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ABB ACS 600 MultiDrive, User Manual

The ABB ACS 600 MultiDrive is a state-of-the-art product designed to enhance industrial operations. To ensure user safety, it is accompanied by comprehensive "Safety And Product Information" manual. Download this manual for free from manualshive.com, to gain invaluable insights and maximize the potential of this powerful product.

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ACA 635 IGBT Supply Sections User’s Manual 

ix

Chapter 8 – Parameters

Overview   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
1 Actual Signals  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
2 Actual Signals  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
3 Actual Signals  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
4 Information   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
7 Control Word  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8 Status Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
9 Fault Words  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
11 Reference Selects  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
13 Analogue Inputs   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
14 Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
15 Analogue Outputs  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
16 System Control Inputs  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
18 LED Panel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
19 Data Storage  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

Trend Monitoring with Drive Window   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14
Sending a value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14
19 Data Storage Parameter Table  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-15

21 Start/Stop Functions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
23 DC Bus Reference   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-18

24 Reactive Power  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
30 Fault Functions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
51 Communication Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
70 DDCS Control  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
71 DriveBus Communication  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
90, 91 Data Set Receive Addresses   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
92, 93 Data Set Transmit Addresses  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
98 Option Modules  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
99 Start-up Data  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

Appendix A – Technical Data

Ratings  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  A-1
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  A-1
Ratings 380...690 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  A-2

Dimensions and Weights  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Input Power Connection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Harmonic Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  A-5

Switching Frequency   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Ambient Conditions   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Efficiency   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Fuses  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

IGBT Supply Section AC Fuses  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  A-6
IGBT Supply Unit DC Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Summary of Contents for ACS 600 MultiDrive

Page 1: ...A 635 IGBT Supply Sections ISU 260 to 4728 kVA ACS 600 User s Manual This manual includes Safety Commissioning of the Supply Section with ISU Functional Description Parameters Fault Tracing Technical Data ...

Page 2: ...U program parameters TSU commissioning IGBT Supply Sections User s Manual 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...

Page 3: ... IGBT Supply Sections 260 to 4728 kVA User s Manual This manual concerns the ACS 600 MultiDrive supply sections ACA 635 equipped with an IGBT Supply Unit and the ACS ACC 617 drives 3BFE 64013700 R0125 REV B EN EFFECTIVE 10 11 2000 SUPERSEDES 21 10 1999 ...

Page 4: ......

Page 5: ... 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 inver...

Page 6: ...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 stopp...

Page 7: ... 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 ACA 635 The resonance current might damage some unit in the network Supply transformer Low voltage Other drives Low voltage Other load than drives and motors Supply transformer Medium voltage network ACA 635 Neighbouring network Low voltage Othe...

Page 8: ...Safety Instructions vi ACA 635 IGBT Supply Sections ...

Page 9: ... 2 Operation Basics Operation of ISU 2 1 Main Circuit Diagram 2 1 Control 2 1 Voltage Waveform 2 1 Diagram 2 2 Current Waveform 2 2 Line Current 2 2 DC Current 2 3 Harmonics 2 3 Voltage Harmonics 2 4 Line Current Harmonics 2 4 Chapter 3 Hardware Description Main Components of ACS 600 MultiDrive with ISU 3 1 Supply Section 3 1 Auxiliary Control Unit 3 2 Incoming Unit 3 2 Filter Unit 3 2 IGBT Supply...

Page 10: ...Chapter 5 Earth Fault Protection Overview 5 1 Floating Network 5 1 Insulation Monitoring Device 5 1 System earthed Network 5 2 Chapter 6 Firmware Description Overview 6 1 Control Principle 6 2 Identification Routine 6 4 Charging 6 5 Synchronization 6 5 Starting Sequence 6 6 Start by the Starting Switch 6 7 Start via Fieldbus 6 8 Level Start 6 9 Stop 6 9 Missing Phase 6 10 Control Diagram 6 11 Cont...

Page 11: ...9 Data Storage Parameter Table 8 15 21 Start Stop Functions 8 16 23 DC Bus Reference 8 18 Example 8 18 24 Reactive Power 8 18 30 Fault Functions 8 19 51 Communication Module 8 20 70 DDCS Control 8 20 71 DriveBus Communication 8 22 90 91 Data Set Receive Addresses 8 23 92 93 Data Set Transmit Addresses 8 24 98 Option Modules 8 25 99 Start up Data 8 26 Appendix A Technical Data Ratings A 1 Abbreviat...

Page 12: ... Supply Sections A 8 Drive Control Unit NDCU 2x A 9 NIOC Board Connections A 10 Control Panel A 11 NLMD 01 Monitoring Display A 11 NIOC Board Specifications A 11 Applicable Standards A 12 CE Marking A 13 Compliance with the EMC Directive A 13 Machinery Directive A 14 Appendix B Circuit Diagrams Overview B 1 ...

Page 13: ... section Parameters of the IGBT supply unit control program Fault tracing Technical data giving information concerning the ratings fuses cooling requirements power losses etc Study this manual carefully before installing commissioning operating or servicing the supply section equipped with an IGBT supply unit We expect that you have a basic knowledge of physical and electrical fundamentals electri...

Page 14: ...ppendix A Technical Data in this manual Preventive Maintenance as above Installation of Optional Modules and DriveWindow as above Install any optional modules and DriveWindow according to the instructions given in Chapter 3 Electrical Installation Associating ISU with DriveWindow DriveWindow Start up Guide EN code 36458585 When associating DriveWindow 1 3 and 1 4 with the ISU proceed as follows Us...

Page 15: ...e main circuit of the IGBT supply is shown below 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 Voltage Waveform The high frequency switching and high du dt slightly distorts the voltage...

Page 16: ...ent has a sinusoidal waveform whereas the d c current consists of a d c component and a high switching frequency component Line Current A typical line current iu waveform is shown below u2 denotes converter input voltage 400 300 200 100 0 100 200 300 400 100 102 104 106 108 110 112 114 116 118 u0 u1 V t ms 500 400 300 200 100 0 100 200 300 400 500 100 102 104 106 108 110 112 114 116 118 iu u2 A V ...

Page 17: ...dge does because of the sinusoidal waveform of the line current The typical spectrum of the line current and line to line voltage harmonics is quite wide but there are no high individual components The Total Harmonic Distortion THD in voltage depends highly on the Short Circuit Ratio in the Point of Common Coupling PCC refer to Appendix A Technical Data 0 50 100 150 200 250 300 350 400 450 500 100...

Page 18: ...ntal voltage n denotes the order of the harmonic Line Current Harmonics A typical spectrum of the line current harmonics is shown below Each harmonic is presented as a percentage of the fundamental current n denotes the order of the harmonic 0 1 2 3 4 5 6 7 THD 11 21 31 41 51 61 71 81 91 101 111 121 131 141 151 161 171 181 191 n 0 0 5 1 1 5 2 2 5 3 3 5 4 THD 11 21 31 41 51 61 71 81 91 101 111 121 ...

Page 19: ...on 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 Auxiliary Control Unit Incoming Unit IGBT Supply Unit Filter Unit Braking Unit optional Supply Section Drive Sections Common DC Bus 24 V ICU ISU FIU ACU Chopper AC Resistor Inverter Inverter NAMC NAMC 1 L 1242 rpm I SPEED 124 2 rpm CURRENT 76 A T...

Page 20: ...nel and NLMD 01 Monitoring Display Optional voltage and current meters Control wiring and relays Auxiliary voltage filter for sensitive equipment IN 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 a c supply ...

Page 21: ... Board NGPS in frame sizes R12i and up for supplying power to NGDR boards Gate Driver Board NGDR Converter The converter consists of an IGBT bridge which forms controlled d c voltage from the supply network a c voltage The bridge is capable of delivering braking energy back to the network Frame Size A converter ACN 634 xxxx consists of R8i to R9i one converter module R10i to R12i three phase modul...

Page 22: ...re of the ACS 600 MultiDrive inverter One NAMC board controls the converter module It is located in the Auxiliary Control Unit inside the Drive Control Unit NDCU box as well as the NIOC board The supply section is equipped with an a c reactor and AC and DC fuses Parallel Connected Modules Parallel connected IGBT supply converter module configuration is equal to parallel connected inverter module c...

Page 23: ...figuration is beneficial when the motoring power is considerably higher than the braking power and the brakings are short Start mode DC LEVEL START Parameter 21 01 value 1 must be used During motoring the ISU is not modulating only the free wheeling diodes are conducting The motoring current is flowing mainly through the DSU diode bridge because the line impedance of the ISU is a lot higher than t...

Page 24: ...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 Braking Chopper Braking Resistor ...

Page 25: ...rs to the more detailed instruction Action Information Check that the mechanical and electrical installation of the frequency converter is inspected and OK See ACS 600 MultiDrive Hardware Manual EN code 63700118 or ACx 6x7 Hardware Manual EN code 61329005 Refer to Installation Checklist and Insulation Checks Chapter 3 Ensure that the insulation resistance of the assembly is checked according to in...

Page 26: ...ings Check the settings of the relays for the emergency stop circuit See the circuit diagrams delivered with the device Check the settings of the time relays See the circuit diagrams delivered with the device Check the settings of other relays See the circuit diagrams delivered with the device Check the settings of the breakers switches of the auxiliary circuits See the circuit diagrams delivered ...

Page 27: ...ge 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 re...

Page 28: ...by using the switch and meter on the cabinet door This is an optional feature If included see the circuit diagrams delivered with the device Check the secondary side voltage of the auxiliary voltage transformer Close the protection switch on the secondary side See the circuit diagrams delivered with the device Close the breakers of the auxiliary circuits one by one Check each circuit by measuring ...

Page 29: ...ts 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 on load values It is recommended to set relatively low current values at the first voltage switch on Ensure that all cabinet doors are closed Be ready ...

Page 30: ...e 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 dis...

Page 31: ...tings stays Fan runs noiselessly 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 This is an optional feature IRDH265 x If included see the circuit diagrams delivered with the device For information on the protection principle see the IRDH265 Operating Manual by Bender code T...

Page 32: ...ET1 or FBDSET 10 depending on what datasets the overriding system uses 98 02 COMM MODULE Connect the fibre optic cables to channel CH0 on the NAMC board Set the node address and communication mode for channel CH0 as follows 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 coommuni...

Page 33: ... is available in IRDH265 Operating Manual code TGH1249 published by the manufacturer BENDER companies System earthed Network 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 Diagram This diagram shows earth fault protection implemented with internal current tran...

Page 34: ...explaining the control principle only The following symbols are used Actual signal or parameter described in Chapter 8 Parameters 11 11 Parameter actual signal below 100 described in Chapter 8 Parameters 113 05 Parameter above 100 These parameters are not visible to the user unless passcode is entered for the Parameter Lock in Parameter 16 03 PASS CODE These parameters are not allowed to be change...

Page 35: ...esented by an equivalent circuit with an AC choke and vector diagrams below where ____ motoring _ _ _ generating U1 network voltage vector U2 line converter voltage vector UL AC choke voltage vector y network flux vector y line converter flux vector yL AC choke flux vector d power transfer angle U1 U2 I jwL d jwLi UL U1 U2 I y y yL U2gen Igen ...

Page 36: ...librium 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 a c 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...

Page 37: ...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 a identification routine must be completed The identification routine is executed each time after the NAMC board is powered The identification routine can be executed manually also after next start without power up by setting the Para...

Page 38: ...ntify 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 ISU must be stopped during a phase order change The synchronization can also be done with only one 200 ms short circuit by Parameter 99 06 FAST SYNC selection YES Note In this case no phase order check is...

Page 39: ...oor or via fieldbus is presented below For description of the starting procedure see the next pages Code Parameter Unit Description 140 10 ZERO VECT LENGTH 200 ms Length of the short circuit pulse 140 11 PHASE LOSS LIMIT A Current limit for short circuit current 99 06 FAST SYNC One short circuit pulse is used Fault 9 02 SUPPLY PHASE Synchronization failed phase s missing 9 11 SYNCHRO FLT Synchroni...

Page 40: ...0 5 s 2 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 acknowledg...

Page 41: ... in position 1 2 by rising edge of digital input DI2 from starting switch and simultaneous high level of Parameter 7 01 MAIN CTRL WORD bit 0 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 0 Charging contactor Main contact...

Page 42: ...ff switch on the cabinet door is disabling the modulator and opening 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 The...

Page 43: ...vals defined by Parameter 142 03 NET TEST DEL If the voltage in the DC link falls below the limit defined by Par 145 04 DC UNDERVOLT TRIP the ISU will open the main contactor breaker and a fault Parameter 9 11 bit 14 DC UNDERVOLT is generated The sensitivity to the detection of a missing supply phase can be set by the following parameters Code Parameters Unit Description 142 01 NET LOST CUR LIM A ...

Page 44: ...oller 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 Direct torque and flux hysteresis control calculation Actual value Reference value control flux torque Hysteresis Flux ref Torque ref Optimal switching logic ASICs Torque bits Flux bits Control bits S1 S1 S3 DC voltage S1 S2 S3 L...

Page 45: ...eter 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 Description 23 01 DC VOLT REF User given reference 113 01 DC REF MAX Upper limit for the reference 113 02 DC ...

Page 46: ... are used to calculate the output of the PID algorithm The output of the DC voltage controller is Parameter 122 04 TORQUE REF LIM which is used as torque reference for hysteresis control The sign of rotation supply phase order determines the sign of torque reference The PID controller parameters are pretuned There is no need to retune them The active power is calculated as a product of angular vel...

Page 47: ...ion will cause a voltage rise in the DC link When the voltage reaches the limit of Parameter 145 03 DC OVERVOLT TRIP bit 15 DC OVERVOLT of Parameter 9 11 SUPPLY FAULT WORD will be set and the ISU will trip An alarm Parameter 9 12 SUPPLY ALARM WORD bit 5 CURRENT LIM is generated when the line current Actual Signal 1 06 LINE CURRENT is exceeds the value of Parameter 137 04 CURRENT LIMIT Par 137 04 C...

Page 48: ...nt limit parameters are presented below Reactive Power Control The base value for the flux reference is Parameter 150 01 FLUX REF USED NOM The DC voltage and output voltage references are defined during identification routine for setting cosfii to 1 0 However the voltage level in the network can fluctuate greatly To have cosfii equal to 1 0 at every point the DC voltage and output voltage referenc...

Page 49: ...l DC voltage 150 01 FLUX REF USED NOM Nominal flux reference 2 05 113 05 DC REF Q CTRL V DC voltage reference from cosfii control 130 02 FLUX SQ REF Squared flux reference from cosfii control 24 01 123 04 Q POWER REF Reactive power in percentage of the nominal power 1 07 161 15 REACTIVE POWER kVAr Calculated reactive power 120 03 QPOW RAMP UP s Ramp up time 120 04 QPOW RAMP DOWN s Ramp down time 1...

Page 50: ...e 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 The ACA 635 is equipped with advanced protection features that continuously guard the unit against damage and down time due to incorrect operating conditions and...

Page 51: ...2 or Par 13 10 MINIMUM AI3 is set to 4 mA Check for proper analogue control signal level Check the control wiring CH0 TIMEOUT Par 9 12 bit 0 Communication break detected on CH0 receive can be deactivated see Parameter 70 04 Check the fibre optic cables between the NAMC board and overriding system or fieldbus adapter Test with new fibre optic cables Check that the CH0 node address Par 70 01 CH0 NOD...

Page 52: ...SET 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 ID N CHANGED The ID number of the ISU has been changed from 1 the change is not displayed on the Control Panel CDP 312 To change the ID number back to 1 go to Drive Selection Mode by pressing DRIVE Press ENTER Set...

Page 53: ... converter nominal voltage DC UNDERVOLT Par 9 02 bit 2 Par 9 11 bit 14 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 The default trip limit is 293 V d c for 415 V units 354 V d c for 500 V units and 488 V d c for 690 V units The tip limit can be changed with Par 30 12 DC UNDERVOLT TRIP Check supply an...

Page 54: ... NINT board On units with parallel connected inverters replace the NPBU board OVERCURRENT Par 9 01 bit 1 Par 9 11 bit 1 Input current is excessive The overcurrent trip limit is 0 98 Par 4 08 CONV MAX CURRENT The trip limit is approximately 190 of the converter nominal current I1N Par 4 05 CONV NOM CURRENT Check motor load Check supply voltage Check that there is no power factor compensation capaci...

Page 55: ...hase module block 2 If a faulty power plate is detected replace the whole phase module SC INU 3 Par 9 01 bit 14 Short circuit in parallel connected phase module block 3 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 r...

Page 56: ...o 4 Fault fixed Yes No No Frame Size 2xR11i 2xR12i 4xR11i or 4xR12 Yes Is the difference between Par 3 12 PP 0 TEMP to Par 3 15 PP 3 TEMP 5 C Yes No A faulty fibre between NINT and NPBU boards Change the fibre Yes No Contact ABB for permission to set Par 30 03 EARTH FAULT LEVEL to 5 Fault fixed Yes No Contact ABB for permission to set Par 30 03 EARTH FAULT LEVEL to 6 Fault fixed Yes No Change cabl...

Page 57: ...Chapter 7 Fault Tracing 7 8 ACA 635 IGBT Supply Sections ...

Page 58: ... 1 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 ACA 635 IGBT Supply Unit ...

Page 59: ...TORING kWh This actual signal counts the kilowatt hours of motoring power flow from mains to intermediate circuit 1 100 kWh 1 17 KWH GENERATING kWh This actual signal counts the kilowatt hours of regenerative braking power flow from intermediate circuit to mains 1 100 kWh 1 19 AI1 V 0 10 Non scaled value of analogue input AI1 See Par 13 0 AI1 HIGH VALUE and 13 02 AI1 LOW VALUE 10000 10 V or 20 mA ...

Page 60: ...arameter Unit Description Integer Scaling 3 ACTUAL SIGNALS 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 Trac...

Page 61: ...age 4 02 DTC SW VERSION C xxxx Software version number of the flux software This fixed part of the software consists of the line converter control operation system communication control of the DDCS channels and Modbus software for the control panel 4 03 APPLIC SW VERSION C IxAx xxxx The application software name can be identified by means of this signal This part of the software has been written u...

Page 62: ...tops modulation 4 6 0 Not in use 7 RESET 0 Þ 1 Makes a reset 0 8 15 0 Not in use Parameter 8 01 MAIN STATUS WORD Status signals of the line converter Bit Name Value STATE Description 0 RDY_ON 1 Ready to switch on no fault 0 Not ready to switch on fault 1 RDY_RUN 1 Ready to operate DC bus charged 0 Not ready to operate 2 RDY_REF 1 Operation enabled 0 3 TRIPPED 1 Fault 0 No fault 4 5 6 Not in use 7 ...

Page 63: ...lock 4 9 02 FAULT WORD 2 0 SUPPLY PHASE Missing phase during synchronisation 1 Not 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 NIOC temperature 8 Not 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 Communi...

Page 64: ...t 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 Code Parameter Bit Name Description 9 FAULT WORDS NINT NAMC U V W Converter Phase Module Block Converter Constructed of Two to Four Par...

Page 65: ...uring 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 9 12 SUPPLY ALARM WORD 0 CH0 TIMEOUT Communication break detected 1 PANEL LOST Local control lost 2 Not in use 3 AI MIN FU...

Page 66: ... AI1 The hardware filter time constant is 20 ms 1 1 ms 13 04 AI2 HIGH VALUE I 0 32768 32767 This value corresponds to the maximum input in milliamperes 20 mA on analogue input AI2 1 1 13 05 AI2 LOW VALUE I 0 32768 32767 This value corresponds to the minimum input in milliamperes 0 or 4 mA on analogue input AI2 1 1 13 06 MINIMUM AI2 I 0 mA 1 0 mA 2 4 mA This value corresponds to the minimum referen...

Page 67: ...O2 BIT NUMBER Example When bit number 0 RDY_ON of 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 Invertation of the output is set with a minus sign of the Par 14 04 value 1 1 14 05 DO2 BIT NUMBER 0 0 15 This parameter s...

Page 68: ...1 s 15 05 SCALE AO1 R 100 0 65536 Nominal value of AO1 Par 15 01 ANALOGUE OUTPUT 1 It corresponds to 20 mA at the output Example Par 1 06 LINE CURRENT is linked 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 1 1 15 06 ANALOGUE OUTPUT 2 I 101 0 30000 Analogue output signal 2 source selection See example ...

Page 69: ...he Parameter Lock The default 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 16 06 PARAMETER BACKUP I DONE 0 DONE Parameter value after the saving has been completed 1 SAVE Parameter saving from RAM to permanent FPROM memory Note Parameter changes done through the CDP 312 Control Panel...

Page 70: ...tual 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 18 01 LED PANEL OUTPUT I 109 0 30000 Signal source selection for the NLMD 01 Monitoring Display Example To link Par 1 09 POWER to the display set Parameter 18 01 to value 109 1 1 18 02 SCALE PANEL R 100 0 65536 Scaling factor for the NL...

Page 71: ...monitoring channel to read Parameter 19 01 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 14 Index 1 NAMC xx Data set table Data set Index 1 14 2 3 GroupIndex 90 08 19 01 Address Assignment of Data set A For DriveWindow PC Tool Index 2 Index 3...

Page 72: ... 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 ...

Page 73: ...ceeds the level of Par 21 02 DC VOLTAGE LEVEL 21 02 DC VOLTAGE LEVEL R See table below See table below Intermediate circuit DC voltage level at which the modulation starts 21 03 STOP LEVEL TIME 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 21 04 STOP LEVEL POWER R 0 kW kW Motoring power to stop the mod...

Page 74: ... Supply Sections 8 17 The functions set by this parameter group are visualised below Uc is intermediate circuit DC voltage P is converter supply power P U Pm Pg Uc t Par 21 03 Par 21 04 Par 21 02 Modulation starts Modulation stops P Pg ...

Page 75: ...compensated simply by setting Parameter 23 01 DC VOLT REF to value 565 However the input current to produce the output power is still calculated on the basis of 380 V P Ö3 380 line current 24 Reactive Power Code Parameter T y p e Range Description Integer Scaling 23 DC VOLT REF 23 01 DC VOLT REF R See table below User given setpoint value for intermediate circuit DC voltage reference 1 1 V Code Pa...

Page 76: ...ce 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 reaction 1 1 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 DI...

Page 77: ...T y p e Default Alternative Settings Fieldbus Equivalent Description Integer Scaling 70 DDCS CONTROL 70 01 CH0 NODE ADDR R 1 1 125 Node address for channel CH0 When using the AC 80 system the address must be 1 In other control systems node address is set according to the application 1 1 70 02 CH0 LINK CONTROL R 10 1 15 DDCS channel CH0 intensity control for transmission LEDs This parameter can be ...

Page 78: ...intensity control for transmission LEDs This value is adjusted through the link including each device in the link This parameter can be used in special cases to optimise the communication performance in the link 1 1 70 19 CH0 HW CONNECTION B 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 ...

Page 79: ...rnative Settings Fieldbus Equivalent Description Integer Scaling 71 DRIVEBUS COMM 70 01 CH0 DRIVEBUS MODE B YES This parameters selects the communication mode for channel CH0 on the NAMC board The new mode becomes valid only on the next NAMC board power on 1 1 0 NO DDCS mode 1 YES DriveBus mode with AC 80 controller ...

Page 80: ... 4 90 06 D SET 12 VAL 3 0 4 90 07 D SET 14 VAL 1 0 100 90 08 D SET 14 VAL 2 0 100 90 09 D SET 14 VAL 3 0 100 90 10 D SET 16 VAL 1 0 100 90 11 D SET 16 VAL 2 0 100 90 12 D SET 16 VAL 3 0 100 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 ...

Page 81: ... 2 0 100 92 09 D SET 15 VAL 3 0 100 92 10 D SET 17 VAL 1 912 100 92 11 D SET 17 VAL 2 115 100 92 12 D SET 17 VAL 3 122 100 92 13 D SET 19 VAL 1 0 500 92 14 D SET 19 VAL 2 0 500 92 15 D SET 19 VAL 3 0 500 92 16 D SET 21 VAL 1 108 500 92 17 D SET 21 VAL 2 112 500 92 18 D SET 21 VAL 3 0 500 93 01 D SET 23 VAL 1 0 500 93 02 D SET 23 VAL 2 0 500 93 03 D SET 23 VAL 3 0 500 93 04 D SET 25 VAL 1 0 500 93 ...

Page 82: ... terminals 1 I O The ISU control program reads the control commands through the digital input terminals 98 02 COMM MODULE I NO This parameter defines the control mode and place in the REMOTE mode 1 NO The drive is controlled using I O DI2 2 FBA DSET1 The drive is controlled through the communication link CH0 using datasets 1 and 2 This is a typical setting for use with a fieldbus adapter module 3 ...

Page 83: ...tion with phase order check two synchronization pulse 1 YES Synchronization without phase order check one synchronization pulses 99 07 LINE SIDE ID RUN B NO 0 NO Line side converter ID Run is not performed after next start 1 YES Next start makes line side converter ID Run It takes about 5 seconds After ID Run converter keeps on modulating It is not allowed to load the motor during the ID Run 99 08...

Page 84: ...ss room Supply Section I1N Total rms input current continuous a c current Duty Cycle 1 min 5 min I1base Maximum base current with I1max I1max Short term rms overload a c current allowed for one minute every 5 minutes Duty Cycle 10 s 60 s I1base Maximum base current with I1max I1max Short term rms overload a c current allowed for 10 seconds every 60 seconds SN Rated apparent supply power of the sup...

Page 85: ...368 308 276 414 240 480 R8i 2300 9 6 62 ACA 635 0495 5 490 565 473 424 636 365 730 R9i 2300 14 7 62 ACA 635 0610 5 610 700 586 525 788 456 912 R10i 4650 18 3 67 ACA 635 0935 5 855 987 826 741 1111 638 1277 R11i 4650 25 7 67 ACA 635 1385 5 1270 1466 1227 1099 1649 957 1914 R12i 6200 38 1 70 ACA 635 1760 5 1625 1876 1570 1407 2110 1276 2552 2xR11i 9300 48 8 70 ACA 635 2625 5 2411 2784 2329 2088 3133...

Page 86: ...00 600 2x 1000 1500 2130 3350 ACA 635 2820 3 9600 600 1000 4x 1000 1000 2130 4100 IBGT supply sections 380 500 V Range UN 500 V ACA 635 0325 5 1800 400 400 400 600 2130 650 ACA 635 0495 5 2000 400 400 600 600 2130 700 ACA 635 0610 5 2800 600 400 600 1000 2130 1100 ACA 635 0935 5 3200 600 600 1000 1000 2130 1250 ACA 635 1385 5 3700 600 600 1000 1500 2130 1850 ACA 635 1760 5 5200 600 600 2x 1000 100...

Page 87: ...ge it is possible to drive a 690 V motor with nominal motor voltage Short circuit Capability IEC 439 The rated short time withstand current of a drive equipped with an IGBT supply section is given below Frequency 50 2 Hz or 60 2 Hz Maximum rate of change 17 s Unbalance Max 3 of nominal phase to phase input voltage Voltage Dips Max 15 Power Factor cos j1 1 00 fundamental at nominal load l I1 Irms c...

Page 88: ...rcuit power of the supply network source to the fundamental apparent power of the ACA 635 at point of common coupling Rsc Scc Sequ where Scc short circuit power at point of common coupling PCC Sequ apparent power of the equipment calculated with rated rms line current Switching Frequency 2 kHz average Ambient Conditions See ACS 600 MultiDrive Safety and Product Information EN code 63982229 guide o...

Page 89: ...5 3 690 700 170M5874 DIN 43653 2 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 DIN 43620 3 ACA 635 0495 5 660 1000 170M6814 3 ACA 635 0610 5 1250 1250 170M6299 ACA 635 0935 5 690 700 170M5874 DIN 43653 2 ACA 635 1385 5 690 900 170M5876 2 ACA 635 1760 5 690 700 170M5874 2 ACA 63...

Page 90: ...les and DIN 46329 for aluminium cables IGBT Supply Section Frame Type UN V Size IN A Type IGBT Supply Section Frame Type UN V Size IN A Type 415 V and 500 V Range 690 V Range R8i R10i 660V 3 630 170M6810 R8i R10i 1250V 3SHT 400 170M6303 R9i R11i 2xR11 4xR11i R12i 2xR12i 660V 3 1000 170M6814 R9i R11i 4xR11i R12i 2xR12i 4xR12i 1250V 3SHT 630 170M6205 PDM code 00018306 Screw Torque Nm Soft aluminium ...

Page 91: ...8 ACA 635 2145 3 16x 13x18 18 270x711 18 ACA 635 2820 3 16x 13x18 18 270x711 18 440V 460V 500V ACA 635 0325 5 4x Æ14 6 270x511 6 ACA 635 0495 5 4x Æ14 6 270x511 6 ACA 635 0610 5 4x Æ14 6 270x511 6 ACA 635 0935 5 6x 13x18 6 270x911 6 ACA 635 1385 5 8x 13x18 6 270x911 6 ACA 635 1760 5 16x 13x18 12 195x501 12 ACA 635 2625 5 16x 13x18 18 270x711 18 ACA 635 3450 5 16x 13x18 18 270x711 18 575V 660V 690V...

Page 92: ...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 24 V...

Page 93: ...rter fan 2 DI2 Stop Start 3 DI3 Acknowledgement of main contactor 4 DI4 Earth fault 5 DI5 6 DI6 Reset 7 24V 24 V d c max 100 mA 8 24V 9 DGND Digital Ground X23 Fixed 1 24 V Auxiliary voltage output non isolated 24 V d c 250 mA 2 GND X25 Fixed 1 RO11 Relay output 1 Charging contactor control 2 RO12 3 RO13 X26 Fixed 1 RO21 Relay output 2 Fault 1 2 RO22 3 RO23 X27 Fixed 1 RO31 Relay output 3 Main con...

Page 94: ...xternal control connection board NIOC 01 of the IGBT supply section For external control connections of the control section refer to Common Drive Control Manuals IGBT Supply Section NIOC 01 Board Constant Voltage Output Voltage 10 VDC 0 5 Full scale Range at 25 C Temperature Coefficient 100 ppm C max Maximum Load 10 mA Applicable Potentiometer 1 kW to 10 kW Auxiliary Power Output Voltage 24 VDC 10...

Page 95: ...on of harmonic currents in low voltage power supply sytems with rated currrent greater than 16 A for line current IEC 1000 2 4 Class 3 Compatibility levels in industrial plants for low frequency conducted disturbances for line voltage IEEE 519 1992 Recommended practicies and requirements for harmonic control in electrical power systems Total demand distortion TDD Relay Outputs Three Relay Outputs ...

Page 96: ... converters comply with the EMC Directive in industrial low voltage network and IT networks unearthed mains with the following provisions Industrial Low Voltage Network 1 It is ensured that no excessive emission is propagated to neighbouring low voltage networks In some cases the natural suppression in transformers and cables is sufficient If in doubt the supply transformer with static screening b...

Page 97: ...2 The ACS 600 MultiDrive is installed according to the instructions given in the Hardware Manual EN code 63700118 3 The motor and control cables are selected as specified in the Hardware Manual EN code 63700118 4 Note The ACS 600 MultiDrive must not be equipped with EMC filtering when installed to floating networks The mains becomes connected to earth potential through the EMC filter capacitors In...

Page 98: ...upply sections equipped with an IGBT supply unit for helping to understand the configuration of the supply section The diagrams do not necessarily match with each delivery The wiring varies depending on the power rating and the selected equipment The circuit diagrams valid for each supply section are included in the delivery ...

Page 99: ...Appendix B Circuit Diagrams B 2 ACA 635 IGBT Supply Sections H ...

Page 100: ...Appendix B Circuit Diagrams ACA 635 IGBT Supply Sections B 3 ...

Page 101: ...Appendix B Circuit Diagrams B 4 ACA 635 IGBT Supply Sections ...

Page 102: ...Appendix B Circuit Diagrams ACA 635 IGBT Supply Sections B 5 ...

Page 103: ...Appendix B Circuit Diagrams B 6 ACA 635 IGBT Supply Sections ...

Page 104: ...Appendix B Circuit Diagrams ACA 635 IGBT Supply Sections B 7 ...

Page 105: ...Appendix B Circuit Diagrams B 8 ACA 635 IGBT Supply Sections ...

Page 106: ...Appendix B Circuit Diagrams ACA 635 IGBT Supply Sections B 9 ...

Page 107: ...Appendix B Circuit Diagrams B 10 ACA 635 IGBT Supply Sections ...

Page 108: ......

Page 109: ...3BFE 64013700 R0125 REV B EFFECTIVE 10 11 2000 EN 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 ...

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