ABB ACS 600, ACS 800 Users Manual

ACS 600, ACS 800

This manual includes

•Safety

•Commissioning of the Supply Section with ISU

•Functional Description

•Parameters

•Fault Tracing

•Technical Data

User’s Manual

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 EN EFFECTIVE: 07.07.2003

2003 ABB Oy. All Rights Reserved.

Safety Instructions

Overview	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.
Installation and	These safety instructions are intended for all who work on the ACA 6xx
Maintenance Safety	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 UDCand 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.

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.

Automatic Resets

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

Safety Instructions

Dedicated Transformer

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

Low voltage

Other load than

Motors

Drive

drives and motors

Other drives

or

Medium voltage network

Supply transformer

Low voltage

Other load than

Drive

drives and motors

Other drives and motors

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	CHANGED: ACS/ACC 617 line-side converter has been replaced by
Converter	the ACS 800-17 line-side converter.

Chapter 1 - About this Page 1-2, User Interface CHANGED: The user interface of the IGBT

Manual Supply Unit is a CDP 312 Control Panel or a PC, which is equipped with a DDCS board and DriveWindow.

Chapter 2 - Operation Page 2-3 CHANGED: Voltage and current distortion

Basics

Spectrum of the Voltage Distortion

2
1,5
1
0,5
0
THD	11	21	31	41	51	61	71	81	91	101	111	121	131	141	151	161	171	181	191

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1

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Spectrum of the Current Distortion

4
3,5
3
2,5
2
1,5
1
0,5
0
THD	11	21	31	41	51	61	71	81	91	101	111	121	131	141	151	161	171	181	191

Chapter 3 - Hardware

Description

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)

	5
	4.5
	4
<![if ! IE]> <![endif]>[%]	3.5
<![if ! IE]> <![endif]>THD	3
	2.5
<![if ! IE]> <![endif]>Current
	2
	1.5
	1
	0.5
	0
	0	10	20	30	40	50	60	70	80	90	100

Rsc (Short-circuit Ratio) at PCC

2	Update notice

Update Notice

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

PCC (Point of Common Coupling)

	5
	4
<![if ! IE]> <![endif]>[%]
<![if ! IE]> <![endif]>THD	3
<![if ! IE]> <![endif]>Voltage	2
	1
	0
	0	10	20	30	40	50	60	70	80	90	100

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.

ICU

FIU

ISU

Converter

Module

OESA

AC fuses

DC fuses

~

=

Charging circuit

230/115 V

<![if ! IE]> <![endif]>NAMC/

<![if ! IE]> <![endif]>RMIO

NDCU/RDCU

ACU

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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	10000 = 10 V or
			AI1. See Par. 13.01 AI1 HIGH	20 mA
			VALUE and 13.02 AI1 LOW VALUE.

Page 8-4 CHANGED:

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

Character Example			Meaning
no
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	Default	Alternative	Description	Integer
		y		Settings		Scaling
		p		( ) Fieldbus
		e		Equivalent
13	ANALOGUE
	INPUTS
13.12	MINIMUM	I	0 V	(1) 0 V	This value corresponds to the
	AI1			(2) -10 V	minimum reference from
					analogue input AI1.

4	Update notice

					Update Notice
Page 8-22 CHANGED:
Code	Parameter	T	Default	Alternative	Description	Integer
		y		Settings		Scaling
		p
				( ) Fieldbus
		e
				Equivalent
70	DDCS
	CONTROL
70.20	CH3 HW	B	STAR		This parameter is used for	1=1
	CONNECTION				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).

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.

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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

X32 X22

X23	X33
X25

	X26	X68
	X27
		X57

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7

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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.)

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

2) 0 = open, 1 = closed

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

3)	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

4)See parameter 21.09 START INTRL FUNC.

X20

1

VREF-

Reference voltage -10 VDC,

2

GND

1 kohm < RL < 10 kohm

X21

1

VREF+

Reference voltage 10 VDC,

2

GND

1 kohm < RL < 10 kohm

3

AI1+

Speed reference 0(2) ... 10 V,

4

AI1-

Rin > 200 kohm

5

AI2+

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

6

AI2-

Rin = 100 ohm

7

AI3+

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

8

AI3-

Rin = 100 ohm

rpm

9

AO1+

Motor speed 0(4)...20 mA = 0...motor nom.

10

AO1-

speed, RL < 700 ohm

A

11

AO2+

Output current 0(4)...20 mA = 0...motor

12

AO2-

nom. current, RL < 700 ohm

X22

1

DI1

Stop/Start

2

DI2

Forward/Reverse 1)

3

DI3

Not in use

4

DI4

Acceleration & deceleration select 2)

5

DI5

Constant speed select 3)

6

DI6

Constant speed select 3)

7

+24V

+24 VDC max. 100 mA

8

+24V

9

DGND

Digital ground

10

DGND

Digital ground

11

DIIL

Start interlock (0 = stop) 4)

X23

1

+24V

Auxiliary voltage output, non-isolated,

2

GND

24 VDC 250 mA

X25

1

RO11

Relay output 1: ready

2

RO12

3

RO13

X26

1

RO21

Relay output 2: running

2

RO22

3

RO23

X27

1

RO31

Relay output 3: fault (-1)

Fault

2

RO32

3

RO33

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

8	Update notice

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.

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.)

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

2) 0 = open, 1 = closed

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

3) 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

4)See parameter 21.09 START INTRL FUNC.

X20

1

VREF-

Reference voltage -10 VDC,

2

GND

1 kohm < RL < 10 kohm

X21

1

VREF+

Reference voltage 10 VDC,

2

GND

1 kohm < RL < 10 kohm

3

AI1+

Speed reference 0(2) ... 10 V,

4

AI1-

Rin > 200 kohm

5

AI2+

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

6

AI2-

Rin = 100 ohm

7

AI3+

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

8

AI3-

Rin = 100 ohm

rpm

9

AO1+

Motor speed 0(4)...20 mA = 0...motor nom.

10

AO1-

speed, RL < 700 ohm

A

11

AO2+

Output current 0(4)...20 mA = 0...motor

12

AO2-

nom. current, RL < 700 ohm

X22

1

DI1

Start (

)

2

DI2

Stop (

)

3

DI3

Forward/Reverse 1)

4

DI4

Acceleration & deceleration select 2)

5

DI5

Constant speed select 3)

6

DI6

Constant speed select 3)

7

+24V

+24 VDC max. 100 mA

8

+24V

9

DGND

Digital ground

10

DGND

Digital ground

11

DIIL

Start interlock (0 = stop) 4)

X23

1

+24V

Auxiliary voltage output, non-isolated,

2

GND

24 VDC 250 mA

X25

1

RO11

Relay output 1: ready

2

RO12

3

RO13

X26

1

RO21

Relay output 2: running

2

RO22

3

RO23

X27

1

RO31

Relay output 3: fault (-1)

Fault

2

RO32

3

RO33

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9

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RMIO Board Specifications

Analogue inputs	With Standard Application Program two programmable differential current inputs
	(0 mA / 4 mA ... 20 mA, Rin = 100 ohm) and one programmable differential voltage
	input (-10 V / 0 V / 2 V ... +10 V, Rin > 200 kohm).
	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: > 60 dB at 50 Hz
	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
	2)
Analogue outputs	Two programmable current outputs: 0 (4) to 20 mA, RL < 700 ohm
	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: 1 ms
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.

10	Update notice

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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	Type Code
	Character no.		Options
ACA 635	ACA635xxxxxxxxxxxx...		0,1
	16

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11

Update Notice

Appendix B Circuit

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

Diagrams

RDCU

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Chapter 1 – About this Manual

What this Chapter	This chapter describes the intended audience and contents of this
Contains	manual. It contains a table referring to tasks described in other
	manuals.
Intended Audience	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.
Parameter Setting	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.
To which Products	This manual applies to the ACA 635 supply sections and ACS 800-17
this Manual Applies	drives which contain the IGBT Supply Unit.
Contents	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

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Chapter 1 – About this Manual

	Appendix B – Circuit Diagrams contains some example circuit
	diagrams of the ACA 635.
ISU-related
Information in Other
Manuals
Task	See
Mechanical and Electrical	ACS 600 MultiDrive Hardware Manual (EN code: 63700118) or ACS800-17 Hardware
Installation of the Drive	Manual (EN code: 64638505)
Installation of Optional Modules
and DriveWindow
Preventive Maintenance
Technical Data for the	ACS800-17 Hardware Manual (EN code: 64638505)
ACS 800-17
Associating ISU with	DriveWindow Start-up Guide (EN code: 36458585)
DriveWindow	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.	Click OK.
	Do you wish to associate it?
	Associate ‘ISU600-xxxx-x’ With	Choose ACS600 MultiDrive
		from the list.
	Do you wish association ‘ISU600-xxxx-x’ = ACS600	Click Yes.
	MultiDrive be permanent?
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

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.

Main Circuit Diagram

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

Control and Gate Drivers

Common DC bus

Idc

Supply network

IU	LCL Filter

Uc

Converter

Control

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

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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 (iU) and voltage (uUV) waveforms are shown below.

(A, V)

1200
					uUV
800
		iU
400
0	2	4	6	8	10	12	14	16	18	20	22	24	26	28	30	32	34	36	t (ms)
0																			38
-400
-800
-1200

DC Current A typical DC current (idc) waveform is shown below.

(A)
500		idc
450
400
350
300
250
200
150
100
50
0
100	102	104	106	108	110	112	114	116	118	t (ms)

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	Chapter 2 – Operation Basics
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.

Spectrum of the Voltage A typical spectrum of the voltage distortion at the output of the DIstortion transformer is shown below. Each harmonic is presented as a

percentage of the fundamental voltage. n denotes the ordinal number of the harmonic.

2
1,5
1
0,5
0
THD	11	21	31	41	51	61	71	81	91	101	111	121	131	141	151	161	171	181	191

Spectrum of the Line A typical spectrum of the line current distortion is shown below. Each Current Distortion harmonic is presented as a percentage of the fundamental current. n

denotes the ordinal number of the harmonic.

4
3,5
3
2,5
2
1,5
1
0,5
0
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

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Chapter 2 – Operation Basics

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