Firmware Description

Starting Sequence

MAIN CTRL WORD

7.01

During the charging procedure the main contactor is closed, and after the synchronization routine is completed, the modulator is started and the ISU runs normally.

A simplified block diagram of the modulator starting (from starting switch on the cabinet door or via fieldbus) is presented below. For description of the starting procedure, see the next pages.

MCW = (0)

I/O = (1)

(0)

(1)

(0)

(1)

(0)

(1)

SWITCH

> 1

MAIN STATUS WORD

8.01

bit 8

bit 0

DI2

bit 3

COMMAND SEL

98.01

ACA 635 IGBT Supply Unit Program 6-5

Chapter 6 – Firmware Description

Start by the Starting

Switch

On/off switch

On/off from relay via

1. digital input DI2

Charging contactor

Main contactor

Synchronization

4, 5, 6

Modulating

By default, the ISU control commands (ON/OFF) are given by the starting switch on the cabinet door which is wired to digital input DI2. The starting sequence is as follows:

2.5 s

0.5 s

Step Function

1. ISU control receives the ON command (DI2 rising edge) from the starting switch.

2. ISU control logic closes the charging contactor control circuit (RO1).

3. ISU control logic closes the main contactor and cooling fan control circuit (RO3).

4. ISU control logic receives the “main contactor on” acknowledgement (DI3).

5. ISU control logic receives the “cooling air fan in operation” acknowledgement (DI1).

6. ISU synchronizes itself to the supply network in case DC voltage is OK (charging is completed successfully).

7. ISU control starts modulation and opens the charging contactor control circuit (RO1). The inverter units can be started.

6-6 ACA 635 IGBT Supply Unit Program

Chapter 6 – Firmware Description

Start via Fieldbus To enable the fieldbus control Parameter 98.01 COMMAND SEL must

be set to MCW. The DC bus can be charged and the modulator started separately via fieldbus. The DC bus can be charged in two ways:

1. by rising edge of Parameter 7.01 MAIN CTRL WORD bit 0 and simultaneous high level of digital input DI2 (starting switch on the cabinet door in position 1).

High level of digital input DI2

Parameter 7.01 MAIN CTRL WORD bit 0 (starts charging)

Charging contactor

Main contactor

Parameter 7.01 MAIN CTRL WORD bit 0 = 1

Digital input DI2 (starts charging)

Charging contactor

Main contactor

2.5 s

0.5 s

2. by rising edge of digital input DI2 (from starting switch) and simultaneous high level of Parameter 7.01 MAIN CTRL WORD bit 0.

2.5 s

0.5 s

The modulator is started by high level of Parameter 7.01 MAIN CTRL WORD bit 3, and stopped by low level of bit 3. The modulator can be started only after the charging of the DC bus is completed.

Parameter 7.01 MAIN CTRL WORD bit 3

Synchronization

Modulation

ACA 635 IGBT Supply Unit Program 6-7

Chapter 6 – Firmware Description

Stop

Missing Phase

A stop signal from the on/off switch on the cabinet door disables the modulator and opens the main contactor. The modulator can be stopped also from the key on the Control Panel and from DriveWindow in local mode, and from an overriding system in remote mode. These functions do not open the main contactor.

When the modulator is stopped in local mode or by an overriding system, the ISU moves to 6-pulse diode bridge mode.

There is no direct AC voltage measurement in the ISU. The lost supply voltage is identified with current and DC voltage measurement.

When the ISU detects that the current has been below 0.64 percent of

10s/60s

for 1.5 milliseconds, an alarm (Parameter 9.12 SUPPLY ALARM WORD bit 10 NET LOST) is generated. The ISU tries to resynchronize as long as the DC voltage is greater than the value of Parameter 30.12 DC UNDERVOLT TRIP. The resynchronizing checks are made at 20 ms intervals. If the voltage in the DC link falls below the limit defined by Par. 30.12 DC UNDERVOLT TRIP, the ISU will open the main contactor/breaker and a fault (Parameter 9.11 bit 14 DC UNDERVOLT) is generated.

Code Parameters Unit Description

30.12 DC UNDERVOLT TRIP V Undervoltage tripping limit

Alarm

9.12 bit 10 NET LOST Supply lost alarm

Fault

9.11 bit 14 DC UNDERVOLT Undervoltage tripping

6-8 ACA 635 IGBT Supply Unit Program

Chapter 6 – Firmware Description

Control Diagram

Hysteresis

Torque ref.

Flux ref.

A block diagram of the measurements and principle of the ISU control

program is shown below. S1, S2 and S3 denote the power switches.

Direct torque and flux

hysteresis control

Actual flux

Actual value calculation

Reactive power control

DC voltage control

Switching frequency control

Actual

torque

Torque bits

Flux bits

Control bits

ASICs

Optimal switching logic

DC voltage

S1, S2, S3

Current

S1, S1, S3

Supply network

Controllers

Reactive power reference

Switching frequency reference

DC voltage reference

The control includes two main controllers:

• torque and flux hysteresis control

• dc voltage controller.

On the basis of measurements the following items are calculated:

• actual value for flux

• actual value for torque

• actual value for reactive power

• estimate for frequency.

ACA 635 IGBT Supply Unit Program 6-9

Chapter 6 – Firmware Description

DC Voltage Controller The ISU control has two reference values for the DC voltage control:

• Parameter 23.01 DC VOLT REF (user given reference)

• Parameter 2.05 DC REF Q-CTRL (minimum DC voltage reference

calculated by reactive power controller).

DC REF Q-CTRL

2.05

DC VOLT REF

23.01

RAMPING

120.01 DC RAMP UP

120.02 DC RAMP DOWN

SELECTOR

MAX(A,B)

LIMITER

113.01 DC REF MAX

113.02 DC REF MIN

In normal mode, the ramped value of Parameter 23.01 DC VOLT REF is selected if it is higher than Parameter 2.05 DC REF Q-CTRL. The DC reference ramping times are set by Parameters 120.01 DC UP TIME and 120.02 DC DOWN TIME. Minimum and maximum values for the DC reference are set by Parameters 113.01 DC REF MAX and

113.02 DC REF MIN.

Reference List The references are listed below.

Code Parameter Unit Description

23.01 DC VOLT REF V User given reference

113.01 DC REF MAX V Upper limit for the reference = 1.2

113.02 DC REF MIN V Lower limit for the reference = 0.65

120.01 DC RAMP UP s DC voltage reference ramp time from 0

120.02 DC RAMP DOWN s DC voltage reference ramp time from

Actual Value

1.10 160.04 DC VOLTAGE V Actual DC voltage

2.05 DC REF Q-CTRL V Reference from reactive power control

2.06 DC REF RAMP V Ramped and limited reference

DC REF RAMP

2.06

DC VOLTAGE

1.10

sqrt(2) · Par. 4.04 CONV NOM VOLTAGE

sqrt(2) · Par. 4.04 CONV NOM VOLTAG

to sqrt(2)

· Par. 4.04 CONV NOM

VOLTAGE. Default 1 s.

· Par. 4.04 CONV NOM

sqrt(2) VOLTAGE to 0. Default 1 s.

Torque ref.

for hysteresis control

The DC voltage controller is the primary controller for the ISU.

The DC voltage controller keeps the DC voltage in a preset reference in all load conditions. An error signal is calculated from DC voltage measurement (Actual Signal 1.10 DC VOLTAGE) and Actual Signal

2.06 DC REF RAMP. The output of the DC voltage PI controller is the torque reference for hysteresis control.

6-10 ACA 635 IGBT Supply Unit Program

Chapter 6 – Firmware Description

The PI controller parameters are pretuned. There is no need to retune

them.

Reactive Power Control The reactive power control sets the flux reference for hysteresis control

to values with which zero reactive power is achieved.

Reactive power control is capable of generating a preset amount of

reactive power (Parameter 24.01 Q POWER REF) to the network

(positive = capacitive, negative = reactive) by changing the flux length.

Increasing the ISU flux length higher than the network flux length,

capacitive power is generated to the network and vice versa. Increased

flux means that the output voltage of the ISU is higher than the network

voltage.

Reactive power control parameters are listed below.

Code Parameter Unit Description

24.01 Q POWER REF % Reactive power in percentage of the nominal power

1.07 REACTIVE POWER kVAr Calculated reactive power

120.03 QPOW RAMP UP s Reactive power reference ramp up time from 0 kVAr to the absolute value of Par.

4.06 CONV NOM POWER. Default 1 s.

120.04 QPOW RAMP DOWN s Reactive power reference ramp down time from the absolute value of Par. 4.06 CONV NOM POWER to 0 kVAr. Default 1s.

A block diagram of reactive power control is shown below.

Q POWER REF

24.01

RAMPING

PI Flux ref. for hysteresis control

120.03 QPOW RAMP UP

120.04 QPOW RAMP DOWN

1.07

REACTIVE POWER

ACA 635 IGBT Supply Unit Program 6-11

Chapter 6 – Firmware Description

6-12 ACA 635 IGBT Supply Unit Program

Chapter 7 – Fault Tracing

Overview

This chapter explains the fault tracing procedure based on the warning and fault messages given by the ISU program. A factory installed control panel in the line-side converter is required in this procedure. For control panel use and motor-side inverter fault tracing, see the Firmware Manual of the application program.

All warning and fault messages are presented in tables below with information on the cause and remedy for each case. Most warning and fault conditions can be identified and cured with that information. If not, contact an ABB service representative.

CAUTION! Do not attempt any measurement, parts replacement or other service procedure not described in this manual. Such action will void guarantee, endanger correct operation, and increase downtime and expense.

WARNING! All electrical installation and maintenance work described in this chapter should only be undertaken by a qualified electrician. The Safety Instructions on the first pages of this manual must be followed.

Fault Tracing

Fault Resetting An active fault can be reset either by pressing the keypad RESET key,

The drive is equipped with advanced protection features that continuously guard the unit against damage and down time due to incorrect operating conditions and electrical and mechanical malfunctions.

The warning message disappears when any of the Control Panel keys is pressed. The warning will reappear in one minute if conditions remain unchanged. If the drive is operated with the Control Panel detached, the red LED in the Control Panel mounting platform indicates fault condition.

For setting of programmable warning and fault messages and functions, refer to Chapter 8 – Parameters.

by digital input or fieldbus, or switching the supply voltage off for a while. When the fault has been removed, the drive can be started.

ACA 635 IGBT Supply Sections, ACS800-17 7-1

Chapter 7 – Fault Tracing

Fault History When a fault is detected, it is stored in the Fault History. The last faults

and warnings are stored with the time the fault was detected.

WARNING! After a fault reset, the drive will start if the start signal is on. Before the reset, switch off the external start signal or ensure that it is safe to start.

The Fault History can be viewed by pressing or in the Actual Signal Display Mode. The Fault History can then be scrolled with and . To exit the Fault History press or . The Fault History can be cleared by pressing the RESET key.

Fault and Warning

The tables below show the warning and fault messages.

Messages

Warning Messages

Warning Cause What to do

ACS 600 TEMP/ ACS 800 TEMP Par. 9.12 bit 4

AI<MIN FUNC Par. 9.12 bit 3

CH0 COM LOST Par. 9.12 bit 0

CURRENT LIM Par. 9.12 bit 5

DI5 = 0 Par. 9.12 bit 14

Excessive IGBT module temperature. A warning is given if the temperature exceeds 115 °C.

I/O reference 4...20 mA is below 3.1 mA when Par. 13.06 MINIMUM AI2 or Par. 13.10 MINIMUM AI3 is set to 4 mA.

Communication break detected on CH0 receive. (can be deactivated: see Parameter 70.04)

Current limit is exceeded. The limit is 220% of

1base(10s/60s)

Digital input DI5 is OFF (0). Check the function indicated via digital input

Check ambient conditions. Check air flow and fan operation. Check heatsink fins for dust pick-up. Check line current against unit current.

Check for proper analogue control signal level. Check the control wiring.

Check the fibre optic cables between the NAMC board / RDCO module and overriding system (or fieldbus adapter). Test with new fibre optic cables. Check that the CH0 node address (Par. 70.01 CH0 NODE ADDR) is correct in the ISU.

Check the status of the fieldbus adapter. See appropriate fieldbus adapter manual.

Check parameter settings of Group 51, if a fieldbus adapter is present. Check the connections between the fieldbus and the adapter. Check that the bus master is communicating and correctly configured.

Limit inverter actual power or lower the reactive power percentage in Par. 24.01 Q POWER REF.

DI5.

7-2 ACA 635 IGBT Supply Sections, ACS800-17

Warning Messages

Warning Cause What to do

E EARTH FLT Par. 9.12 bit 13

EARTH FAULT Par. 9.12 bit 13

NET LOST Par. 9.12 bit 10

PANEL LOST Par. 9.12 bit 1

NO COMMUNICATION (x)

ID N CHANGED The ID number of the ISU has been changed

LOAD FACTORY Factory parameter settings are being restored. Please wait.

IT (Ungrounded) Network Impedance between a live part (e.g. phase conductor, DC link, motor cable or motor) and earth/ground is too low. Earth fault in LCL filter, line converter, DC link, inverter(s), motor cables or motor.

Earthed/Grounded Network The sum of line currents measured with internal current transducers is too high. Earth fault in LCL filter, line converter, DC link, inverter(s), motor cables or motor, or current unbalance in parallel connected converters.

Network voltage is lost during modulation. Line current is below 0.0064 may cause DC link undervoltage.

A Local Control device (CDP 312 or DriveWindow) has ceased communicating. This can be caused by disconnection of the selected local control device during local control or an internal fault in the local controlling device. This warning transfers the ISU to remote mode.

This message is generated by the Control Panel CDP 312 control program. There is a cabling problem or a hardware malfunction on the Panel Link. (4) = Panel type is not compatible with the version of the converter application program.

from 1 (the change is not displayed on the Control Panel CDP 312).

· I

10s/60s

. The situation

Check motors. Check motor cables. Check ISU. Check inverter(s). Check LCL filter.

Check motors. Check motor cables. Check ISU fuses (parallel connected units). Check ISU. Check inverter(s). Check LCL filter.

Check network conditions.

Check Control Panel connector. Replace Control Panel in the mounting platform.

Check the Panel Link connections. Press the RESET key. The panel reset may take up to half a minute, please wait. Check the Panel type and the version of the drive application program. The Panel type is printed on the cover of the Panel.

To change the ID number back to 1 go to Drive Selection Mode by pressing DRIVE. Press

ENTER. Set the ID number to 1. Press ENTER.

Chapter 7 – Fault Tracing

Fault Messages

Fault Text Cause What to do

ACS 600 TEMP/ ACS 800 TEMP Par. 9.01 bit 3 Par. 9.11 bit 3

AMBIENT TEMP Par. 9.02 bit 7

CHARGING FLT Par. 9.11 bit 0

ACA 635 IGBT Supply Sections, ACS800-17 7-3

Excessive IGBT module temperature. The trip level is 125 °C.

I/O control board temperature is lower than +5 °C or exceeds +73 °C.

DC link voltage is not high enough after charging procedure. DC link voltage has not exceeded the value of Par. 30.12 DC UNDERVOLT TRIP or current is not below 5% of I charging.

at the end of the

10s/60s

Check ambient conditions. Check air flow and fan operation. Check heatsink fins for dust pick-up. Check line current against unit current.

Check ambient temperature in the auxiliary control unit (ACU).

Check charging circuit fuses. Check charging circuit. Check possible short-circuit in DC link. Check the setting of Par. 30.12 DC UNDERVOLT TRIP.

Chapter 7 – Fault Tracing

Fault Messages

Fault Text Cause What to do

CH0 COM LOST Par. 9.02 bit 12 Par. 9.11 bit 10

DC OVERVOLT Par. 9.01 bit 2 Par. 9.11 bit 15

DC UNDERVOLT Par. 9.02 bit 2 Par. 9.11 bit 14

Faulty PPCC link (DC voltage measurement is zero).

Communication break detected on CH0 receive. (programmable fault, see Parameter 70.05)

Intermediate circuit DC voltage is excessive. This can be caused by

1. static or transient overvoltages in the mains.

2. too high supply voltage during synchronisation. The default trip limit is 740 VDC for 415 V units, 891 VDC for 500 V units and 1230 VDC for 690 V units. The trip limit can be changed with Par.

30.11 DC OVERVOLT TRIP. Intermediate circuit DC voltage is not sufficient.

This can be caused by a missing mains phase, a blown fuse or a rectifier bridge internal fault.

Check the PPCC link. See fault message PPCC LINK.

Check the fibre optic cables between the NAMC board / RDCO module and the overriding system (or fieldbus adapter). Test with new fibre optic cables.

Check that the CH0 node address (Parameter

70.01) is correct in the ISU.

Check the status of the fieldbus adapter. See appropriate fieldbus adapter manual. Check parameter settings of Group 51, if a fieldbus adapter is present. Check the connections between the fieldbus and the adapter. Check that the bus master is communicating and correctly configured.

Check the level of supply voltage, DC voltage and converter nominal voltage.

Check supply and inverter fuses. Check supply voltage.

The default trip limit is 293 VDC for 415 V units, 354 VDC for 500 V units and 488 VDC for 690 V units. The tip limit can be changed with Par. 30.12 DC UNDERVOLT TRIP.

DI5 = 0 Par. 9.11 bit 2

E EARTH FLT Par. 9.11 bit 4

EARTH FAULT Par. 9.01 bit 4 Par. 9.11 bit 12

Digital input DI5 is OFF (0). Check the function indicated via digital input

DI5.

Earthed/grounded Network The sum of line currents measured with internal current transducers is too high. Earth fault in LCL filter, line converter, DC link, inverter(s), motor cables or motor, or current unbalance in parallel connected converters.

Check motors. Check motor cables. Check ISU. Check inverter(s). Check LCL filter.

Check motors. Check motor cables. Check ISU fuses (parallel connected units). Check ISU. Check inverter(s). Check LCL filter.

7-4 ACA 635 IGBT Supply Sections, ACS800-17

Fault Messages

Fault Text Cause What to do

FAN FLT Par. 9.11 bit 5

IO FAULT Par. 9.02 bit 6

MAIN CNT FLT Par. 9.11 bit 6

NET VOLT FLT Par. 9.11 bit 9

OVER SWFREQ Par. 9.02 bit 9

OVERCURRENT Par. 9.01 bit 1 Par. 9.11 bit 1

PPCC LINK Par. 9.02 bit 11

SHORT CIRC Par. 9.01 bit 0

Fan is not rotating, or contactor connection is loose.

I/O communication fault or error detected on CH1. This can be caused by a fault in the NIOC board / RDCO module / RMIO board or a faulty/ loose fibre optic cable connection.

Main contactor is not functioning properly, or loose wiring.

Mains voltage is out of allowable range during synchronisation or ID Run. Trip limits are 208 V for 415 V units, 250 V for 500 V units and 345 V for 690 V units.

Switching overfrequency fault. This may be due to a hardware fault in the electronic boards.

Input current is excessive. The overcurrent trip limit is 0.98 CURRENT). The trip limit is approximately 190% of the converter nominal current I

4.05 CONV NOM CURRENT).

NINT board current measurement or communication fault between the NAMC/RMIO and NINT boards. The fault indication is not activated, when the DC link voltage is disconnected, but the NAMC/ RMIO board has an external power supply. The indication is activated when the charging is completed and the DC link voltage is “high”.

Short-circuit current has been detected on a power plate.

· (Par. 4.08 CONV MAX

(Par.

Check the acknowledge circuit connection to the digital input DI1. Check the condition of the bearings of the fan motor by rotating fan motor manually. If the bearings are faulty replace the fan (available as spare part). Replace the fan if trippings continue and the bearings are OK.

Check for loose connections between the NIOC and NAMC board (or on RDCO module). Test with new fibre optic cables. If the fault is still active, replace the NIOC board / RDCO module / RMIO board.

Check main contactor control circuit wiring and signal wiring. Check main contactor control voltage level (should be 230 V).

Check mains voltage. Start again.

Replace the NAMC/RMIO board. Replace the NINT board. On units with parallel connected inverters, replace the NPBU board.

Check motor load. Check supply voltage. Check that there is no power factor compensation capacitors in the supply. Check ISU power semiconductors and current transducers.

Check the fibre optic cables connected between the NAMC/RMIO and NINT boards. In parallel connected inverters, also check the cabling on the NPBU-xx board. If the fault is still active, replace the NPBU board (only with parallel connected inverters), NAMC/RMIO and NINT board (in this order) until the fault disappears. Test with new fibre optic cables in the PPCC (power plate control board) link.

Measure the resistance of the power plate(s). If a faulty power plate is detected, replace the power plate and the NINT and NGDR boards, or change the whole converter phase module. Check the main circuit.

Chapter 7 – Fault Tracing

ACA 635 IGBT Supply Sections, ACS800-17 7-5

Chapter 7 – Fault Tracing

Fault Messages

Fault Text Cause What to do

SC (INU 1) Par. 9.01 bit 12

SC (INU 2) Par. 9.01 bit 13

SC (INU 3) Par. 9.01 bit 14

SC (INU 4) Par. 9.01 bit 15

SUPPLY PHASE Par. 9.02 bit 0

SYNCHRO FLT Par. 9.11 bit 13

USER MACRO There is no User Macro saved or the file is

Short-circuit in parallel connected phase module block 1

Short-circuit in parallel connected phase module block 2

Short-circuit in parallel connected phase module block 3

Short-circuit in parallel connected phase module block 4

Missing phase during synchronisation Check supply fuses.

Synchronisation to supply network is failed. Supply frequency has changed too much after ID Run.

defective.

Check the fibre optic cables between the NPBU board channel CH1 and the NINT board of phase module block 1. Check the motor and the motor cable. Check all power plates in the phase module block 1. If a faulty power plate is detected, replace the whole phase module.

Check the fibre optic cables between the NPBU board channel CH1 and the NINT board of phase module block 2. Check the motor and the motor cable. Check all power plates in the phase module block 2. If a faulty power plate is detected, replace the whole phase module.

Check the fibre optic cables between the NPBU board channel CH1 and the NINT board of phase module block 3. Check the motor and the motor cable. Check all power plates in the phase module block 3. If a faulty power plate is detected, replace the whole phase module.

Check the fibre optic cables between the NPBU board channel CH1 and the board of phase module block 4. Check the motor and the motor cable. Check all power plates in the phase module block 4. If a faulty power plate is detected, replace the whole phase module.

Check for supply network unbalance. Perform the ID Run again. See Parameter

99.07.

Create the User Macro again.

What to Do in Case of an Earth Fault Indication

This section describes how to trace the cause of an internal earth fault indication (Warning/Fault EARTH FAULT).

An earth fault indication does not always signify an actual earth fault. The indication can sometimes be caused by a faulty IGBT or a faulty NGDR control board.

7-6 ACA 635 IGBT Supply Sections, ACS800-17

Earth fault indication

network?

Chapter 7 – Fault Tracing

Flowchart Use this flowchart for tracing the cause of an earth fault indication and

for locating faulty parts. The flowchart includes remedies.

Check whether

Par. 160.01 IU and Par. 160.03 IW are

appr. 0 A when

UDC is on.

Ye s

Measure Earth leakage on motor or cabling?

Yes

Change: damaged motor, switchgear or cabling

Fault fixed?

Yes

Set Par. 30.03 EARTH FAULT LEVEL to 5.

Fault fixed?

Yes

Par. 3.12 PP 0 TEMP

Change :

1. NINT board

2. current transducers

3. cabling between NINT and NXPP boards and current transducers

4. NXPP board

Frame Size

2xR11i, 2xR12i

4xR11i or 4xR12?

Ye s

Is the

difference between

to Par. 3.15 PP 3

TEMP < 5 °C?

Yes

1. Locate the hottest power plate: See Par. 3.12 PP 0 TEMP to Par. 3.15 PP 3 TEMP and ACS 600 Service Manual:

Indicator LEDs on the NINT and NXPP Boards.

2. Change the NGDR board of the hottest power plate.

Fault fixed?

Yes

Faulty NGDR board. Breakthrough fault.

Change the NGDR board of the adjacent power plate.

Fault fixed?

A faulty

fibre between NINT

and NPBU

boards?

Contact ABB for

permission to set Par.

30.03 EARTH FAULT LEVEL to 6.

Yes

Faulty NGDR board. No control.

Yes

Change

Change the fibre.

Fault fixed?

cabling to less capacitive

Yes

ACA 635 IGBT Supply Sections, ACS800-17 7-7

Chapter 7 – Fault Tracing

7-8 ACA 635 IGBT Supply Sections, ACS800-17

Chapter 8 – Parameters

Overview

Parameters for the IGBT supply unit control program are described in the tables below.

Symbols used in the tables: Column Type: I = integer, R = real, B = boolean, C = character string ISU = IGBT Supply Unit

IGBT Supply Unit Program 8-1

Chapter 8 – Parameters

1 Actual Signals

Code Parameter Range/Unit Description Integer Scaling

1 ACTUAL

SIGNALS

1.05 FREQUENCY Hz Calculated line frequency 100 = 1 Hz

1.06 LINE CURRENT A Measured line current 1= 1 A

1.07 REACTIVE POWER kVAr Calculated reactive power (positive = capacitive, negative = reactive).

1.08 POWER kW Calculated line converter power (positive = power flow from supply network to intermediate circuit, negative = power flow from intermediate circuit to supply network).

1.09 POWER % Input power in percentage of nominal value (Par. 4.06 CONV NOM POWER)

1.10 DC VOLTAGE V Measured intermediate circuit voltage 1= 1 V

1.11 MAINS VOLTAGE V Calculated input voltage 1= 1 V

1.12 PP TEMP

1.13 TIME OF USAGE h Elapsed time meter. The timer is running when the NAMC/

1.14 KWH SUPPLY kWh This actual signal counts the kilowatt hours in operation. 1 = 100 kWh

1.15 DI6-1 STATUS 0000000...

1.16 KWH MOTORING kWh This actual signal counts the kilowatt hours of motoring

1.17 KWH GENERATING kWh This actual signal counts the kilowatt hours of regenerative

1.19 AI1 [V] 0...10 Non-scaled value of analogue input AI1. See Par. 13.01

1.20 AI2 [mA] 0...20 Non-scaled value of analogue input AI2. See Par. 13.04

1.21 AI3 [mA] 0...20 Non-scaled value of analogue input AI3. See Par. 13.08

1.22 RO3-1 STATUS 0000000...

1.23 AO1 [mA] 0...20 mA Value of analogue output 1 signal in milliamperes. For

1.24 AO2 [mA] 0...20 mA Value of analogue output 2 signal in milliamperes. For

1.26 LED PANEL

OUTPUT

1.27 COSFII Calculated cosfii 100 = 1

°C

0111111

0000111

% Monitoring of the NLMD-01 LED panel output. See

Temperature of the power plate in degrees Celcius 1 = 1 °C

RMIO board is powered.

Status of the digital inputs DI6 to DI1 in the software. 0 VDC = “0” +24 VDC = “1”

Example

Control Panel (CDP 312) display when digital inputs DI1 and DI4 are activated is 0001001, where the digits for digital inputs are read from right to left (DI1 to DI6).

(power flow from supply network to intermediate circuit).

braking (power flow from intermediate circuit to supply network).

AI1 HIGH VALUE and 13.02 AI1 LOW VALUE.

AI2 HIGH VALUE and 13.05 AI2 LOW VALUE.

AI3 HIGH VALUE and 13.09 AI3 LOW VALUE. Status of the standard I/O board relay outputs.

Example

Control Panel (CDP 312) display when relay outputs 2 and 3 are activated is 0000110, where the digits are read from right to left (DO1 to DO6)

signal selecting and scaling, see Parameter Group 15.

Parameter Group 18.

1 = 1 kVAr

1= 1 kW

1= 1%

1 = 1 h

1= 1

1 = 100 kWh

10000 = 10 V or 20 mA

20000 = 20 mA, 2 V or 10 V

20000 = 20 mA

1 = 1

20000 = 20 mA

1= 1

8-2 IGBT Supply Unit Program

Chapter 8 – Parameters

2 Actual Signals

Code Parameter Unit Description Integer

Scaling

2 ACTUAL

SIGNALS

2.05 DC REF Q-CTRL V Minimum voltage reference of intermediate circuit calculated by reactive power control

2.06 DC REF RAMP V Ramped and limited intermediate circuit voltage reference for power control

2.07 DC REF INITIALIZ V Initialized intermediate circuit voltage reference based on line-side ID Run. The voltage reference is calculated from DC voltage measurement and is approximately sqrt(2) voltage.

· supply network

1 = 1 V

3 Actual Signals

Code Parameter Unit Description Integer

3 ACTUAL

SIGNALS

3.12 PP 0 TEMP

3.13 PP 1 TEMP ºC The highest power plate temperature of phase module block 2. 1 = 1 ºC

3.14 PP 2 TEMP ºC The highest power plate temperature of phase module block 3. 1 = 1 ºC

3.15 PP 3 TEMP ºC The highest power plate temperature of phase module block 4. 1 = 1 ºC

ºC

Scaling

These parameters are visible in parallel connected units (frame sizes 2xR11i/R12i and 4xR11i/R12i) only and show the highest power plate temperatures of the phase module blocks no. 1 to 4 (see Chapter 3 – Hardware Description: IGBT Supply Unit). LEDs on the NINT board indicate the hottest phase (U, V or W) of each module block. See Chapter 7 – Fault Tracing / What to Do in Case

of an Earth Fault Indication.

The highest power plate temperature of phase module block 1. 1 = 1 ºC

IGBT Supply Unit Program 8-3

Chapter 8 – Parameters

4 Information

The software version (Parameters 4.01 and 4.03) is expressed as follows:

Character noExample Meaning

1 I I = Input bridge software 2 X Product: X= ISU 3XSoftware type:

A = application software (Parameter 4.03) 4 G Control board: G = NAMC-51, R = RMIO 5 to 8 6000 Software version number: 6000 = NAMC-51, 7000 = RMIO

Code Parameter T

4INFORMATION

4.01 SOFTWARE PACKAGE VER

4.02 DTC VERSION B xxxx Software version number of the flux software. This fixed part of

4.03 APPLIC NAME C IXAx xxxx The application software name can be identified by means of

4.04 CONV NOM VOLTAGE

4.05 CONV NOM CURRENT

4.06 CONV NOM POWER

4.07 CONV MAX VOLTAGE

4.08 CONV MAX CURRENT

4.09 INVERTER TYPE

Range/Unit Description Integer

y p e

C IXXx xxxx This signal describes the software of the downloaded loading

package.

the software consists of the line converter control, operation system, communication control of the DDCS channels and Modbus software for the control panel.

this signal. This part of the software has been written using PC elements.

R V Downloaded line converter nominal supply voltage 1 = 1 V

R A Downloaded line converter nominal line current 1 = 1 A

R kW Line converter nominal power. 1 = 1 kW

R V Maximum value of converter voltage measuring range 1 = 1 V

R A Maximum value of converter current measuring range 1 = 1 A

C xxxxxx x xxx Line-side converter type -

Scaling

8-4 IGBT Supply Unit Program

Chapter 8 – Parameters

7 Control Word

8 Status Word

Parameter 7.01 is the control word of the line converter. The control word is a 16-bit packed boolean word displayed as a hex value and updated at 10 ms intervals.

Parameter 7.01 MAIN CTRL WORD (Control word of the line converter)

Bit Name Value Description

0ON 0 ⇒1 Starts charging

OFF 0 Opens main contactor

1, 2 0 Not in use

3 START 1 Starts modulation

0 Stops modulation

4...6 0 Not in use

7 RESET 0 ⇒1 Makes a reset

0–

8...15 0 Not in use

This parameter is a 16-bit packed boolean word displayed as a hex value and updated at 4 ms intervals.

Parameter 8.01 MAIN STATUS WORD (Status signals of the line converter)

Bit

0 RDY_ON 1 Ready to switch on = no fault

1 RDY_RUN 1 Ready to operate = DC bus charged

2 RDY_REF 1 Operation enabled

3 TRIPPED 1 Fault

4, 5, 6 – Not in use

7 ALARM 1 Warning

8MODULATING 1

9 REMOTE 1 Drive control location: REMOTE

10 NET OK 1 Network voltage is OK.

11 – Not in use

12, 13 – Not in use

14 CHARGING 1 Charging contactor closed

15 – Not in use

Name

Val ue

0 Not ready to switch on = fault

0 Not ready to operate

0 No fault

0No Warning

Line converter modulates.

Line converter not modulating

0 Drive control location: LOCAL

0 Network voltage is lost.

0 Charging contactor open

STATE/Description

IGBT Supply Unit Program 8-5

Chapter 8 – Parameters

9 Fault Words

These parameters are 16-bit words. They are displayed as hex values. Bit value 1 = Fault, and 0 = No Fault. Parameters are updated at 100 ms intervals.

Code Parameter Bit Name Description

9 FAULT WORDS

9.01 FAULT WORD 1

0 SHORT CIRC Short-circuit in the main circuit 1 OVERCURRENT Overcurrent 2 DC OVERVOLT Intermediate circuit DC overvoltage 3 ACS 600/800 TEMP IGBT module overtemperature 4 EARTH FAULT Internally detected earth fault 5, 6 Not in use 7 Internal faults. If this bit is 1, write down the value of Parameter

9.03. Contact ABB.

8...11 Not in use 12 SC (INU1) Short-circuit in parallel connected phase module block 1 13 SC (INU2) Short-circuit in parallel connected phase module block 2 14 SC (INU3) Short-circuit in parallel connected phase module block 3 15 SC (INU4) Short-circuit in parallel connected phase module block 4

9.02 FAULT WORD 2

0 SUPPLY PHASE Missing phase during synchronisation 1Not in use 2 DC UNDERVOLT Intermediate circuit DC undervoltage

3...5 Not in use 6 IO FAULT I/O device fault on CH1 7 AMBIENT TEMP I/O control board temperature 8Not in use 9 OVER SWFREQ Switching overfrequency 10 Not in use 11 PPCC LINK Current measurement or communication fault of NINT board 12 CH0 COM LOST Communication break on CH0

13...15 Not in use

9.03 FAULT WORD 3

0 FLT (F1_7) Factory default parameter file error 1 USER MACRO User Macro file error 2 FLT (F1_4) EPROM operating error 3 FLT (F1_5) FPROM data error 4 FLT (F2_12) Internal time level 2 overflow (100 ms) 5 FLT (F2_13) Internal time level 3 overflow (1 ms) 6 FLT (F2_14) Internal time level 4 overflow (50 ms) 7 FLT (F2_15) Internal time level 5 overflow (1 s) 8 FLT (F2_16) State machine overflow 9 FLT (F2_17) Application program execution error 10 FLT (F2_18) Application program execution error 11 FLT (F2_19) Illegal instruction 12 FLT (F2_3) Register stack overflow 13 FLT (F2_1) System stack overflow 14 FLT (F2_0) System stack underflow 15 Reserved

8-6 IGBT Supply Unit Program

Chapter 8 – Parameters

Code Parameter Bit Name Description

9 FAULT WORDS

9.07 INT FAULT INFO * Bits 0 to 3 are in use with parallel-connected converters only.

Control board NINT 1 (of phase module block 1) is connected to branching unit board NPBU channel CH1, NINT 2 is connected

to channel CH2 etc. 0 NINT 1 FAULT NINT 1 board fault * 1 NINT 2 FAULT NINT 2 board fault * 2 NINT 3 FAULT NINT 3 board fault * 3 NINT 4 FAULT NINT 4 board fault * 4 NPBU FAULT NPBU board fault * 5Not in use 6 U-PH SC U Short-circuit in phase U upper-leg IGBT(s) 7 U-PH SC L Short-circuit in phase U lower-leg IGBT(s) 8 V-PH SC U Short-circuit in phase V upper-leg IGBT(s) 9 V-PH SC L Short-circuit in phase V lower-leg IGBT(s) 10 W-PH SC U Short-circuit in phase W upper-leg IGBT(s) 11 W-PH SC L Short-circuit in phase W lower-leg IGBT(s)

12...15 Not in use

Converter Phase Module Block

Upper-leg IGBTs

NAMC/

NINT

RMIO

Lower-leg IGBTs

UVW

Converter Constructed of Two to Four Parallel-connected Phase Module Blocks

NDCU/RDCU

NAMC/ RMIO

NINT

NXPP

NGDR

NXPP

NGDR

NPBU

CH1

NGDR

CH2

CH3

NXPP

NGDR

VUW VUW

NINT 2

NGDR

NXPP

NGDR

NINT 3

NGDR

WVU

IGBT Supply Unit Program 8-7

Chapter 8 – Parameters

Code Parameter Bit Name Description

9 FAULT WORDS

9.11 SUPPLY FAULT WORD

0 CHARGING FLT DC link short-circuit during charging 1 OVERCURRENT Overcurrent 2 DI5 = 0 External fault indicated via DI5

9.12 SUPPLY ALARM WORD

3 ACS 600 TEMP /

ACS 800 TEMP 4 E EARTH FLT Earth fault detected by an external monitoring device 5 FAN FLT Fan failure. Fault is activated 5 seconds after failure. 6 MAIN CNT FLT Main contactor failure 7 SHORT CIRC Short-circuit in the main circuit (indication from power plate). 8 Internal faults. If this bit is 1, write down the value of Parameter

9 NET VOLT FLT Supply voltage out of range during synchronisation 10 CH0 COM LOST Communication break on CH0 11 Not in use 12 EARTH FAULT Internally detected earth fault 13 SYNCHRO FLT Synchronisation to supply failed 14 DC UNDERVOLT Intermediate circuit DC undervoltage 15 DC OVERVOLT Intermediate circuit DC overvoltage

0 CH0 TIMEOUT Communication break detected 1 PANEL LOST Local control lost 2 Not in use 3 AI<MIN FUNC Current below 4 mA (4 mA minimum selected) 4

5 CURRENT LIM Current limit exceeded

6...9 Not in use 10 NET LOST Network voltage lost 11, 12 Not in use 13 EARTH FAULT Internally detected earth fault

14 DI5 = 0 External fault indicated via DI5 15 Not in use

ACS 600 TEMP/

ACS 800 TEMP

E EARTH FLT Earth fault detected by an external monitoring device

IGBT module temperature is excessive.

9.03. Contact ABB.

IGBT module temperature is excessive.

8-8 IGBT Supply Unit Program

11 Reference Selects

Chapter 8 – Parameters

Code Parameter T

11 REFERENCE

SELECT

11.01 DC REF SELECT I PARAM

11.02 Q REF SELECT I PARAM

Default Alternative Settings

y p e

23.1

24.1

( ) Fieldbus Equivalent

(1) PARAM 23.1; (2) AI1; (3) AI2; (4) AI3

(1) PARAM 24.1; (2) AI1; (3) AI2; (4) AI3

Description Integer

Source for intermediate circuit DC voltage reference

Source for reactive power reference 1 = 1

13 Analogue Inputs

Code Parameter T

13 ANALOGUE

INPUTS

13.01 AI1 HIGH VALUE I 20000 -32768...32767 This value corresponds to the maximum input

13.02 AI1 LOW VALUE I 0 -32768...32767 This value corresponds to the minimum input

13.03 FILTER AI1 R 1000 0...30000 ms Filter time constant for analogue input AI1.

13.04 AI2 HIGH VALUE I 0 -32768...32767 This value corresponds to the maximum input

13.05 AI2 LOW VALUE I 0 -32768...32767 This value corresponds to the minimum input

13.06 MINIMUM AI2 I 0 mA (1) 0 mA; (2) 4 mA This value corresponds to the minimum

13.07 FILTER AI2 R 1000 ms 0...30000 ms Filter time constant for analogue input AI2.

13.08 AI3 HIGH VALUE I 10000 -32768...32767 This value corresponds to the maximum input

13.09 AI3 LOW VALUE I 0 -32768...32767 This value corresponds to the minimum input

13.10 MINIMUM AI3 I 0 mA (1) 0 mA; (2) 4 mA This value corresponds to the minimum

13.11 FILTER AI3 R 1000 ms 0...30000 ms Filter time constant for analogue input AI3.

13.12 MINIMUM AI1 I 0 V (1) 0 V; (2) -10 V This value corresponds to the minimum

Default Alternative Settings

y p e

( ) Fieldbus Equivalent

Description Integer

voltage on analogue input AI1.

The hardware filter time constant is 20 ms.

in milliamperes (20 mA) on analogue input AI2.

in milliamperes (0 or 4 mA) on analogue input AI2.

reference from analogue input AI2.

The hardware filter time constant is 20 ms.

in milliamperes (20 mA) on analogue input AI3.

in milliamperes (0 or 4 mA) on analogue input AI3.

reference from analogue input AI3.

The hardware filter time constant is 20 ms.

reference from analogue input AI1.

Scaling

1 = 1

Scaling

1 = 1

1 = 1 ms

1 = 1

1 = 1 ms

1 = 1

1 = 1 ms

IGBT Supply Unit Program 8-9

Chapter 8 – Parameters

14 Digital Outputs

Code Parameter T

14 DIGITAL

OUTPUTS

14.04 DO2 GROUP+INDEX

14.05 DO2 BIT NUMBER

Default Range Description Integer

y p e

801 -199999...+199999 This parameter selects the signal that controls

digital output D02 by the bit specified with Par.

14.05 DO2 BIT NUMBER. Example Par 8.01 MAIN STATUS WORD is selected to digital output D02, the value of Par. 14.04 is set to 801, where 8 indicates the group and 01 the index of the selected signal. The bit number is specified with Par. 14.05 DO2 BIT NUMBER. Note: Inversion of the output is set with a minus sign of the Par. 14.04 value.

0 0...15 This parameter specifies the bit number of the

signal selected with Par. 14.04 DO2 GROUP+ INDEX. See the example above.

: When bit number 0 (RDY_ON) of

Scaling

1 = 1

8-10 IGBT Supply Unit Program

15 Analogue Outputs

Chapter 8 – Parameters

Code Parameter T

15 ANALOGUE

OUTPUTS

15.01 ANALOGUE OUTPUT 1

15.02 INVERT AO1 B NO (0) NO; (1) YES Analogue output signal 1 inversion

15.03 MINIMUM AO1 I 0 mA (1) 0 mA; (2) 4 mA;

15.04 FILTER AO1 R 0.10 s 0...10 s Filter time constant for AO1 100 = 1 s

15.05 SCALE AO1 R 100 0...65536 Nominal value of AO1 (Par. 15.01

15.06 ANALOGUE OUTPUT 2

15.07 INVERT AO2 B NO (0) NO; (1) YES Analogue output signal 2 inversion

15.08 MINIMUM AO2 I 0 mA (1) 0 mA; (2) 4 mA

15.09 FILTER AO2 R 0.10 s 0...10 s Filter time constant for AO2 100 = 1 s

15.10 SCALE AO2 R 3000 0...65536 Nominal value of AO2 signal (Par. 15.06

Default Alternative Settings

y p e

I 106 0...30000 Analogue output signal 1 source selection.

I 101 0...30000 Analogue output signal 2 source selection.

( ) Fieldbus Equivalent

(3) 10 mA

Description Integer

Example: analogue output 1, set Parameter 15.01 to value 2301.

Analogue output signal 1 offset in milliamperes

ANALOGUE OUTPUT 1). It corresponds to 20 mA at the output. Example: to Parameter 15.01 ANALOGUE OUTPUT 1. The value of Par. 15.05 is 100. When the value of Par. 1.06 LINE CURRENT is 100 A, the output of AO1 is 20 mA.

See example in Par. 15.01.

Analogue output signal 2 offset in milliamperes

ANALOGUE OUTPUT 2). It corresponds to 20 mA at the output. See example in Par.

15.05.

To link Par. 23. 01 DC VOLT REF to

Par. 1.06 LINE CURRENT is linked

Scaling

1 = 1

IGBT Supply Unit Program 8-11

Chapter 8 – Parameters

16 System Control Inputs

Code Parameter

16 SYSTEM CTR

INPUTS

16.02 PARAMETER LOCK

16.03 PASS CODE I 0 Pass code for the Parameter Lock. The default

16.06 PARAMETER BACKUP

Default Alternative Settings

T y p e

B OPEN Using this parameter, unauthorised parameter

IDONE

( ) Fieldbus Equivalent

(1) LOCKED Parameter changes are disabled. (0) OPEN Parameter changes are enabled.

(0) DONE Parameter value after the saving has been

(1) SAVE Parameter saving from RAM to permanent

Description

changes by CDP 312 Control Panel or the DriveWindow PC tool can be inhibited for Parameter Groups 0...99.

value is 0. To open the Parameter Lock for parameter groups below 100, change the value to

358. After the Parameter Lock is opened, the value is automatically reset.

completed.

FPROM memory.

Note: Parameter changes done through the CDP 312 Control Panel or DriveWindow are saved automatically to FPROM. Parameter changes done by an overriding control system (e.g. fieldbus or AC 80) via CH0 of the NAMC board / RDCO module are saved only to the volatile RAM memory. The changes need to be saved to FPROM separately using this parameter selection.

8-12 IGBT Supply Unit Program

18 LED Panel Control

Chapter 8 – Parameters

Code Parameter T

18 LED PANEL

CTRL

18.01 LED PANEL OUTPUT

18.02 SCALE PANEL R 100 0...65536 Scaling factor for the NLMD-01 Monitoring

Default Range Description Integer

y p e

The NLMD-01 Monitoring Display has a LED bar to show an absolute real type value: 0 50 100 150 %

The source and the scale of the display signal are defined by this parameter group.

Note: If NLMD -01 and CDP 312 Control Panel are used together, Actual Signal 1.26 LED PANEL OUTPUT must be the first signal in CDP 312 Actual Signal Display Mode. Otherwise the NLMD-01 LED bar display will show an incorrect value.

I 109 0...30000 Signal source selection for the NLMD-01

Monitoring Display. Example: set Parameter 18.01 to value 109.

Display. Example: Parameter 18.01. The frequency is 50 Hz (= 100

To link Par. 1.09 POWER to the display

Par. 1.05 FREQUENCY is linked to

· 50 = 5000 as integer scaled). Value 5000 of

Parameter 18.02 gives 100% display on the NLMD-01.

Scaling

1 = 1

IGBT Supply Unit Program 8-13

Chapter 8 – Parameters

19 Data Storage

Trend Monitoring with

Drive Window

APC2, AC80

PC element ACSRX

Data set 14

Index: 1 Index: 2

Index: 3

Parameters of this group are storages for receiving information from or sending it to an overriding system. The parameters are unconnected. They can be used for linking, testing and commissioning purposes.

Example 1.

Address of data set 14 index 2 is 90.08. To monitor a signal assigned for drive control from data set 14 index 2 (data word 14.2) using DriveWindow, follow the steps below.

3. Set Parameter 90.08 D SET 14 VAL 2 to 1901 (denoting Parameter

19.01).

4. Set DriveWindow monitoring channel to read Parameter 19.01.

RMIO/

NAMC-xx

Data set table

Index

Data set

2 3

Address Assignment of Data set

GroupIndex

90 08

For DriveWindow PC Tool

19.01

Drive Window

Parameter table

19.01

A = a value assigned from overriding system to drive control

Sending a value Example 1.

To send a value to overriding system data set 15 index 2, set Parameter 92.08 D SET 15 VAL 2 to 1902 by a CDP 312 Control Panel or DriveWindow.

APC2, AC80

PC element ACSRX

Data set 15

Index: 1 Index: 2

Index: 3

RMIO/

NAMC-xx

Data set table

Index

Data set

2 3

Address Assignment of Data set

GroupIndex

92 08

B = a value assigned for overriding system application

From DriveWindow PC Tool

19.02

Drive Window

Parameter table

19.02

8-14 IGBT Supply Unit Program

Chapter 8 – Parameters

19 Data Storage

Parameter Table

Integer scaling of these parameters is 1 = 1, the type is real and the range is -32768...+32767.

Code Parameter

19 DATA STORAGE

19.01 DATA 1

19.02 DATA 2

19.03 DATA 3

19.04 DATA 4

19.05 DATA 5

19.06 DATA 6

19.07 DATA 7

19.08 DATA 8

IGBT Supply Unit Program 8-15

Chapter 8 – Parameters

21 Start/Stop Functions

Code Parameter T

21 START/STOP

21.01 DC LEVEL START B NO (0) NO Disable level start

21.02 DC VOLTAGE LEVEL

Default Range/Unit Description

y p e

(1) YES Enable level start. The selection is not recommended

for units with an LCL filter. Consult ABB before setting this parameter to YES. Note: If Par. 99.08 AUTO LINE ID RUN is set to YES, the ISU performs the ID Run in NAMC/RMIO board power-up and modulates for one second thereafter. The ISU stops and waits until DC voltage exceeds the level of Par. 21.02 DC VOLTAGE LEVEL.

R See table

below.

See table below. Intermediate circuit DC voltage level at which the

modulation starts

Par. 4.04 CONV

NOM VOLTAGE

(V)

415 646 380 706 500 778 457 851 690 1073 632 1174

Default of Par. 21.02:

1.1 · sqrt(2) · Par. 4.04

CONV NOM VOLTAGE

(V) Minimum (V) Maximum (V)

(65% ...120%) · sqrt(2) · Par. 4.04

Range of Par. 21.02:

CONV NOM VOLTAGE

21.03 STOP LEVEL TIME

21.04 STOP LEVEL POWER

R 1000 ms ms Modulator is stopped when the power is higher than

defined with Par. 21.04 STOP LEVEL POWER for a time defined with this parameter.

R 0 kW kW Motoring power to stop the modulator

8-16 IGBT Supply Unit Program

Chapter 8 – Parameters

The functions set by this parameter group are visualised below.

stands for intermediate circuit DC voltage. P stands for converter

supply power.

P, U

Par. 21.04

Par. 21.02

Par. 21.03

Modulation starts

Modulation stops

IGBT Supply Unit Program 8-17

Chapter 8 – Parameters

23 DC Bus Reference

By changing the value of Parameter 23.01 DC VOLT REF from the default setting, the DC link voltage can be raised higher than with a conventional 6-pulse diode rectifier in order to compensate a low voltage level in the network.

Note: Check the motor insulation requirement. See ACS 600 MultiDrive Safety and Product Information guide (EN code

63982229) or ACS800-17 Hardware Manual (EN code 64638505).

WARNING! When setting this parameter, consult your local ABB representative. The LCL filter of the supply section may overheat.

Example If the supply voltage is 380 V, and the motor voltage 400 V, the voltage

difference can be compensated simply by setting Parameter 23.01 DC VOLT REF to value 565 (i.e. sqrt(2) · 400 V). However, the line converter power is still calculated on the basis of 380 V: P = sqrt(3) · 380 · line current.

Code Parameter

23 DC VOLT REF

23.01 DC VOLT REF R See table below. User-given setpoint value for intermediate circuit DC voltage

Range Description Integer

y p e

reference

Par. 4.04 CONV NOM

VOLTAGE

(V)

415 380 706 500 457 851 690 632 1174

Range of Par. 23.01:

(65% ...120%) · sqrt(2) · Par. 4.04

CONV NOM VOLTAGE

Minimum (V) Maximum (V)

Scaling

1 = 1 V

Note: The program limits the minimum value to sqrt(2) · U the actual supply voltage.

, where UAC denotes

24 Reactive Power

Code Parameter

24 REACTIVE

POWER

24.01 Q POWER REF

8-18 IGBT Supply Unit Program

Default Range Description Integer

y p e

0% -100%...+100% Setpoint value for reactive power control in

percentage of Par. 4.06 CONV NOM POWER. Reactive power control is capable of generating the set amount of reactive power to the network (positive = capacitive, negative = reactive).

Scaling

1 = 1%

30 Fault Functions

Chapter 8 – Parameters

Code Parameter

Default Alternative

y p e

Settings

( ) Fieldbus

Description Integer

Scaling

Equivalent

30 FAULT

1 = 1

FUNCTIONS

30.02 EARTH FAULT B WARNING (0) WARNING A warning is given in an earth fault condition. 1 = 1 (1) FAULT Converter trips in an earth fault. 1 = 1

30.03 EARTH FAULT

LEVEL

R 4 for frame

sizes R6i to R12i; 5 for frame sizes 2xR11i, 2xR12i, 4xR11i, 4xR12i

Non-parallel connected converters (frame sizes R6i, R7i, R8i, R9i, R11i and R12i): This parameter sets the earth fault trip level through the PPCC link. In frame sizes R6i and R7i, the default setting cannot be changed. Parallel connected converters (frame sizes 2xR11i, 2xR12i, 4xR11i, 4xR12i): current

1 = 1

unbalance protection of converter output, e.g,

in a short-circuit. 1 1% unbalance in the sum current 2 3% unbalance in the sum current 3 8% unbalance in the sum current 4 13% unbalance in the sum current 5 18% unbalance in the sum current 6 28% unbalance in the sum current 7 39% unbalance in the sum current 8 62% unbalance in the sum current

30.04 EXT EARTH FAULT

I NO Earth fault detector is connected to digital input

DI4. This parameter selects the converter

1 = 1

reaction.

(1) NO Not in use (2) DI4=0 FAULTS Converter trips on EARTH FAULT if DI4 is OFF

(0).

(3) DI4=1 FAULTS Converter trips on EARTH FAULT if DI4 is ON

(1).

(4) DI4=0 ALARMS A warning is given if DI4 is OFF (0). (5) DI4=1 ALARMS A warning is given if DI4 is ON (1).

30.05 EXT EVENT I NO This parameter selects the converter reaction

to the state of digital input DI5.

(1) NO Not in use (2) DI5=0 ALARMS A warning is given if DI5 is OFF (0). (3) DI5=0 FAULTS Converter trips if DI5 is OFF (0).

30.11 DC OVERVOLT TRIP

R 740/891/1230 0...747 VDC

(415 V units)

0...900 VDC (500 V units)

0...1242 V DC (690 V units)

Intermediate circuit DC overvoltage trip limit. The lower range limit is determined by Par.

30.12 DC UNDERVOLT TRIP. When the setting of this parameter is changed, the corresponding higher range limit of Par. 30.12 DC OVERVOLT TRIP will also change.

1 = 1

IGBT Supply Unit Program 8-19

Chapter 8 – Parameters

30.12 DC

R 293/354/488 0...747 VDC UNDERVOLT TRIP

51 Communication Module

Code Parameter

51 COMMUNICATION

MODULE

51.01 FIELDBUS PAR1

51.02 ...

FIELDBUS_PAR2 ...15

51.15

70 DDCS Control

(415 V units)

0...900 VDC (500 V units)

0...1242 V DC (690 V units)

Intermediate circuit DC undervoltage trip limit. The higher range limit is determined by Par.

30.11 DC OVERVOLT TRIP. When the setting of this parameter is changed, the corresponding lower range limit of Par. 30.11 DC OVERVOLT TRIP will also change. This

1 = 1

parameter also determines DC voltage check limit during charging.

Description

y p e

This group defines the communication parameters for a fieldbus adapter module. The parameter names are copied from the module when it is installed and its connection to the drive is activated with Parameter 98.02 COMM MODULE. See the module manual.

Module type and software version

According to module type

Code Parameter

70 DDCS CONTROL

70.01 CH0 NODE ADDR

70.02 CH0 LINK CONTROL

70.03 CH0 BAUD RATE

Default Alternative Settings

y p e

1 1...125 Node address for channel CH0. When

( ) Fieldbus Equivalent

Description Integer

using the AC 80 system, the address must be 1 to 12. When using the APC2 system, the address must be 1. In other control systems, the node address is set according to the application.

10 1...15 DDCS channel CH0 intensity control for

transmission LEDs. This parameter can be used in special cases to optimise the communication performance in the link.

4 Mbit/s (0) 8 Mbit/s (not in use);

(1) 4 Mbit/s; (2) 2 Mbit/s (not in use); (3) 1 Mbit/s

Channel CH0 communication speed. This parameter must be set to 4 Mbits/s, when FCI communication module is used. Otherwise, the overriding system automatically sets the communication speed.

Scaling

1 = 1

1= 1

8-20 IGBT Supply Unit Program

Chapter 8 – Parameters

70.04 CH0 TIMEOUT

70.05 CH0 COMM LOSS CTRL

70.06 CH1 LINK CONTROL

70.15 CH3 NODE ADDR

70.16 CH3 LINK CONTROL

70.19 DDCS CH0 HW CONN

100 ms 0...60000 ms The delay time before a communication

break fault is indicated. The time count starts when the link does not update the message. During the time elapsing, CH0 TIMEOUT warning is set by 9.12 SUPPLY ALARM WORD bit 0. When the value of Par. 70.04 is zero, timeout is not monitored and CH0 COM LOST fault is not indicated regardless of the value of Par. 70.05.

FAULT This parameter is in use when Par. 98.01

COMMAND SEL is set to MCW and Par.

98.02 COMM MODULE to FBA DSET1, FBA DSET10 or INVERTER.

(1) NO FAULT A warning is given on communication loss

on channel CH0.

(2) FAULT Converter trips on communication loss on

channel CH0.

10 1...15 DDCS channel CH1 intensity control for

transmission LEDs in each device in a link. The parameter can be used in special cases to optimise the communication performance in the link.

1 1...254 Node address for channel CH3. This

channel is normally used with the start-up and maintenance tools. If the CH3 channels of several drives have been connected in a ring or star (by branching unit) configuration, each one must be assigned a unique node address. The new node address becomes valid only after auxiliary power shutdown of the NAMC/RMIO board.

15 1...15 DDCS channel CH3 intensity control for

transmission LEDs in each device in a link. The parameter can be used in special cases to optimise the communication performance in the link.

STAR This parameter is used for enabling or

disabling regeneration of channel CH0 optical transmitter in DDCS mode. DDCS mode is typically used with APC2, AC70 and AC450 controllers. In regeneration mode, any message received by the channel is echoed back. This parameter is not in use in DriveBus mode.

(0) RING Regeneration enabled. Select RING if the

CH0 channels on the NAMC boards / RDCO modules are connected in a ring configuration.

(1) STAR Regeneration disabled. Select STAR with

a star configuration such as AC450 – CI810 – NDBU-95 optical branching unit(s) – NAMC board / RDCO module (RMIO board).

1 = 1 ms

1 = 1

1=1

IGBT Supply Unit Program 8-21

Chapter 8 – Parameters

70.20 CH3 HW CONNECTION

71 DriveBus Communication

Code Parameter

71 DRIVEBUS

COMM

71.01 CH0 DRIVEBUS MODE

STAR This parameter is used for enabling or

disabling regeneration of channel CH3 optical transmitter. In regeneration mode any message received by the channel is echoed back.

(0) RING Regeneration enabled. Select RING if the

CH3 channels on the NAMC boards / RDCO modules are connected to a ring configuration.

(1) STAR Regeneration disabled. Select STAR with

a star configuration such as DriveWindow (PC) – NDBU-95 optical branching unit(s) – NAMC board / RDCO module (RMIO board).

Default Alternative Settings

y p e

YES This parameters selects the

( ) Fieldbus Equivalent

Description Integer

communication mode for channel CH0 on the NAMC board / RDCO module.The new mode becomes valid only on the next NAMC/RMIO board power-on.

(0) NO DDCS mode (1) YES DriveBus mode with AC 80 controller

1=1

Scaling

1 = 1

8-22 IGBT Supply Unit Program

Chapter 8 – Parameters

90, 91 Data Set Receive Addresses

Parameters of this group are addresses for received data from the overriding system.

Overriding System

DDCS link

RMIO/

Ch0

NAMC-xx

Dataset Table

10 12

Address Assignment of Dataset

Group

90.01.. .90.18

91.01...91.09

AMC Table

Data set receive addresses with the NAMC-51/RMIO board are given below. D SET 10 VAL 1 denotes the receive address of data set 10 value 1. Integer scaling of the parameters is 1 = 1 and range 0...9999.

Code Parameter Default Updating Interval (ms)

90, 91 DATA SET RECEIVE

ADDRESSES

90.01 D SET 10 VAL 1 701 2

90.02 D SET 10 VAL 2 0 2

90.03 D SET 10 VAL 3 0 2

90.04 D SET 12 VAL 1 0 4

90.05 D SET 12 VAL 2 0 4

90.06 D SET 12 VAL 3 0 4

90.07 D SET 14 VAL 1 0 10

90.08 D SET 14 VAL 2 0 10

90.09 D SET 14 VAL 3 0 10

90.10 D SET 16 VAL 1 0 10

90.11 D SET 16 VAL 2 0 10

90.12 D SET 16 VAL 3 0 10

90.13 D SET 18 VAL 1 0 100

90.14 D SET 18 VAL 2 0 100

90.15 D SET 18 VAL 3 0 100

90.16 D SET 20 VAL 1 0 100

90.17 D SET 20 VAL 2 0 100

90.18 D SET 20 VAL 3 0 100

91.01 D SET 22 VAL 1 0 100

91.02 D SET 22 VAL 2 0 100

91.03 D SET 22 VAL 3 0 100

91.04 D SET 24 VAL 1 0 100

91.05 D SET 24 VAL 2 0 100

91.06 D SET 24 VAL 3 0 100

91.07 D SET 32 VAL 1 0 100

91.08 D SET 32 VAL 2 0 100

91.09 D SET 32 VAL 3 0 100

IGBT Supply Unit Program 8-23

Chapter 8 – Parameters

92, 93 Data Set Transmit Addresses

Parameters of this group are signal addresses for transmitted data to the overiding system.

Overriding System

DDCS link

RMIO/

Ch0

NAMC-xx

Dataset Table

11 13

Address Assignment of Dataset

Group

92.01.. .92.18

93.01...93.09

AMC Table

Data set transmit addresses with the NAMC-51/RMIO board are given below. D SET 11 VAL 1 denotes the transmit address of data set 11 value 1. Integer scaling of the parameters is 1 = 1 and range 0...9999.

Code Parameter Default Updating Interval (ms) /

Description

92, 93

92.01 D SET 11 VAL 1 801 2

92.02 D SET 11 VAL 2 110 2

92.03 D SET 11 VAL 3 0 2

92.04 D SET 13 VAL 1 0 4

92.05 D SET 13 VAL 2 111 4

92.06 D SET 13 VAL 3 106 4

92.07 D SET 15 VAL 1 911 10

92.08 D SET 15 VAL 2 0 10

92.09 D SET 15 VAL 3 0 10

92.10 D SET 17 VAL 1 912 10

92.11 D SET 17 VAL 2 115 10

92.12 D SET 17 VAL 3 122 10

92.13 D SET 19 VAL 1 0 100

92.14 D SET 19 VAL 2 0 100

92.15 D SET 19 VAL 3 0 100

92.16 D SET 21 VAL 1 108 100

92.17 D SET 21 VAL 2 112 100

92.18 D SET 21 VAL 3 0 100

93.01 D SET 23 VAL 1 0 100

93.02 D SET 23 VAL 2 0 100

93.03 D SET 23 VAL 3 0 100

93.04 D SET 25 VAL 1 0 100

93.05 D SET 25 VAL 2 0 100

93.06 D SET 25 VAL 3 0 100

DATA SET TRANSMIT ADDRESSES

8-24 IGBT Supply Unit Program

98 Option Modules

Chapter 8 – Parameters

Code Parameter T

98 OPTION

MODULES

98.01 COMMAND SEL B I/O This parameter selects the control command

98.02 COMM MODULE I NO This parameter defines the control mode and place in

Default Alternative

y p e

Settings

( ) Fieldbus Equivalent

(0) MCW The ISU control program reads the control commands

(1) I/O The ISU control program reads the control commands

(1) NO The drive is controlled using I/O: DI2. (2) FBA DSET1 The drive is controlled through the communication link

(3) FBA DSET10 The drive is controlled through the communication link

(4) INVERTER Not in use

Description

interface(s).

via a serial link and through the digital input terminals.

through the digital input terminals.

the REMOTE mode.

(CH0) using datasets 1 and 2. This is a typical setting for use with a fieldbus adapter module.

(CH0) using datasets 10 to 33. (for example APC2, AC 70, AC80, NPBA-02, NCSA-01)

IGBT Supply Unit Program 8-25

Chapter 8 – Parameters

99 Start-up Data

Code Parameter

Default Alternative

y p e

Settings

( ) Fieldbus

Description

Equivalent

99 START UP

DATA

99.01 LANGUAGE I ENGLISH (0) ENGLISH (1) ENGLISHAM (2) DEUTSCH

The line-side converter displays the information in the selected language. Note: only English is available at the time of publishing.

(3) ITALIANO (4) ESPAÑOL (5) PORTUGUÊS (6) NEDERLANDS (7) FRANÇAIS (8) DANSK (9) SUOMI (10) SVENSKA

99.02 DEVICE NAME C Max. 32 characters The name of the supply section can be typed here by

DriveWindow. The name is shown in the System Configuration display of DriveWindow.

99.06 FAST SYNC B YES (0) NO Synchronization with phase order check (1) YES Synchronization without phase order check

99.07 LINE SIDE ID

RUN

BNO (0) NO Line-side converter ID Run is not performed after next

start.

(1) YES Next start makes ID Run for the line-side converter. It

takes about 5 seconds. After the ID Run, the converter keeps on modulating. It is not allowed to load the line-side converter during the ID Run.

99.08 AUTO LINE ID

RUN

B YES (0) NO No automatic line-side converter ID Run after power-up of

the NAMC/RMIO board and start. The parameter does not set Par. 99.07 to YES (ID Run request can still be set with Par. 99.07 if required).

(1) YES Line-side converter ID Run is performed automatically

after power-up of the NAMC/RMIO board and next start. The parameter sets Par. 99.07 to YES. Note: ID Run takes about 5 seconds. It is not allowed to load the lineside converter during the ID Run. If the ID Run has been performed once, Par. 99.08 can be set to NO (ID Run request can still be set with Par. 99.07 if required).

99.09 APPLIC

BNO (0) NO

RESTORE

99.10 SUPPLY ID

NUMBER

I 0 0...32767 This parameter can be used by the overriding system to

check the right connections of the optical cables to the drive type. This parameter requires support from the overriding system to verify the correct connection.

8-26 IGBT Supply Unit Program

Ratings

Appendix A – Technical Data

Abbreviations This table explains the abbreviations used in the following rating table.

Supply Section

Duty Cycle (1 min / 5 min)

4/5min

1/5min

Duty Cycle (10 s / 60 s)

50/60s

10/60s

Total rms input current (continuous AC current)

Maximum base current with I

1/5min

Short term rms overload AC current (allowed for one minute every 5 minutes).

1/5min

4/5min

Maximum base current with I

1 min 4 min

1max

Short term rms overload AC current (allowed for 10 seconds every 60 seconds)

10/60s

50/60s

Rated apparent supply power of the supply section Nominal power of intermediate DC link (continuous active motor or

10 s

50 s

generator power)

loss

Power loss Nominal mains voltage

Notes Note 1: The ratings correspond to voltage U

230 V or 115 V.

Note 2: P

is the heat loss of a unit with basic options. The value

loss

depends on the options included. Note 3: Noise level applies to echoless room.

and fan supply voltage

ACA 635 IGBT Supply Sections A-1

Appendix A – Technical Data

Ratings 380...690 V This table shows the nominal ratings for the IGBT supply sections.

Type Marking Nominal Ratings Duty Cycle (1 min / 5 min) Duty Cycle (10 s / 60 s) Frame

kVA

4/5min

1/5min

50/60s

10/60s

Size

Air Flow P

Noise

loss

Level

kW dBA

IGBT supply sections (380...415 V Range,UN = 415 V) ACA 635-0265-3 260 379 254 284 426 260 520 R8i 2100 6.4 60

ACA 635-0405-3 400 576 386 432 684 395 790 R9i 2100 9.7 60 ACA 635-0765-3 760 1006 673 755 1132 691 1384 R11i 4180 16.8 65 ACA 635-1125-3 1120 1494 1000 1121 1681 1036 2072 R12i 5680 25.0 68 ACA 635-1440-3 1440 1913 1280 1434 2152 1381 2762 2xR11i 8210 32.0 68 ACA 635-2145-3 2140 2838 1900 2129 3193 2072 4144 2xR12i 11210 47.5 70 ACA 635-2820-3 2820 3744 2506 2809 4212 2762 5524 4xR11i 16270 62.7 71 IBGT supply sections (380...500 V Range,UN = 500 V)

ACA 635-0325-5 320 368 308 276 414 240 480 R8i 2100 7.7 60 ACA 635-0495-5 490 565 473 424 636 365 730 R9i 2100 11.8 60 ACA 635-0935-5 930 987 826 741 1111 638 1277 R11i 4180 20.7 65 ACA 635-1385-5 1380 1466 1227 1099 1649 957 1914 R12i 5680 30.7 68 ACA 635-1760-5 1760 1876 1570 1407 2110 1276 2552 2xR11i 8210 39.3 68 ACA 635-2625-5 2620 2784 2329 2088 3133 1915 3829 2xR12i 11210 58.2 70 ACA 635-3450-5 3450 3673 3073 2754 4132 2552 5104 4xR11i 16270 76.8 71 IGBT supply sections (525...690 V Range,UN = 690 V)

ACA 635-0315-6 310 264 305 198 297 179 358 R8i 2100 7.6 60 ACA 635-0485-6 490 410 473 308 461 265 530 R9i 2100 11.8 60 ACA 635-0900-6 900 695 802 521 781 464 927 R11i 4180 20.1 65 ACA 635-1385-6 1380 1064 1229 798 1196 695 1389 R12i 5680 30.7 68 ACA 635-1710-6 1710 1320 1524 990 1485 926 1853 2xR11i 8210 38.1 68 ACA 635-2545-6 2540 1959 2262 1469 2204 1390 2780 2xR12i 11210 56.6 70 ACA 635-3350-6 3350 2584 2984 1938 2907 1853 3706 4xR11i 16270 74.6 71 ACA 635-5140-6 5140 3956 4568 2967 4451 2778 5557 4xR12i 22270 114.2 71

PDM code 00145936-F

A-2 ACA 635 IGBT Supply Sections

Appendix A – Technical Data

Dimensions and Weights

This table shows the dimensions and weights of the IGBT supply sections. The weights are estimates and apply to units with basic options and aluminium DC busbars. The width and weight of the auxiliary control unit are included: 400 mm (for frame sizes R8i and R9i, approximately 100 kg) or 600 mm (for frame sizes R11i and above, approximately 150 kg).

Type Marking Width

IGBT supply sections (380...415 V Range,UN = 415 V) ACA 635-0265-3 1600 2130 550

ACA 635-0405-3 1600 2130 550 ACA 635-0765-3 2800 2130 1180 ACA 635-1125-3 3300 2130 1780 ACA 635-1440-3 4200 2130 2060 ACA 635-2145-3 5200 2130 3210 ACA 635-2820-3 7600 2130 3820 IBGT supply sections (380...500 V Range,UN = 500 V)

ACA 635-0325-5 1600 2130 550 ACA 635-0495-5 1600 2130 550 ACA 635-0935-5 2800 2130 1180 ACA 635-1385-5 3300 2130 1780 ACA 635-1760-5 4200 2130 2060 ACA 635-2625-5 5200 2130 3210 ACA 635-3450-5 7600 2130 3820 IGBT supply sections (525...690 V Range,UN = 690 V)

ACA 635-0315-6 1600 2130 550 ACA 635-0485-6 1600 2130 550 ACA 635-0900-6 2800 2130 1180 ACA 635-1385-6 3300 2130 1780 ACA 635-1710-6 4200 2130 2060 ACA 635-2545-6 5200 2130 3210 ACA 635-3350-6 7600 2130 3820 ACA 635-5140-6 9600 2130 6120

Height

Weight

PDM code 00145936-F

Height of the cabinet is 2074 for IP 54R.

ACA 635 IGBT Supply Sections A-3

Appendix A – Technical Data

Input Power Connection

Voltage (U1):

380/400/415 VAC 3380/400/415/440/460/480/500 VAC 3525/550/575/600/660/690 VAC 3-

phase for 415 VAC units

phase for 500 VAC units

phase for 690 VAC units

-40...+10% variation from converter nominal voltage is allowed. Short-circuit Capability (IEC 439): The rated short-time withstand

current of a drive equipped with an IGBT supply section is given below.

Frame Size I

R8i, R9i 37 78 R11i, R12i 50 105

Frequency: 50 Unbalance: Max.

± 2 Hz or 60 ± 2 Hz. Maximum rate of change 17%/s.

± 3% of nominal phase to phase input voltage

cw / 1 s

Voltage Dips: Max. 25% Power Factor:

cos 1.00=

-------- ϕ

rms

(fundamental at nominal load)

cos 0.98>⋅=

(total), where

is power factor

is fundamental input current rms value,

is total input current rms value.

rms

A-4 ACA 635 IGBT Supply Sections

Appendix A – Technical Data

Harmonic Distortion This table gives total harmonic distortion (THD) of the ACA 635.

Definitions

THD

Voltage

44 20

0.8 4 100

Total Harmonic Distortion:













THD

∑

THD

Current

nth harmonic component

fundamental current

THD is calculated as follows: ratio of the rms value of the harmonics (n = 2...40) to the rms value of the fundamental. The voltage THD depends on the short-circuit ratio. The spectrum of the distortion also contains interharmonics. See also Applicable Standards.

Ratio of the short-circuit power of the supply network (source) to the fundamental apparent power of the ACA 635 at point of common coupling:

= short-circuit power at point of common coupling (PCC),

= apparent power of the equipment calculated with rated rms line

equ

= Scc/S

equ

, where

current.

Switching Frequency

Ambient Conditions

Efficiency

3 kHz (average).

See ACS 600 MultiDrive Safety and Product Information (EN code: 63982229) guide or ACS800-17 Hardware Manual (EN code: 64638505).

> 97.5% at nominal power level

ACA 635 IGBT Supply Sections A-5

Appendix A – Technical Data

Fuses

IGBT Supply Section AC

Fuses

The fuses (ultrarapid) of the IGBT supply section are given below. Only ultra rapid fuses guarantee proper protection for the rectifier semiconductors. Equivalent fuses from other manufacturers can also be used.

and I

denote nominal voltage and current of the fuse

respectively.

The AC fuses used in the ACA 635 IGBT supply sections are listed below.

IGBT Supply Type

ACA 635-0265-3 660 630 170M6810 ACA 635-0405-3 660 1000 170M6814 3

ACA 635-0765-3 690 700 170M5874 ACA 635-1125-3 690 900 170M5876 2 ACA 635-1440-3 690 700 170M5874 2 ACA 635-2145-3 690 900 170M5876 2 ACA 635-2820-3 690 700 170M5874 2

ACA 635-0325-5 660 630 170M6810 ACA 635-0495-5 660 1000 170M6814 3

(V)

(A)

Fuse

Type S i z e

DIN 43620

DIN 43653

DIN 43620

ACA 635-0935-5 690 700 170M5874 ACA 635-1385-5 690 900 170M5876 2 ACA 635-1760-5 690 700 170M5874 2 ACA 635-2625-5 690 900 170M5876 2 ACA 635-3450-5 690 700 170M5874 2

ACA 635-0315-6 1250 400 170M6303 ACA 635-0485-6 1250 630 170M6205 3SHT

ACA 635-0900-6 690 900 170M5876 ACA 635-1385-6 690 700 170M5874 2 ACA 635-1710-6 690 900 170M5876 2 ACA 635-2545-6 690 700 170M5874 2 ACA 635-3350-6 690 900 170M5876 2 ACA 635-5140-6 690 700 170M5874 2

DIN 43653

DIN 43620

DIN 43653

3SHT

A-6 ACA 635 IGBT Supply Sections

ABB ACS 600, ACS 800 Users Manual

Specifications and Main Features

Frequently Asked Questions

User Manual