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ACA 6xx Frequency Converters

3 to 4300 kW

Hardware Manual

This manual concerns ACS 600 MultiDrive
frequency converters equipped with an ACA 631/
633 Diode Supply Section, an ACA 632/634/636/
637/638/639 4Q Thyristor Supply Section or an
ACA 635 IGBT Supply Section, and with the
ACA 610 Drive Sections.

Chapters 2 and 3 also apply to ACS/ACC 607,
ACS/ACC 627 and ACS/ACC 677 frequency
converter types -0760-6, -0930-5, -0900-6 or
above (from 630 to 3000 kW). In the text, they are
collectively referred to as ACx 6x7. The parts
applicable to ACx 6x7 only are marked

ACx 6x7

.

3AFY 63700118 R0125 REV E

EN

EFFECTIVE: 2.5.2001

SUPERSEDES: 7.2.2000

ã

2001 ABB Industry Oy. All Rights Reserved.

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Summary of Contents for ACA 6 Series

Page 1: ...ACA 6xx Frequency Converters 3 to 4300 kW ACS 600 MultiDrive Hardware Manual This manual includes Safety Installation Commissioning of the Drive Section Maintenance ...

Page 2: ...am parameters TSU commissioning IGBT Supply Section ISU 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 Pr...

Page 3: ... ACA 635 IGBT Supply Section and with the ACA 610 Drive Sections Chapters 2 and 3 also apply to ACS ACC 607 ACS ACC 627 and ACS ACC 677 frequency converter types 0760 6 0930 5 0900 6 or above from 630 to 3000 kW In the text they are collectively referred to as ACx 6x7 The parts applicable to ACx 6x7 only are marked ACx 6x7 3AFY 63700118 R0125 REV E EN EFFECTIVE 2 5 2001 SUPERSEDES 7 2 2000 ã 2001 ...

Page 4: ......

Page 5: ... Wait 5 minutes after switching off the supply before starting work Always ensure by measuring that the voltage between terminals UDC and UDC and 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 run...

Page 6: ... 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 frequency converter Do not open the drive section swit...

Page 7: ...nomena which result in a fuse blow are as follows At start a charging current high enough for charging all the inverters flows to the connected ones In Thyristor Supply Sections the DC voltage may overshoot the controller bridge change limit causing an immediate change to regeneration and a high reverse current The DC voltage may overshoot the braking chopper controller voltage limit causing an im...

Page 8: ...Safety Instructions vi ACS 600 MultiDrive ...

Page 9: ... Example 1 3 Drive Unit 1 3 Inverter 1 4 Control Boards 1 5 Power Plate 1 8 Main Circuit Diagram 1 9 Voltages from the Supply Section 1 11 Drive Section Configurations 1 11 Drive Section Fuses 1 11 Single Inverter Modules 1 13 Parallel Connected Phase Module Blocks 1 13 Chapter 2 Mechanical Installation General 2 1 Required Tools 2 1 Cabinet Construction 2 2 Moving of the Shipping Split 2 3 by Cra...

Page 10: ...Cable 3 5 Control Panel Cable 3 5 Insulation Checks 3 6 Motor and Motor Cable 3 6 DC Busbars 3 6 Fuses 3 7 Internal Fuses 3 7 Cable Routing 3 8 Control Cable Ducts 3 8 Power Cable Busbars 3 9 Mains Cable Connection 3 10 Low Power Supply 3 10 High Power Supply 3 11 Motor Cable Connection 3 13 High Power Applications 3 14 Parallel Connected Inverters 3 14 Inverter Modules of Frame Sizes R2i to R5i 3...

Page 11: ... Installation Checklist Installation Checklist 4 1 Chapter 5 Commissioning the Drive Section Overview 5 1 Installation Checklist 5 1 Checks with No Voltage Connected 5 2 Connecting Voltage to Auxiliary Circuits 5 3 Checks with Voltage Connected to Auxiliary Circuits 5 4 Connecting Voltage to Drive Section 5 5 Checks with Voltage Connected to Drive Section 5 7 On load Checks 5 7 Control from Overri...

Page 12: ...x ACS 600 MultiDrive Hardware Manual ...

Page 13: ...ssioning parameters fault tracing and product information see Supply Sections User s Manual DSU TSU or IGBT Preventative maintenance Note Fault and warning messages given by the software are described in ACS 600 Firmware Manual for System Standard or Crane Drive Application Program or in Supply Sections User s Manual DSU TSU or IGBT Other Manuals The guide Safety and Product Information English co...

Page 14: ... included in IGBT Supply Units only Two drive sections are drawn in the diagram even though the number of them varies The Braking Unit is an option For a more detailed description of the Supply Unit refer to the Supply Sections User s Manuals This chapter describes the Drive Section in more detail Auxiliary Control Unit Incoming Unit Braking Unit optional Supply Section Drive Sections Common DC Bu...

Page 15: ...y optional Example A block diagram of a 2 x R11i drive section is shown below Drive Unit The drive unit includes the parts listed below Inverter External Inverter Unit Cooling Fans frames R6i to 4 x R12i only Drive Control Units NDCU which include an Application and Motor Controller NAMC Board and a standard I O NIOC Board Optical Branching Unit NPBU with parallel connected units Control wiring an...

Page 16: ...controlled a c voltage from the intermediate circuit d c voltage An inverter controls one motor Frame Size An Inverter ACN 634 xxxx contains R2i to R9i one inverter module R10i to R12i three phase modules ACN 644 xxxx one inverter 2 x R11i 2 x R12i two times three phase modules ACN 644 xxxx two phase module blocks Þ one inverter 4 x R11i 4 x R12i four times three phase modules ACN 644 xxxx four ph...

Page 17: ...ol pulses for the insulated gate bipolar transistors IGBTs power supply board for gate drivers NGPS in V phase module power supply board NPOW 62 in V phase module This board is not included in frame sizes R2i and R3i main circuit board NBUB in frame size R3i An inverter of frame size 2 x R12i includes twice the control boards of an R12i inverter An inverter of frame size 3 x R12i includes three ti...

Page 18: ... Control Board Diagram 2 x R8i 2 x R9i This diagram shows the control boards that control an inverter of sizes 2 x R8i and 2 x R9i NAMC NDCU NINT NGDR NGDR NGDR NGDR NGDR NGDR Two NGDR boards control one power plate U Power plate phase V phase W phase NINT NGDR NGDR NGDR NGDR NGDR NGDR NAMC NPBU NDCU W phase V phase U phase V U W NINT NGDR NGDR NGDR NGDR NGDR NGDR V U W ...

Page 19: ...ram shows the control boards that control an inverter of size R12i NAMC NDCU NINT NGDR NGDR NGDR NGDR NXPP NGDR NGDR NGDR NGDR Two NGDR boards control one power plate NXPP NGDR NGDR NGDR NGDR W phase V phase U phase Power plate NAMC NDCU NINT NGDR NGDR NGDR NGDR NGDR NGDR NXPP NGDR NGDR NGDR NGDR NGDR NGDR Two NGDR boards control one power plate NXPP NGDR NGDR NGDR NGDR NGDR NGDR W phase V phase U...

Page 20: ...hoto shows one power plate with the NGDR boards connected NINT NGDR NGDR NGDR NGDR NGDR NGDR NXPP NGDR NGDR NGDR NGDR NGDR NGDR NXPP NGDR NGDR NGDR NGDR NGDR NGDR NAMC NINT NGDR NGDR NGDR NGDR NGDR NGDR NXPP NGDR NGDR NGDR NGDR NGDR NGDR NXPP NGDR NGDR NGDR NGDR NGDR NGDR NPBU NDCU W phase V phase U phase V U W V U W NGDR board Power plate terminal terminal Insulated base plate P3 P2 P1 P2 ...

Page 21: ... Manual 1 9 Main Circuit Diagram Frame Size R8i R9i Frame R8i R9i contains three phase modules each producing one of the three phases driving the motor Power Plate Common DC bus Uc W phase M 3 V phase U phase Phase Module P3 P1 P2 Optional du dt filter ...

Page 22: ...g one of the three phases driving the motor Each phase module consists of three parallel connected power plates Six IGBTs with free wheeling diodes are integrated to a single power plate The figure below shows the connection of one phase Power Plate Common DC bus Uc U phase M 3 V phase W phase Phase Module P3 P1 P2 P3 P1 P2 P3 P1 P2 ...

Page 23: ...an voltage is taken from the 230 115 V a c transformer in the Auxiliary Control Unit via thermal protection switch F10 F11 or F12 depending on the frame size The 24 V auxiliary voltage source is powered from a 230 115 V a c transformer in ACU via F31 or for frame sizes R7i and smaller via F10 The emergency stop and the optional uninterrupted power supply UPS are wired from the Auxiliary Control Un...

Page 24: ...n the inverter unit frames R2i to R4i In Type 2 the charging is monitored internally frames R5i and R6i In Type 3 the charging circuitry and monitoring are implemented with external components frames R7i to R12i In drive sections with parallel connected inverter units each unit has its own switch fuse with a charging circuit L L 1L 1L L L 1L 1L L L 1L 1L Type 1 Type 2 Type 3 NCHM xx Charging Monit...

Page 25: ...e the Drive Control Unit NDCU box together with the NIOC board Parallel Connected Phase Module Blocks One NAMC board controls all parallel connected phase module blocks via an optical branching unit NPBU 4x which forwards commands simultaneously to the interface NINT boards of the blocks Each block is supplied via fuses M 3 Optional du dt filter s 1L 1L NAMC NDCU NAMC M 3 Optional du dt filter s L...

Page 26: ...Chapter 1 Introduction 1 14 ACS 600 MultiDrive Hardware Manual ...

Page 27: ...ght vertical position The floor that the unit is installed on should be of non flammable material as smooth as possible and strong enough to support the weight of the unit The floor flatness must be checked with a spirit level before the installation of the cabinets into their final position The maximum allowed deviation from the surface level must be 5 mm measured every 3 m The installation site ...

Page 28: ...verters Cabinet Construction The air cooled ACS 600 MultiDrive and the ACx 6x7A use the same cabinet construction In marine versions the cabinet includes in addition vibration dampers and handles on the doors ACS 600 MultiDrive and ACx 6x7 Marine Applications ACS 600 MarineDrive Cabinet Door Opening ...

Page 29: ...e cabinets Insert the lifting ropes or slings into the holes of the lifting lugs The lifting lugs can be removed not mandatory once the cabinets are in their final location If the lifting lug is removed the bolts for each lug must be refastened to maintain the degree of protection of the cabinet ACx 6x7 IP 54 Allowed minimum height of lifting ropes or slings for IP 54 shipping splits is 2 metres ...

Page 30: ...reful when transporting the shipping splits Tilting of the cabinets must be avoided Moving of the shipping split is to be done only with the cabinets upright Remove the bottom wooden frame which is part of the shipment Lay the shipping split on the rollers and move the unit carefully until it is close to its final location Remove the rollers by lifting the shipping split using a crane or fork lift...

Page 31: ...ter lifting as they disturb the cooling of the unit Remove the lifting lug of marine versions Refasten the original bolts or fasten the upper vibration dampers if used in order to maintain the degree of protection of the cabinet The cabinets can be moved into their final position by using an iron bar and a wooden piece at the bottom edge of the cabinet Care is to be taken to properly place the woo...

Page 32: ...ons Note Any height adjustment of the cabinets must be done before fastening the cabinets together Height adjustment can be done by using metal shims between the bottom frame and floor 2 Remove the lifting bars if used and the lifting lugs in marine applications Place the original bolts or upper vibration dampers to the holes 3 Fasten the first shipping split to the next shipping split Each shippi...

Page 33: ... Insert the clamp into the longitudinal hole in the edge of the cabinet frame body and fasten it with a bolt to the floor Allowed maximum distance between the fastening clamps is 800 mm Dimensions of the fastening clamp Cabinet frame body Cabinet frame body Fastening hole distances for the common cabinet are given below Fastening bolt M10 to M12 3 8 to 1 2 Cubicle Width Hole Distance mm 200 400 a ...

Page 34: ...tween the fastening points is 800 mm Fastening holes inside the cabinet a 1 0 5 IP 54 IP 20 42 Small gap between the 200 mm 400 mm 600 mm 800 mm 1000 mm and 1500 mm cubicles 25 Side plates of the cabinet 15 mm Back plate of the cabinet 10 mm Fastening hole distances for the common cabinet are given below Fastening bolt M10 to M12 3 8 to 1 2 Cubicle Width Hole Distance mm 200 a 50 400 a 250 600 a 4...

Page 35: ...mm wide transverse sections which the floor must carry Viewed from above Side view This area can be used for a cable conduit With heavy cabinets support the structural C sections from below Prevent the cooling air flow from the cable conduit to the cabinet by bottom plates To ensure the degree of protection for the cabinet use the original bottom plates delivered with the unit With user defined ca...

Page 36: ...uld be welded to the cabinet frame as well and the dampers would be damaged Cabinets without vibration dampers can be welded although it is not not recommended from bottom as follows Connect the return conductor of the welding equipment low to the cabinet frame within 0 5 metres of the welding point WARNING If the welding return wire is connected improperly the welding circuit may damage electroni...

Page 37: ...with M10 or M12 bolts through the holes in the vibration damper flat bar 2 If there is not enough room behind the cabinets for installation use the fastening method shown in figure 2 3 Fasten the upper vibration dampers For the positions of the upper vibration dampers see the accompanying dimension drawing of the shipping split 4 Fasten the support arms to the upper vibration dampers and roof wall...

Page 38: ...ining section Special screws M6 for fastening the cabinets together are enclosed in a plastic bag inside the last cabinet of the shipping split The threaded bushings are already mounted on the post Working Order 1 Fasten the front post of the joining section with six screws to the front frame post of the next cabinet Threaded bushing Maximum tightening torque is 5 Nm 3 ft lbs 5 ...

Page 39: ...ection 600 mm wide joining section Remove the partitioning plates 3 Fasten the back post of the joining section with five screws below the busbar joining part to the post of the next cabinet 4 Replace the intermediate plate and the partitioning plate s in the 5 upper part of it after connecting the DC Busbars see next page Busbar joining section Intermediate plate Back posts accessable Partitionin...

Page 40: ...rew the bolts of the joint pieces 3 Connect the busbars with the joint pieces see figure below For aluminium busbars joint grease e g TK Penetral made by Framatome Connectors USA Inc Burndy Electrical must be used to avoid corrosion and to ensure good electrical connection The oxide layer must be scrubbed off from the joints before applying the grease 4 Replace the front metal plate into its origi...

Page 41: ...PE Busbar The PE busbar connection is shown below Lifting a Double Roof When the drive is equipped with a double roof M10 Tightening torque 35 40 Nm 25 30 ft lbs Joint piece 1 1 Lift the upper part of the roof plate up from the transportation position 2 Lock the roof to its final position with the M6 screws 2 ...

Page 42: ...Chapter 2 Mechanical Installation 2 16 ACA 6xx Sections and ACS ACC 6x7 132 to 3000 kW Frequency Converters ...

Page 43: ...ter 3 Electrical Installation WARNING The electrical installation described in this chapter should only be carried out by a qualified electrician The Safety Instructions on the first pages of this manual must be followed Negligence of these instructions can cause injury or death ...

Page 44: ...nt 6 If multiple motors are connected to the inverter module a separate thermal overload switch or a compact circuit breaker must be used for protecting the cable and the motor These devices may require a separate fuse to cut off the short circuit current The rated voltage of the mains cables should be Uo U 0 6 1 kV for 690 VAC rated equipment Uo rated voltage between the conductor and the earth U...

Page 45: ...m shield armour The minimum requirement of the motor cable shield of the ACx 600 is shown below It consists of a concentric layer of copper wires with an open helix of copper tape The better and tighter the shield the lower the emission level and the bearing currents Symmetrical shielded cable three phase conductors and a concentric or otherwise symmetrically constructed PE conductor and a shield ...

Page 46: ... a e g JAMAK by NK Cables Finland must be used for analogue signals and the pulse encoder signals Employ one individually shielded pair for each signal Do not use common return for different analogue signals A double shielded cable is the best alternative for low voltage digital signals but single shielded twisted multipair cable Figure b is also usable The analogue and digital signals should be r...

Page 47: ...se damping in the cable the cable ends therefore should be ground with fine sand paper Relay Cable The cable type with braided metallic screen e g ÖLFLEX LAPPKABEL Germany has been tested and approved by ABB Industry Control Panel Cable In remote use the cable connecting the Control Panel to the ACx 600 must not exceed 3 metres The cable type tested and approved by ABB Industry is used in Control ...

Page 48: ...r WARNING Insulation checks must be performed before connecting the ACx 600 to the mains Before proceeding with the insulation resistance measurements make sure that the ACx 600 is disconnected from the mains Motor and Motor Cable 1 Check that the motor cable is disconnected from the ACx 600 output terminals U2 V2 and W2 2 Measure the insulation resistances of motor cable and the motor between eac...

Page 49: ...tion manual for ACS 600 MultiDrive If a fuse is blown it must be replaced with a similar ultrarapid fuse Internal Fuses The fuse types used with different supply sections of ACS 600 MultiDrive frequency converters and ACx 6x7 units from 630 to 3000 kW are listed below Fuse Type Supply Section 1 Supply AC fuses B1 B2 B3 2 Branch fuses Each semiconductor of the rectifier bridge is protected with a f...

Page 50: ...caused by the rapid changes in the frequency converter output voltage Where control cables must cross power cables make sure they are arranged at an angle as near to 90 degrees as possible Extra cables should not be run through the ACx 600 The cable trays shall have good electrical bonding to each other and to the earthing eletrodes Aluminium tray systems can be used to improve local equalizing of...

Page 51: ...rs of large ACx 600 units is shown below If necessary the same screw can be used for connecting two cable lugs on both sides of the busbar Cable lugs with one or two holes can be used Always use a torque wrench for tightening the busbar connections Note In inverter modules R6i and R7i only one cable lug can be connected to a busbar screw 40 mm 100 mm 50 ...

Page 52: ...incoming supply or an inverter different are the cabinet dimensions and the location of the terminals for the cables The cabling direction may also vary top or bottom The N conductor is not normally used with ACx 600 frequency converters although it is visible in the following diagrams Low Power Supply A low current 300 A cable connection when one cable is sufficient is represented below L1 L2 L3 ...

Page 53: ... either one end or both ends Metal conduit shield L1 L2 L3 N Note The paint should be removed to allow a good connection to the cabinet frames throughout the whole perimeter of the metal conduit or a bus duct The metal conduit or the bus duct metal should be electrically continuous throughout its complete length It is recommended to arrange the cables as shown alongside to achieve a current distri...

Page 54: ... phase current will induce voltage to the cable shield If the shields are connected to each other at both ends of the cable current will flow in the cable shield In order to prevent this and to ensure personal safety the cable shield must be connected only to PE at the transformer side and insulated on the converter side The connection is represented below L1 L2 L3 N Transformer Converter L1 L2 L3...

Page 55: ...eparate PE conductor system is used only if local safety regulations do not allow earthing of the ACx 600 and the motor merely through the cable screen This solution increases motor bearing currents compared to symmetrical shielded cable thus causing extra wear L1 L2 L3 U2 V2 W2 PE Drive Section U1 V1 W1 PE M 3 U2 V2 W2 PE Drive Section U1 V1 W1 PE M 3 U2 V2 W2 PE Drive Section U1 V1 W1 PE M 3 L1 ...

Page 56: ...low Parallel connected cables are drawn as single cables to simplify the drawings Requirements for parallel connected cables and cables for motors with two separate windings are given as follows The maximum allowed difference in cable length is 5 i e the length of the longest cable divided by that of the shortest cable must be less than or equal to 1 05 lmax lmin 1 05 Cables must be of the same ty...

Page 57: ...2 where n 1 2 3 With four parallel blocks the number of cables must be n x 4 where n 1 2 3 Otherwise the output cabling must be done from a separate output cubicle 1 2 3 1 2 3 1 2 3 U2 V2 W2 1 2 3 1 2 3 1 2 3 M 3 PE OUTPUT Phase Module Block U2 V2 W2 PE OUTPUT Phase Module Block 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 V1 W1 U1 Inverter Motor with single connection or with two separate windings which a...

Page 58: ...ommon Motor Connection Terminal Motor cable connections for parallel connected inverters with a common output cubicle s are presented below 2 x R11i R12i 4 x R11i R12i Motor with single connection or with two separate windings which are connected together in the terminal box Motor with dual connections two separate windings ...

Page 59: ... R12i without Common Motor Connection Terminal Motor cable connections for four parallel connected inverters without a common output cubicle are presented below Motor with single connection or with two separate windings which are connected together in the terminal box Motor with dual connections two separate windings ...

Page 60: ...e If connection terminals are outside the module make the connections like this Tighten the screw to the torque given in ACS 600 MultiDrive Safety and Product Information Appendix A If connection terminals are inside the module 1 remove the module cover 2 make the connections Tighten the screw to the torque given in ACS 600 MultiDrive Safety and Product Information Appendix A PE PE U2 V2 W2 U2 V2 ...

Page 61: ...to 800 mm see page 3 21 Motor cable connection 1 Strip the cable 3 cm at the cabinet entry if EMC sleeves are used 2 Lead the cable unstripped to the busbar terminals behind the fan 3 Connect the cables to the terminals with cable lugs 4 Connect the shield conductor to the PE busbar Control cable connection Connect the control cables to the appropriate terminal block on the DIN rail PE terminal of...

Page 62: ...e cable 3 cm at the cabinet entry if EMC sleeves are used 4 Lead the cable unstripped to the busbar terminals behind the fan 5 Connect the cables to the terminals with cable lugs 6 Connect the shield conductor to the PE busbar 7 Replace the fan 8 Connect the fan power lead Control cable connection Connect the control cables to the appropriate terminal block on the DIN rail ACx 6x7 units 630 to 300...

Page 63: ...2i optional common motor output of parallel connected inverter modules when the number of cables does not match the rule given on page 3 15 optional Cable entry from the bottom is shown below The top entry is accomplished in the same way except that cables are entering or exiting the cabinet from the top PE terminal of the cabinet Motor cable Busbar for motor cable connection PE conductor shield o...

Page 64: ...and connect them to earth terminal or PE busbar Peel off 3 to 5 cm of the outer insulation of the cable above the entry plate for the 360 high frequency earthing Fasten the conductive sleeve to the cable shield with a cable tie Seal the slot between the cable and mineral wool sheet if used with sealing compound e g CSD F ABB brand name DXXT 11 code 35080082 Tie up the unused conductive sleeves wit...

Page 65: ...provide thermal insulation for the conductor insulator Cover the part of the cable which will be left inside the core s 20 mm below Approximately 1 5 metres of tape is needed per cable Each turn must overlap the previous turn by half the width of the tape 3 Bind the conductors tightly with non conductive electrical tape and a heat resisting non metallic cable tie in order to prevent conductor insu...

Page 66: ... the upper left hand corner of the fields next to the busbar joining sections Connect the loose wires to the next X25 terminal block Connect the loose wires not coming from X25 to the destinations marked on the wire ends Ensure that no unconnected wire ends are left which will be powered when the supply voltage is switched on Last shipping split Shipping split Busbar joining section X25 ACU UPS X2...

Page 67: ... Control Unit see subsection below Connect the twisted screen as short as possible to the earthing terminal Auxiliary Control Unit of ACx 6x7 External control cables and options for ACx 6x7 units 630 to 3000 kW are connected in a 400 mm or 600 mm wide Auxiliary Control Unit NIOC board and X2 2TB terminal block are located on the DIN rail on the left hand side of the cabinet Assembly Door Wire the ...

Page 68: ...x Sections and ACS ACC 6x7 132 to 3000 kW Frequency Converters 360 Earthing at the Cable Entry 360 earthing of the control cable screens by EMI conductive cushions at the bottom of the Auxiliary Control Unit is shown below EMI conductive cushions ...

Page 69: ...wever if very many control cables come to one cabinet plan the installation beforehand as follows 1 Make a list of the cables coming to the cabinet 2 Sort the cables going to the left into one group and the cables going to the right into another group to avoid unnecessary crossing of cables inside the cabinet 3 Sort the cables in each group according to size 4 Group the cables for each grommet as ...

Page 70: ... inside the cabinet through the grommet and the EMI conductive cushions If you have several cables bunch them together at the grommet but ensure that each cable has a proper contact to the cushions on both sides 3 Strip off the cable plastic sheath above the base plate just enough to ensure proper connection of the bare screen and the EMI conductive cushions 4 Earth the screen between the EMI cond...

Page 71: ...rface Cover the turned screen and the stripped cable with copper foil to keep the shielding continuous Note The earthing wire if present must not be cut Push the two parts of the lead through plate together so that the EMI conductive cushions press tightly round the foil covered screen 5 Lock the two parts of the lead through plate by tightening the positioning screws Cable screen Screened twisted...

Page 72: ...0 kW Frequency Converters 6 Top entry If more than one cable go through a grommet the grommet must be sealed by Loctite 5221 catalogue number 25551 Side view Apply Loctite 5221 inside the grommet Attach control cables to the supporting plate Connect the earthing wire to the PE busbar ...

Page 73: ... C 3 R01 NO 1 R02 NC 2 R02 C 3 R02 NO 1 R03 NC 2 R03 C 3 R03 NO 24 V OUT 200 mA RELAY OUTPUT 1 RELAY OUTPUT 2 RELAY OUTPUT 3 NDCU 21 DIGITAL INPUTS ANALOG INPUTS OUTPUTS 1 24 V 2 0 V 1 24 V 2 0 V 3 24 V 4 0 V 1 3 6 V 2 GND DDCS PC DDCS MSTR FOLL DDCS I O DDCSe APPLICATION CONTROLLER PPCS INVERTER NiCd BATT TXD RXD RS 485 TERMINATION X 5 X 5 TERMINATED NOT TERMIN RS 485 RS 485 CONTROL PANEL 24 V IN...

Page 74: ...INVERTER BRC BRAKING CHOPPER RS 485 CONTROL PANEL X21 X22 X28 X29 V25 V26 X24 X23 X25 X26 X27 RS 485 MODBUS RS 485 MODBUS DDCS NAMC I O 1 2 3 4 24 V GND 24 V GND 1 2 3 R01 NC R01 C R01 NO 1 2 24 V GND 1 2 3 R02 NC R02 C R02 NO 1 2 3 R03 NC R03 C R03 NO 1 2 3 4 24 V GND 24 V GND 24 V IN 24 V IN 24 V OUT 200 mA RELAY OUTPUT 1 RELAY OUTPUT 2 RELAY OUTPUT 3 1 2 3 4 DI1 DI2 DI3 DI4 5 6 7 8 DI5 DI6 24 D...

Page 75: ...nction Termination OFF Termination ON default OFF OFF ON NAMC NIOC on off NIOC No 1 SW1 ON NIOC No 2 SW1 OFF NIOC No 3 SW1 OFF NIOC No 4 SW1 ON Drive units at a common earth potential e g installed in the same cabinet Note When drive units are not at a common earth potential or long distance 3 m connection is required NBCI modules can be used Refer to the module manual X28 X29 Straight through cab...

Page 76: ...ntrol Panel and Monitoring Display Monitoring Display only Reversed crossover cable Ident Black pin 1 to pin 6 pin 2 to pin 5 etc Straight through cable Ident Grey pin 1 to pin 1 pin 2 to pin 2 etc Symbols X3 X4 X3 X2 X1 X1 NLMD 01 CDP 312 NDPI 21 X3 NAMC 21 22 Monitoring Display Control Panel Panel Interface Control Panel Panel Interface Terminated Fixed termination Fixed termination No terminati...

Page 77: ...22 NAMC 21 22 NAMC 21 22 The CDP 312 Control Panel can be connected through NDPI 21 or directly to the NAMC 21 22 board to the 6 pin modular connector X3 The modular connectors on the NIOC board are not intended for the Control Panel The maximum cable length between CDP 312 or NDPI 21 and NIOC 01 or NAMC xx is 10 metres In the presence of high level radiofrequency disturbances the length should be...

Page 78: ...3000 kW Frequency Converters Earthing Grounding The boards are earthed to the chassis as shown below back view of the Control Panel mounting platform NDPI 21 NLMD 01 NLMD 01 NLMD 01 X3 X2 1 5 MM AWG 16 55 0 mm 6 MM MAX Crimp terminal 6 3 1 5 DIN M3 ring terminal DIN e g JST 1 25 3 ...

Page 79: ...71341 or Pulse Encoder Interface Module NTAC 0x Installation and Start up Guide EN code 58919730 for the pulse encoder insulation reguirements and connections The pulse encoder shall be insulated from the motor stator or rotor in order to prevent currents from finding their way out from the drive shaft through the encoder with resulting damage to the bearings in both the motor and the encoder NDCO...

Page 80: ... the Auxiliary Control Unit ACx 6x7 units Fibre Optic Link Optional modules are connected via a DDCS fibre optic link to the NAMC board or NDCO board both mounted on top of the NIOC board The terminals to which the cables are connected on the NAMC NDCO board are given in the table below Channel CH1 is on NAMC 11 51 board Channels CH0 CH2 and CH3 are on the NDCO board The NAMC 03 and NAMC 21 22 boa...

Page 81: ...MBd transmitters and receivers Note 2 With 5 MBd optical components only plastic optical cable POF can be used The maximum cable length is 10 metres However when operating at the lower speed of 1 Mbit s normally with DriveWindow the cable length can be extended to 15 metres Note 3 With 10 MBd components either plastic POF or Hard Clad Silica HCS optical cable can be used When the maximum optical p...

Page 82: ...e terminals for the power supply connection vary Consult adapter module manual T R I O Extension Module ACx 600 NAMC NIOC NIOC Terminal X23 The terminals for the power supply connection vary Consult module manual CH1 R T R T CH1 NIOCP Not supported by ACP 600 NIOC Terminal X23 NIOCP Terminal X4 NDCO NDCO Pulse Encoder Module with ACS 600 Crane System Master Follower and Template Application Progra...

Page 83: ...X23 The terminals for the power supply connection vary Consult module manual CH2 The ACP 600 supports the NTACP Double Pulse Encoder instead See NTACP Installation and Start up Guide Pulse Encoder Module NTAC with ACS 600 Standard Application Program NDCO CH1 R T R T T R DriveWindow ACx 600 NAMC R NIOC CH3 NIOCP R T NDCO CH1 R T NDPA NDPC R T NISA R T Desktop PC Laptop PC ...

Page 84: ...ACA 6xx Sections and ACS ACC 6x7 132 to 3000 kW Frequency Converters Installation of Other Optional Equipment Install options such as PTC PT100 relays cubicle heater motor fan starter etc according to circuit diagrams delivered with the unit ...

Page 85: ...d are removed See Chapter 2 Mechanical Installation the cabinet roof is lifted up if double roof See Chapter 2 Mechanical Installation The applicability of the motor and the driven equipment See Safety and Product Information Motor Connection ELECTRICAL INSTALLATION see Chapter 3 Electrical Installation Joining of the shipping splits The DC busbars and PE busbars are properly connected See Chapter...

Page 86: ...d correct direction of rotation see Chapter 3 Electrical Installation Installation of Optional Modules and Pulse Encoder Interface Module NTAC 02 Installation and Start up Manual EN code 58919730 or NIOB 01 User s Guide EN code 64471341 Thermistor cables The connections are appropriate for the sensor used in the motor Prevention of Unexpected Start cables Emergency stop cables When other external ...

Page 87: ...ual must be followed Negligence of the safety instructions can cause injury or death Installation Checklist The installation must be checked before commissioning the Drive Section Action Information Check that the mechanical and electrical installation of the frequency converter is inspected and OK See Chapter 4 Installation Checklist Ensure that the insulation resistance of the assembly is checke...

Page 88: ...ting plate data correspond to the values in the motor list Motor temperature measurement method Pt 100 PTC or other Motor fan of separately ventilated motors Check the current the overcurrent protection setting and the functioning of the fan output control circuit Direction of motor rotation Maximum and minimum speeds fixed speeds Speed scaling factor gear ratio roll diameter etc Acceleration and ...

Page 89: ...ide 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 Disconnect the communication link to the overriding system by removing the fiber optic cables See the circuit diagrams delivered with the device Make sure that the ...

Page 90: ...section Connecting Voltage to Auxiliary Circuits are completed Close the optional disconnecting switch of the drive section if included See section Connecting Voltage to Drive Section below 1 Cooling Fans Check that the cooling air fans rotate freely in the right direction and the air flows upwards A paper sheet set on the lower gratings stays The fan runs noiselessly 2 Parameters Set the drive pa...

Page 91: ...the charging circuit fuses which are live Drive Section without a disconnecting switch If the drive sections only have fuses without a main switch all the sections which have the fuses installed will be powered to a voltage of 1 35 U1 when the main breaker contactor closes To prevent this remove the fuses from the drive sections which you do not wish to receive power If the drive section is not eq...

Page 92: ...H Go to the next step POWERING THE DRIVE SECTION POWERING THE DRIVE SECTION WARNING Before power switch on make sure that a sufficient inverter power is connected to the intermediate circuit Rules of thumb 1 The sum power of the inverters connected must be at least 30 of the sum power of all inverters 2 The sum power of the inverters connected must be at least 30 of the rated power of the braking ...

Page 93: ...ommand and wait until the drive has stopped 2 Open the Prevention of Unexpected Start switch by closing the switch on the control desk the circuit will open The lamp if fitted on the desk should be lit 3 Give a Start command The drive should not start 4 Reset the drive See the circuit diagrams delivered with the device Action Information Check the rotation direction of the motor Check the pulse en...

Page 94: ...th the device 3 Power the unit up 4 Check the start stop functions torque etc references alarm fault words function in case of a communication break updating interval of the drive software other needed points of the application Action Information If disconnecting of a Section is needed 1 Stop the drive by a Stop command and wait until the drive has stopped 2 Open the Prevention of Unexpected Start...

Page 95: ...irflow direction must be from bottom to top Also use a vacuum cleaner at the air outlet to trap the dust Fan rotation must be prevented in order to prevent bearing damage Relays Relays should be checked for function and all connections should be inspected and checked for tightness Any signs of corrosion especially in ground components shall be cleaned off Fan The cooling fan lifespan is approximat...

Page 96: ...as been non operational for more than one year Without reforming capacitors may be damaged when the converter starts to operate The reforming methods introduced here require that the converter has been stocked clean and dry It is recommended to reform the capacitors once a year How to check the converter age Converter serial number defines the week when the converter has been built 8 digit e g 182...

Page 97: ...nce a year to keep the capacitors in operational condition Converters Stocked Non operational for 2 Years and Over Use Method 2 A or Method 2 B both explained below for capacitor reforming if the converter has been stocked or non operational for two or more years WARNING The ACS 600 MultiDrive converters IGBT Supply Units and Drive Units must be reformed outside the cabinet Reform the phase module...

Page 98: ...voltages are given below See Figure 6 1 for the reforming time WARNING The converter supply must be disconnected while the reforming circuit is connected Supply Voltage Recommended Components A R C 380 V U1 415 V SKD 82 16 220 Ohm 700 W 22 nF 2000 V 380 V U1 500 V SKD 82 16 470 Ohm 1200 W 22 nF 2000 V 525 V U1 690 V SKD 82 16 680 Ohm 1700 W 22 nF 2000 V L L R A C U1 1 35 U1 Converter or phase modu...

Page 99: ...mit the current voltage is increased gradually with e g 100 V steps Maximum recommended reforming current is 500 mA An appropriate reforming voltage is 1 35 Ö2 U1 The reforming circuit is shown below See Figure 6 1 for the reforming time WARNING The converter supply must be disconnected while the reforming circuit is connected R 100 Ohm 500 W L L R 1 35 U1 Converter or phase module W2 W1 U2 U1 V2 ...

Page 100: ...Chapter 6 Preventive Maintenance 6 6 ACS 600 MultiDrive ...

Page 101: ......

Page 102: ...ABB Industry Oy Drives P O Box 184 FIN 00381 HELSINKI FINLAND Telephone 358 10 22 2000 Telefax 358 10 22 22681 Internet http www abb com automation 3AFY 63700118 R0125 REV E EFFECTIVE 2 5 2001 EN ...

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