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ABB ACS600 user manual

1. y yu0y C1E0 8 LEC 9VOV AO Aaisnpul gdy ON 494 89V P S SAVE ON 300 H DN 200 1509 NI Bua pu neg 1dep dsay 78 A069 VAMOOYI 068 JGUINN OOGSOY wou 1904 Oct 29 78 A00S VAXOOPL 0G8 6661 POZE ld ponouddy O O sep wa 99 1900 789 NOW SINGON A ddAS anu 166 IBO YAAN ISIAOGNNY pasoda4q 9M0 08 150000 uo pasog z 3 E 5 x S E S S 3 S 3 _ E S 2 8 8 z a Es a a si si 7 a a si m n WE asn ul jou 4 15 Ve 5 N z u i sbuas 4104204 x o 20 9 i VELE z LEX az LEX 10 O ilo GEI so K 8 66X LAS o o ITo o 0 0 7 a i ba Clee sale NED IS SSC Ce W AME ARE i i vig SSIUOOY ZS HOLMIS Su z LON i E al vlasi fas zz E A ino ANN SI00 ANTE i NEJ EE a 8 asijas DST i UOSUGJNS 0U su 005 ISN N TA ZA S 8 E DES LON NIE Raka i E cA NI NM S900 mas ui sgoa E ONIDUYHO iL S6X 3SN NI LON i a 9 39Vd a eat ee x IDA L M0d 590S ts Tone HR NO 3NNILNO9 Da Zi E w 0002 x 30m 00S GEN x _009 x IDA 067 w DOL IDA 001 1 S kawo waijgj E TETI IS HOLMS 1N3eeno IS HOLIMS on 01 39d NO SANILNOO AG zonx IONX ey Alum ZX Sex ez cu gl LO 9SON AL OHv08 IOYLNO9 NSA a kd ELE KT 7 7 RYB n N
2. EO LIO O1 182 9VOV AO fujsnpul gay CTT ou eu Gav L PUS EA oN 900 so f N3 Duc pul Ade DN p awou yoaloid S DI WIDsDOID 1 919 A00S 08 VAxOOrL 089 1661 8 Us IBpur y panosddy jewojsny S l0 sep w sep 20 19 wow vonoes Ajddns eni 1661780 _ ISIADPUNYT POCO A OMO 7500000 uo posog m 4 EJ 1 98 uoj sbpiuq apoig 20 9 zw 9 eat GY 90 DEE N EI N or N OLN Gd ooch ziz Loz LIZ 9 z x x Mel Xx 1 21 x OO E d J t ferg RIN Hlan yee e SIE II GS z ved Sue SEN BUER C zo vi 943 LL4 os IS o Rita H RK a T OVASI OVASI lr ez 2 S 97 veve DAI pu z Iva AE A TATE e 383358 SES 22222 lano gp 1 Sd 9 J EE a gt z S zl gt cine il Wa RE Z EE zz CL loz z A kj ga E SA Sek 60 1013 a 38 deu ST ET tel esl izl eu S eji s si ER 3d Se kel D UT D 2 w t 6 2 0 R AUT GE D 3 3 L d ZS IS 0 Li l el z L td Pd ne 32 g Sol Ce zl ZH OWA a v 07 v es 1940919 JVAOCZ VONnquisip Qua wa INSDAWI juawainsoew EN yops DuryyaDy INDI UON 3DD 0A OJJUOJ 9601 0 uang e 8 JA 9 G y a l ACA 631 633 Diode Supply Sections A 3 Appendix A Circuit Diagrams
3. AVG EarthCurr A 1 6 D Cycle 11 n time 11 gt 12 Up er gt EarthFaultLvl A le Out ve ri I Down EarthFaultFact J 0 1 gt 12 S FaultWord1 7 Sue D n 12 ek a ee MEK 2 1 6 Cycle time amp TcRes EarthFaultDly ms FT 1 6 Cycle time Figure 5 15 Earth fault current supervision Synchronisation The three line voltages are measured through high ohmic resistors The measured signals pass filters of 60 and 120 and the synchronisation is wired to the NMI input of the processor The principle is capable to identify the phase sequence of the network The synchronisation interrupt is inhibited when the network is not connected The software is supervising the synchronisation signals and the length of the cycle 1 If synchronisation is failing during the OFF state the firing pulse release is inhibited Bc Bit14 1 2 If synchronisation is failing during RUNNING the firing pulses are inhibited after 100 ms delay This keeps the DSU running during short network breaks Bc Bit13 and Bit14 1 3 If four consecutive cycle length measurements differ more than 8 the firing pulses are inhibited 4 The actual Synchronisation Fault is generated when one of the conditions above is active the main contactor is closed and there is no Main_Supply_Undervoltage see Figure 5 16 ACA 631 633 Diode Supply Sections 5 13 Chapter 5 Software Description
4. 10 bit 0 1023 BridgeTemp A 2 Bridge Temp CJ n FaultWord1 D a BridgeTmpFact po resist 11 gt 12 s 1 J Filter 100 ms 2 a R o Temp C resist ohm Com res MAX_BRIDGE_TEMP TcRes 8 22 1921 476 7777 30 2055 493 52 2407 534 Bridget 58 2505 544 21090 EMP 1 AlarmWord1 67 2676 561 um 77 2865 578 A 88 3072 596 x 12 99 3307 614 0 9 110 3538 630 CS Figure 5 14 Temperature supervision Earth Fault Current The transformation ratio of the current transformer is 400 1 A The measuring circuit is tuned so that 4 A current in the primary side of the transformer generates 0 5 V voltage in the input of the A D converter If the DSU is connected to an overriding system APC2 AC80 the tripping limit EarthFaultLvl and delay time EarthFaultDly can be changed Limits EarthFault Lvl 4 30 4 30 A EarthFault Dly 10 10 000 10 10 000 ms Initial values EarthFault Lvl 4 4 A EarthFault Dly 20 20 ms Note This function is highly sensitive to the capacitive currents generated by ACS 600 MultiDrive inverters 5 12 ACA 631 633 Diode Supply Sections Chapter 5 Software Description Execution interval 50 Hz gt 3 3 ms 60 Hz gt 2 8 ms 10 bit A D converter 0 5 V 0 1023
5. 0 1023 Z AVG Uc A 1 6 phase e UcActScal UcActAVGScal D time x AVG 3 78 V UCN U_CONSTANT_V e 20 ms 680 V e UcActAVG_v U_AD_CONSTANT_UC x o 773 135 100 Figure 5 3 Uc voltage measurement 5 2 ACA 631 633 Diode Supply Sections DC Current Measurement Ppc Calculation Firing Angle Calculation Charging Chapter 5 Software Description X e NetCurrActAvg_A LNET_CONSTANT AVG ae ee 1 6 AVG 307 phase 20 ms ULIC x e ConCurrActAvg_A LCONSTANT o 250 x CurrTrans_A e ConCurrAct_A LCONSTANT bd 250 OverCurrentLim Figure 5 4 DC current measurement DC current measurement is optional The control does not need this function If the current transformers are connected the DC current can be measured and the DC power calculated The nominal current is set by 8 way DIP switch S1 on the control board NDSC see Checks with No Voltage Connected in Chapter 2 Commissioning the Supply Section with DSU The overcurrent tripping limit is three times the nominal value of the current transformer 300 The DC power can be calculated only if the optional current transformers are connected The power is calculated by multiplying the actual DC current and actual DC voltage as follows ConCurrActAVG_ A UcActAVG_
6. V5 T L Firing pattern during charging mode I I I I Vi V3 V5 Firing pattern during normal mode Figure 1 5 Firing pattern during charging and normal mode With a half controlled bridge and sweeping firing angle neither charging resistors diodes nor contactors are needed 8001 U V Figure 1 6 Line voltages Uc voltage and one line current in charging mode DSU System The Diode Supply Unit is configured in each application by 8 way DIP Configuration switches S1 and S2 on the control board NDSC The meaning of each bit is described in Chapter 2 Commissioning the Supply Section with DSU 1 4 ACA 631 633 Diode Supply Sections Non Redundant 12 Pulse System Redundant 12 pulse Supply Chapter 1 Introduction The Diode Supply Units can be configured in 6 12 or 24 pulse systems If any of the parallel units fails all units will trip Typically the fault signals are wired to each other by hardware or by software through an overriding control system Charging of DC link capacitors can be made with a single unit or by switching the ON signal to each parallel unit simultaneously DSU1 DSU2 DI2 DO1 DI2 DO1 FAULT2 FAULT1 ON OFF1 ON OFF2 Figure 1 7 Example of a non redundan
7. Timeout watch dog If there are no NMI interrupts during 30 firing cycles the output of the watchdog block NoSynchSignal is set to ON state NoSynchSignal Net synchronization software cannot synchronize NoSyni Bc Bit13 Bc Bit14 chronous EN MainContOn SyncFaultFact 8 s FaultWord1 MAIN_SUPLY_UV Bc Bit14 TcRes Net Asymmetry Alarm Uc Ripple Alarm Current Asymmetry Alarm In REV C or later Figure 5 16 Synchronisation supervision The average network voltage is measured between two consecutive firings If there is more than 10 difference between the two measurements and this difference has been measured more than 5 times during a 200 ms cycle a net asymmetry alarm is generated The average Uc voltage is measured between two consecutive firings If there is more than 10 difference between the two measurements and this difference has been measured more than 5 times during 200 ms cycle Uc Ripple Alarm is generated The Uc Ripple Alarm is generated under the following conditions 1 DSU is RUNNING 2 Uc ripple more than 10 3 No Net Asymmetry Alarm One possible reason for the Uc Ripple Alarm is that a branch fuse in one leg of the supply bridge has blown The purpose of this function is to indicate the blowing of a branch fuse in the supply bridge
8. Information No 1 to 3 Nominal supply voltage of the Diode Supply Unit No 4 and 5 Rating of the transformer feeding the current measurement circuit of the NDSC board Transformer is optional See circuit diagrams or the transformer rating plate for the current rating No 6 Charging time for the intermediate circuit DC capacitors 500 ms is suitable for most applications No 8 Supervision of communication break of the DDCS link between the NDSC board and the overriding system S2 defines the address of the Diode Supply Unit in a communication system See the circuit diagrams delivered with the device for the address If the overriding control system is AC80 the node address is between 1 and 8 inclusive If the overriding control system is APC2 the node address is 1 This is an optional feature See the circuit diagrams delivered with the device ACA 631 633 Diode Supply Sections Chapter 2 Commissioning the Supply Section with DSU D Action Auxiliary Control Voltage Transformer Check the wirings to the primary and secondary side terminals of the auxiliary control voltage transformer Information See the circuit diagrams delivered with the device for the correspondence between the wirings and the voltage levels Connecting Voltage to Auxiliary Circuits first time The table below describes how to connect voltage to the Supply Section input ter
9. 1 13 X5 X4 X3 135 Figure 4 1 Layout of the power supply board SDCS POW 1 revision B or later and jumper coding instructions Control Board NDSC 01 e 3 digital inputs LED indication The control board NDSC 01 comprises e 3 1 digital outputs LED indication e DDCS communication link LED indication e 24 VDC 500 mA to supply auxiliary equipment LED indication e isolated firing pulses e voltage measurements Uc DC busbar voltage Uac supply voltage synchronisation e heatsink temperature measurement e current measurement e earth fault current measurement e 7 segment display e two 8 way DIP switches for application specific configuration ACA 631 633 Diode Supply Sections Chapter 4 DSU Hardware Description 233 I These supports Seas eoeoso eososo De should be metallic micro controller Y High Voltage gf XUCI l pa U l xuc2 xui XVI XG1 XC1 XG3 XC3 Figure 4 1 Layout of the control board NDSC 01 Digital Inputs and Outputs The control board contains three digital inputs which are self adaptive for voltage range 24 VDC 230 VAC The channels are galvanically isolated from each other and the rest of the board The filtering time constant for digital inputs is 10 ms The status of each channel is indicated by LED s The digital outputs are relays The t
10. DataSet Description 1 0 No 11 Control word Bit 0 ON 1 2 Not in use 3 RUN 4 6 Not in use 7 RESET 8 15 Not in use 11 Earth Fault tripping limit 12 Earth Fault delay time ACA 631 633 Diode Supply Sections 5 17 Chapter 5 Software Description Signals from DSU Table 5 5 Signals from DSU to overriding system Signal name DataSet DataSet Description No I O No MainStatusWord 10 O1 DSU Status Word Bit O RDY_ON 1 RDY_RUN 2 RUNNING 3 FAULT 4 6 Not in use 7 ALARM 8 Not in use 9 REMOTE 0 remote 10 15 Not in use AuxStatusWord 12 O1 Status of S1 S2 Bit 0 7 Switch S1 8 15 Switch S2 FaultWord1 14 O1 DSU Fault Word Bit SHORT CIRCUIT OVER_CURRENT AUX_UNDER_VOLTAGE BRIDGE_OVER_TEMP EARTH_FAULT NO_C_FAN_ACK 7 Not in use TYPE_CODING_FAULT 9 Not in use 10 DDCS_LINK_COM_ERROR 11 12 Not in use 13 NOT_IN_SYNCHRONISM 14 15 Not in use O OI WN OH 5 18 ACA 631 633 Diode Supply Sections Chapter 5 Software Description Signal name AlarmWord1 DI_StatusWord Bc NetStatusWord DataSet No 16 28 28 DataSet VO No O1 02 03 02 DSU Alarm Word Digital Input Status Internal Status Word Status of synchronization Description Bit 0 3 Not in use 4 BRIDGE_OVER_TEMP_ALARM 5 9 Not in use 10 MAINS_UNDER_VOLT_ALARM 11 NET_ASYMMETRY_ALARM 13 CURRENT_ASYMMETRY_ALARM 14 AUX_UNDER_VOLT
11. 6 1409 190 01 18Z 9W9W O snpu gdy al ON 394 ga 9 399US ON 200 UA ON 200 er 3 buo Qpu neg ONJ dep Zeen 4069 6756 vA1009C TT 0071 swou Jos od OLt WOJBS P 110949 A00S 08 vA0097 089 166 GZ us bpur Td panoiddy J wo sng l0 sep w sep 900 lc9 vov uonoes Ajddns an 1661080 YSMBPUNYP pao day OMT SSOLO000 uo pespq ddVd NO ANNILNOO e a HOH L SZN Wy d us vi LE A dzy AEN A cl o li SEL 78 YE OVAOGZ i E sod iod ZH 09 08 OVA O Z G Le OVA LL Go e ZN TIN y bD oA DUIWON E CO ug EE g zZ m i 90 i EL e Ge E 9 z NEEN Hz 93 6 zj LI sa 164 N AC 1 A ONIHOLINON lt H e el ox nei Hlava Liv de RIGA ic u l 4 ts E ui ES N OL d NO 13534 I lt 0 ZA 82 3 ZHOS DWADEZ y 20 18 i d DN TOYLNOO SNY SE A Je He 94 1 z 200 HOLOVLNOO NIVA 13834 LINWA o H e ER DN d 8 4 NO 300N 30010 NO ATTIVA A ma Y NOILVOIGNI ca PEL 5 6 gt zoa ONINNNA JOBLNOD 440 NO zig 3 Wa TW z BN ZN UN 7 4 D EN Hm L ATTIVE wz fe e ep Ki NOILVOIONI YOLOVLNOD NIYA SS bel SCT fat m 109 Linv4 ONY SNV4 XOY ue Hr Iz D b z d NOILYN9 S30 LNdlNO NOILYN9IS30 LNdNI en d i 23 1 7 3 90 a 9 LA DN y z cz T z I lt i 4 i Ca z 10 0SQN w 1213 ONYOB TOYINO9 NSA Ee EE GENEE N OL ZHOS OWADEZ y S4 L 8 9 G H l l 39000905 7 o Lenger ALAS SI Auoujno ssaidxe Troun saniod paly 0
12. V 1000 See Figure 5 3 and Figure 5 4 P_kW The power calculation has 100 ms filtering The firing angle calculation is based on the relation between Uc voltage and AC voltage Uc Unet see Figure 5 7 This relation is converted to firing angle Alpha using a conversion table In DC link charging mode Alpha is changing along a preset ramp After the charging in normal mode Alpha is locked to 0 and the DSU acts as a diode bridge Charging is carried out by changing the URatioRef see Figure 5 7 When 87 of the nominal Uc voltage is reached 1 35 nominal supply voltage the DSU changes from charging mode to normal mode If UcRef reaches 89 before UcAct is 87 the DSU forces the transition to normal mode The charging time is set by 8 way DIP switch S1 see Checks with No Voltage Connected inChapter 2 Commissioning the Supply Section with DSU on the control board ACA 631 633 Diode Supply Sections 5 3 Chapter 5 Software Description 500 ms 0 ChargeTime Figure 5 5 Charging time selection The DSU changes to charging mode every time a UNET UNDER VOLTAGE ALARM occurs 60 of nominal UNET or when stop command OFF is set During charging mode RUNNING is not set UNet DC curr A Cl o 0 50 100 150 200 250 300 350 400 450 500 550 600 T IME Ms Figure 5 6 Charging the DC link 5 4 ACA 631 633 Diode Sup
13. air circuit breaker current settings to 50 of the on load values Ensure all cabinet doors are closed Be ready to trip the main breaker of the supply transformer if anything abnormal occurs Close the main disconnecting switch of the Supply Section Close the main contactor air circuit breaker of the Supply Section It is recommended to set relatively low current values at the first voltage switch on Note Keep the starting switch of the air circuit breaker in START position for at least 2 s to ensure that the cooling fan accelerates to nominal speed 2 Air Circuit Breaker Current Settings Increase the air circuit breaker current settings to the on load values 2 6 ACA 631 633 Diode Supply Sections Chapter 2 Commissioning the Supply Section with DSU Checks with Voltage Connected to Diode Supply Unit The table below is a commissioning check list for the Supply Section after voltage is connected to the Diode Supply Unit and DC busbars Action Basic Checks Check that the cooling fan in the Supply Section rotates freely in the right direction and the air flows upwards Information A paper sheet set on the lower gratings stays The fan runs noiselessly Earth Fault Protection Based on an Insulation Monitoring Device Check the tuning of the insulation monitoring device for the earth fault protection Bender The insulation monitoring device is tu
14. delivered with the device if included ACA 631 633 Diode Supply Sections 2 5 Chapter 2 Commissioning the Supply Section with DSU Connecting Voltage to Diode Supply Unit The table below describes how to connect voltage to the Diode Supply Unit and the DC busbars for the first time Action Information A If the drive is equipped with a Braking Section the following warning applies of all inverters WARNING Before switching on power make sure that sufficient inverter power is connected to the intermediate circuit Rules of thumb 1 The sum power of the connected inverters must be at least 30 of the sum power 2 The sum power of the connected inverters must be at least 30 of the rated power of the braking section Ph max Ifthe conditions above are not fulfilled the DC fuses of the connected inverter s may blow or the braking chopper may be damaged A WARNING When connecting voltage to the Diode Supply Unit the DC busbars will become live as will all the inverters connected to the DC busbars Make sure that it is safe to connect voltage to the Diode Supply Unit Ensure that e Nobody is working on the unit or circuits that are wired from outside into the cabinets e All cabinet doors are closed First Voltage Switch on for the Diode Supply Unit If the Supply Section is equipped with an air circuit breaker set the
15. in 12 pulse configurations The indication is based on the asymmetry of the rectified line current current bubbles When a branch fuse blows in one leg of the bridge there is a 120 hole in the rectified total line current see Figure 5 17 In DSU the DC current is measured as an average of 1 6 of the net cycle ConCurrAct_A and the whole net cycle ConCurrActAVG_A 5 14 ACA 631 633 Diode Supply Sections Chapter 5 Software Description T T r Figure 5 17 DC current when one branch fuse has blown two current bubbles are missing Conditions for the Current Asymmetry Alarm e DSU is in Normal Mode RUNNING e the actual average current ConCurrActAVG_A is gt 25 of the nominal current of the used current transformer e one of the current bubbles 1 6 falls below 5 of the nominal value of the used current transformer 6 times during a 200 ms cycle DDCS Communication Communication supervision is activated by an 8 way DIP switch S1 see Checks with No Voltage Connected in Chapter 2 Commissioning the Supply Section with DSU on the control board NDSC Communication Fault is generated when the Diode Supply Unit has received the first valid DataSet message and if no valid DataSet messages have been received in 2 seconds after that Communication Alarm is generated if 1 the initialisation of the DDCC ASIC has not been successful after switched on power to the board 2 Supervision is ac
16. sumsojosip Jo asn uononporday us8i8Y paulbquoo uo OWOJU sy u puo uawnoop Siy ur SUD o 3A495914 M ACA 631 633 Diode Supply Sections Appendix A Circuit Diagrams 3 00904 u8ppiqio KROPS SI 1409 ELE OL L8C 9V0V AQ ANsnpu gay didis ON Jey ga Le ON 200 anaa W ON 200 er N3 ONI en Geen 4069 6065 YA 009 0071 awou 108 0J4 SERRURIER A00S 08 VAXOO9Z 089 166188 UsIbpuyd ponoJddy Jawo sng Sap 200 9 wow u01 s lddng on 1661 8Z YSMBPUNYP BEE OM GD 0000 uo pasog 4 3 BS i y TWIS 1 J 0 0 22 bl DS A H uu 7 DS ZIS cial g 3 SE 3 N za 9 soz 02 ZY ZY y 9A 1 6A R n II D W 2 Ly ke Co Xn CI NW Cu 1 9 X6YJN p 89 9 8 A lt 1 dd lt OJ6YLN SE Se 7 S X6vIN e vay uy ny zo vay IZY ZSZY vv mp vel ca solaz vil c3 96 a vel SA L9 I iz 10 I 5 OS ogy 277 337 622 ua gol BH TT U 13 OS UA zl d vi DON lt lt 709986 CJC H 97 5 3 Lis 43 vel Za zy 18 1 2 LIN LIN d ES iu S l S Ev ale D ce T 7 gt su Ei r 13 6 RE ci Isl 6Gl D i Gir BSI Dag 144 H 83 E JL A gzis El 83 46 E iz LIN H vil 83 46 DCH s e 222 zZ a za 9 ZA OVAGL
17. ACS 600 This manual includes e Safety e Commissioning e DSU Operation Basics e DSU Hardware Description e DSU Firmware Description User s Manual Diode Supply Sections 140 to 5200 kVA Ai HD EP PR BED iP ACS 600 MultiDrive Manuals English Originals GENERAL MANUALS Safety and Product Information EN 63982229 e Complete general Safety Instructions e 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 e LED descriptions Modules Product Catalogue EN 64104268 Supply Unit components Drive Unit components Dynamic Braking Units Drive Ware information Dimensional drawings Single line diagrams Auxiliary power consumption Master component tables Modules Installation Manual EN 64119010 e Cabinet assembly e Wiring Grounding and Cabling of the Drive System EN 61201998 e Grounding and cabling principles of a variable speed drive system EMC Compliant Installation and Configuration for a Power Drive System EN 61348280 I
18. AGE 15 UC_RIPPLE_ALARM Bit DI1 DI2 DI3 15 Not in use DP O 0 firing pulses released gt 0 pulses inhibited O OVER CURRENT 1 SHORT CIRCUIT 2 Not in use 3 MAIN SUPPLY UNDERVOLT 4 11 Not in use 12 POWER FAIL 13 NOSYNC PULSE 14 NO SYNCHRONOUS 15 CONTROL RELEASE 1 direction not identified 2 direction identified not in sync 4 direction clockwise sync OK 8 direction anticlockwise sync OK ACA 631 633 Diode Supply Sections 5 19 Chapter 5 Software Description 5 20 ACA 631 633 Diode Supply Sections Appendix A Circuit Diagrams Overview The following pages include circuit diagrams of a supply section equipped with a Diode Supply Unit The circuit diagrams help in understanding the function of DSU The diagrams do not necessarily match the actual wiring of each delivery The wiring varies depending on power rating and the selected equipment The circuit diagrams valid for each Supply Section are included in the delivery ACA 631 633 Diode Supply Sections A 1 Appendix A Circuit Diagrams
19. CU The table below is a commissioning check list for the Supply Section with voltage connected to the input terminals and Auxiliary Control Action Information A meter must be used IF IN DOUBT DO NOT PROCEED WARNING This section includes instructions for checking measuring circuits under voltage Only a qualified person is allowed to do the work Appropriate and approved Ensure the actions described in section Connecting Voltage to Auxiliary Circuits are completed Measure phase voltages by using the switch and volt meter on the cabinet door Check the secondary side voltage of the auxiliary voltage transformer Close the protection switch on the secondary side Close the breakers of the auxiliary circuits one by one Check each circuit by e measuring correct voltage in terminal blocks checking the operation of the devices connected to the circuit Check for the correct connection from an external auxiliary voltage source e g from an Uninterrupted Power Supply UPS to the Auxiliary Control Unit This is an optional feature See the circuit diagrams delivered with the device if included See the circuit diagrams delivered with the device Note The cooling fan of the Diode Supply Unit DSU will start only after the voltage is connected to the DSU and the DSU is operating This is an optional feature See the circuit diagrams
20. HO MAN DA gv Gy 89 ca 20 7 za za 7 o ij 7 hi 7 7 7 s E R k 7 o z s H 7 o gt si 5 5 E bi E n 24 9 zam e i ozx CEF 8 86S 233 8 iss 258 TS al ZV E DEE EP suo do BJD ZG PUD LG xx 33 LINN A ze HOLOv38 00 14 41 i 23 i ql 9 9 9 ER AS e ER sy 2 ao av RE 1 Za 3d Jd CE Mi e E zs lis ui Ez S Zd ld GI BE si zs lis A SE Ir J9Vd 39w1S GHVMYOJ Zd e ld g 3 ee s ISL a E in 8 9 G H 4 l ACA 631 633 Diode Supply Sections Appendix A Circuit Diagrams p m 5 La te Dik a DO SS i i o N o te gt a gt ole le g 5 a e lt Ma ma s ls US e Ie e d a i gt A f La nu t N s x o N a 8 8 Q 3 g m m a ra o z 5 gt M in lt K lo Pi y 5 E m Y T T a gt s a 5 3 o I N gt gt A 4 ACA 631 633 Diode Supply Sections A 5 Appendix A Circuit Diagrams o
21. T_ACK 0 Fan is not ON or main contactor is open 1 Fan is ON and main contactor is closed DI2 ON OFF 0 STOP command 1 RUN command on the rising edge DI3 RESET 1 Fault RESET on the rising edge DO1 FAULT 0 No FAULT 1 FAULT is ON DO2 RUNNING 0 DSU is stopped or it is in charging state 1 DSU operates as a diode bridge DO3 MAIN CON ON 0 Main Contactor open 1 Main Contactor closed DO4 ALARM this relay output is on the power supply board 0 No ALARM 1 ALARM RDY_ON 0 FAULT is on 1 No FAULT RDY_RUN 0 ON command Main Contactor is open y ON command Main Contactor closed 5 6 ACA 631 633 Diode Supply Sections Chapter 5 Software Description RUNNING 0 STOP or charging 1 Normal Mode ALARM 0 No ALARM 1 ALARM is active FAULT 0 No FAULT 1 FAULT ON OFF DI2 MAIN CONT CONTROL DO3 FAN ACK DI CHARGING l RUNNING DO2 Figure 5 8 DSU starting sequence ACA 631 633 Diode Supply Sections 5 7 Chapter 5 Software Description 003 CscRdyRef RUNNING 103 MAIN_CONT_ON o rana RunEN_WithoutFan i 50 ms N amp MAIN_CONT_ACK 26 Figure 5 9 Control logic and status Fault Diagnostics The fault signals can be identified with the 7 segment display and fault and alarm words on the DDCS link If no fault is active the decimal point in the 7 segment display is ON Any fault sets DO3 high Note There is
22. Technical and Ambient Requirements DSU Main Circuit Operation The Diode Supply Unit DSU can operate under following conditions three phase supply voltage voltage deviation 10 frequency range 45 65 Hz rated frequency 50 60 Hz dynamic df dt 17 s permissible operational ambient temperature O 40 C storage temperature 40 55 C relative humidity 5 95 no condensation allowed The Diode Supply Unit DSU contains a 6 pulse half controlled rectifier bridge with 3 thyristors in the upper leg and 3 diodes in the lower leg Module sizes B2 and B3 Module sizes B4 and B5 VII V13 V15 V14 Vi6 V12 VII V13 V15 V14 V16 Vi2 Po Figure 1 2 B2 and B3 have external AC fuses while B4 and B5 have internal AC fuses In a three phase bridge circuit the commutations alternate between the power semiconductors in the upper and lower legs so that six firing pulses are given during each period Thyristors 1 3 and 5 connect the AC line terminals in cyclic sequence to the upper DC busbar Diodes 2 4 and 6 connect the AC terminals in cyclic sequence to the lower DC busbar In the normal steady state operation with continuous current each thyristor in the upper leg and diode in the lower leg carries the current for a 120 peri
23. ZE POP eege PRE Pili 2 1 Checks with No Voltage Connected anawa aaa teas 2 2 Connecting Voltage to Auxiliary Circuits LL 2 4 Checks with Voltage Connected to Auxiliary Circuits LL 2 5 Connecting Voltage to Diode Supply Unit 2 6 Checks with Voltage Connected to Diode Supply Un 2 7 On load CHECKS deoc aries teehee Se eae se ato 2 7 Chapter 3 Earth Fault Protection option EIERE eto a DA a e A A A oda 3 1 Overvoltage Relay Floating Network 3 1 BEE dl ue e DEE EE 3 1 InCase of an Ear EENEG 3 2 Insulation Monitoring Device Floating Network 3 2 Description sr ei Se EE 3 2 inCase of an Earth Faulk saa ecs dada ata Aaa BARR Wad a kd i 3 2 Further Information 3 3 Current Transformer System Earthed Network 3 3 Descriptio ef ierg iaa Aa 3 3 in Case ofan Earth Faulk bs cadera eae goede FZ aa a ata 3 3 ACA 631 633 Diode Supply Sections vii Table of Contents Chapter 4 DSU Hardware Description DSU Gontrol Unika se a a eee oes 4 1 Power Supply Board SDCS POW 1 culi aw da A hana wd 4 1 Control BoardNDGC oi n i 4 2 Digital Inputs and OUTPUTS ee iatale i 4 3 Measurement ata acy Ve tan ao cha dad WE Mt data BG da aay Bice ee lie bi 4 4 Gate PUIS6S ads ot Oe Pe Ae a A nina a fd KA ee Suh yi a Wa 4 4 COMMUNICATION stre ie Sha kee Ba He ene yee dn wae ha dea ee ares 4 5 7 Segment Display Und aaa daa hee GEE 4 5 Chapter 5 Software Description Program REVISION t tiie
24. cessarily prevent fuses from blowing 5 10 ACA 631 633 Diode Supply Sections Chapter 5 Software Description ShortCircuitTest UratioFloat URatioSCTLim1 FaultWord1 t 15 current pulses Bc Bit1 Charging_ON Figure 5 12 DC link short circuit in the start of charging Contactor Acknowledge The status of the main contactor or air circuit breaker and the fan contactor is supervised In high power units the air flow and fan status are supervised with a pressure detector instead of the fan contactor When the main contactor is closed the acknowledgement from the main contactor and the fan must be received within 12 seconds The firing pulses are inhibited as long as the signal FANS MAIN_CONT_ACK 0 If the signal is still O after 12 seconds or if the signal is reset during running the firing pulses are inhibited and a fault is generated and the DSU trips MONO Enable firing pulses t 200 ms Enable fan supervision NetVoltageON FaultWord1 FAN8MAIN_CONT_ACK RDY_RUN Enable firing pulses Figure 5 13 Supervision of the main contactor and fan Temperature Supervision The bridge heatsink temperature is measured with a NTC sensor The tripping limit is 95 C and the alarm limit is 85 C ACA 631 633 Diode Supply Sections 5 11 Chapter 5 Software Description
25. da ol La a i aio i a AA ia ore a AE WA 5 16 DDES COMMUNICATION 5 siero pr il es Sota ed sees Sees 5 16 Signals tO DSU sd Gia tein ed ee Re Guay Oe E eat 5 17 signals from DSU on tarima ir byes Absa A CL eho al 5 18 Appendix A Circuit Diagrams OVER A AA ee a EE EE A 1 viii ACA 631 633 Diode Supply Sections Chapter 1 Introduction Overview of the Manual The Supply Section of ACS 600 MultiDrive and ACS ACC 607 units The Main Components of the Drive Overall View 0760 3 0930 5 0900 6 or above frequency converters consist of Auxiliary Control Unit Incoming Unit Dynamic Braking Unit optional and Supply Unit This manual covers e The commissioning of the Supply Section equipped with a Diode Supply Unit DSU e System hardware and software descriptions of the Diode Supply Unit The descriptions provide the possibility to operate and optimize the unit for a particular system DSU Drive Sections Braking Section optional ACS 600 MultiDirve Diode Supply Unit Common DC Bus Resistor gt 6 E Es Inverter Inverter WI 1 Supply Section Auxiliary Incoming Control Unit Unit ACU ICU Ad m 24V GD AC Figure 1 1 The main components of the drive ACA 631 633 Diode Supply Sections 1 1 Chapter 1 Introduction DSU
26. ency converters The settings required at the start up are given in Chapter 2 Commissioning the Supply Section with DSU Check from the circuit diagrams delivered with the unit if the Earth Fault Protection option is included and on which equipment the protection is based e overvoltage relay e summation current transformer e insulation monitoring device Note With other commercial Earth Fault Protection solutions see the manufacturers description Overvoltage Relay Floating Network L1 L2 L3 Transformer Supply Unit Inverter Units DC Busbar I I R rp m iH T Ro Uo gt 0 A I 7i I 7 I als 7 i 4 IL gt 0 Leakage Current M Collo i KE gt ci E 5 gt Figure 3 1 Overvoltage relay floating network Description f the neutral point of the transformer is not available earth fault supervision is implemented by means ofan artificial neutral point achieved with three resistors R connected to the 3 phase system at one end and together at the other end see Figure 3 1 This resistor assembly is installed inside the ACx 600 An overvoltage relay is used to detect an earth current through resistance Ry that is connected between the artificial neutral point and earth ACA 631 633 Diode Supply Sections 3 1 Chapter 3 Earth Fault Protection option In Case of an Earth Fault Insulation Monitoring De
27. est voltage between the channels is 1500 VAC The starting sequence through digital inputs outputs is described in the Chapter 5 Software Description see Control Logic and Status Connector X3 is an output of 24 VDC voltage 500 mA which can be used for digital inputs or power supply for AMC or APC2 boards This voltage is fuse protected and the status of the fuse is indicated by a LED ACA 631 633 Diode Supply Sections 4 3 Chapter 4 DSU Hardware Description __ X4 1 tt DO1 Fault 3 digital outputs on NDSC 144 2 galvanically isolated with X4 3 relays contact rating 250 xaa DO2 Running ees A S X4 5 N DO3 Main contactor on X4 6 ROSI lt DO4 Alarm 1 digital output on power X96 2 Z supply board SDCS x21 rt DH 3 EE Ti PS DI Main cont and FAN ack 3 digital inputs ea Input voltage 24VDC 230 DI ON OFF control VAC EE DI3 Reset Figure 4 1 Definition of digital inputs DI and digital outputs DO Measurements The control board contains high ohmic voltage measurements for Gate Pulses supply voltages and DC link voltage The voltage level is lowered to an acceptable level with a 7 MQ resistor chain Note The main circuit actual voltage signals U1 V1 W1 Uc1 and Uc2 are not galvanically isolated The heatsink temperature is measu
28. f switch SW1 corresponds to the See the circuit diagrams right input voltage to the board 230 V or 115 V delivered with the device Auxiliary control voltage transformer 2 2 ACA 631 633 Diode Supply Sections Chapter 2 Commissioning the Supply Section with DSU 3 Action Control Board NDSC 01 inside the Diode Supply Unit module Check the position of the DIP switch S1 8 way DIP Switch S1 Positions 1 ON 0 OFF Setting 1 2 3 4 5 6 7 8 Supply voltage 400 VAC 450 VAC 500 VAC 600 VAC Oj O O Oj O O O O O 690 VAC Current transformer 300 A 600 A 2000 A O O Al Oo CH 3000 A Charging time 500 ms 1000 ms DDCS link 0 No supervision 1 Supervised Check the position of the DIP switch S2 if DDCS communication is in use between the NDSC 01 board and the overriding control system 8 way DIP Switch S2 Positions Node 1 ON 0 OFF Address 1 2 3 4 5 6 7 8 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 1 0 1 0 0 0 0 0 0 2 1 1 0 0 0 0 0 0 3 0 0 1 0 0 0 0 0 4 1 0 1 0 0 0 0 0 5 0 1 1 0 0 0 0 0 6 1 1 1 0 0 0 0 0 7 0 0 0 1 0 0 0 0 8 to 255 4 Supply Tripping Circuit Check the operation of the supply transformer tripping option
29. ide is attached Crane Drive EN 3BSE 011179 e 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 e Description of PC and DB elements Advant Controller 80 Reference Manual TC Elements EN 64331868 e 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 e Installation Programming Fault tracing e Technical data ACA 631 633 Diode Supply Sections 140 to 5200 kVA User s Manual This manual concerns six pulse and twelve pulse Diode Supply Sections ACA 631 and ACA 633 for ACS 600 MultiDrive and ACS ACC 607 627 units 0760 3 0930 5 0900 6 or above frequency converters 3AFY 61451544 R0325 EN EFFECTIVE 28 03 2001 SUPERSEDES 20 08 1998 O 2001 ABB Industry Oy All Rights Reserved Safety Instructions Overview The complete safety inst
30. lso live even if the motor is not running Open the switch fuses of all parallel connected inverters before installation or maintenance work in any of them Check the cable connections at the shipping split joints before switching on the supply voltage If the auxiliary voltage circuit of the ACx 600 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 on 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 631 633 Diode Supply Sections iii Safety Instructions In ACx 600 frequency converters 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 use of measuring instruments such as an oscilloscope and their connection to the ACx 600 frequency converters is done with caution and safety always a 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 in
31. mes the recording is interrupted and Type Code Fault is generated The DDCS Distributed Drives Communication Circuit protocol employs datasets The program of the Diode Supply Unit uses the datasets as described below The node address is defined with DIP switch S2 on the NDSC board see Checks with No Voltage Connected in Chapter 2 Commissioning the Supply Section with DSU 5 16 ACA 631 633 Diode Supply Sections Chapter 5 Software Description DS 10 11 MainControlWord 11 01 12 02 13 03 DS 12 13 11 01 12 02 01 MainSatusWord UcActAVG_V ConCurrActAVG_V AuxStatusWord UNetActAVG_V NetCurrActAVG_A FaultWord1 DS 16 17 ii 01 AlarmWord1 DiStatusWord 12 02 13 03 a AAA DS 18 19 M 01 UNetAct_V 12 02 UActScaled 13 03 ConCurrAct_A DS 20 21 EarthFaultLvl n o1 P_Kw EarthFaultDelay 12 02 Bridge Temp 13 03 EarthCurr DS D 22 23 01 02 03 DS n 24 25 01 02 Data1 RequestAddr Data2 RequestAddr DS 26 27 n 01 SW Revision 12 02 13 03 DS 28 29 n 01 NetFrequency 12 02 NetStatusWord 13 03 Be AMADA LLL DS 30 31 n 01 Data1 12 02 Data2 13 03 Data3 Data3 RequestAddr DS 32 33 01 02 03 Figure 5 20 DDCS data sets Signals to DSU Table 5 4 Signals from overriding system to DSU Signal name MainControlWord EarthFaultLvl EarthFaultDly Unit DataSet No 10 A 20 ms 20
32. minals and to the Auxiliary Control Unit ACU for the Action Information WARNING When voltage is connected to the input terminals of the Supply Section the voltage will also be connected to the Auxiliary Control Unit and to auxiliary circuits A also to the ones wired to drive sections Make sure that it is safe to connect voltage to the input terminals Ensure that while the voltage is connected e Nobody is working on the unit or circuits that are wired from outside into the cabinets e The cabinet doors are closed Disconnect the 230 VAC cables that lead from the terminal blocks to the outside of the equipment and have not yet been checked and the connections which may not yet have been completed Make sure that the main contactor air circuit breaker cannot inadvertently be closed by remote control e g by temporarily opening some connection in its control circuit Be ready to trip the main breaker of the supply transformer in case anything abnormal occurs Ensure that all cabinet doors are closed Close the main breaker of the supply transformer Close the main disconnecting switch of the Supply Section Close the main disconnecting switch of the auxiliary circuit ACA 631 633 Diode Supply Sections Chapter 2 Commissioning the Supply Section with DSU Checks with Voltage Connected to Auxiliary Circuits Unit A
33. n A also by measuring that no voltage is connected 1 Air Circuit Breaker Relays Switches If the Supply Section is equipped with an air circuit breaker The trip levels have been preset check the current trip levels of the air circuit breaker at the factory In most applications there is no need to change these settings General rule Ensure the selectivity condition is fulfilled i e the breaker trips at a lower current than the protection device of the supplying network and that the limit is high enough not to cause unnecessary trips during the intermediate DC circuit load peak at start Long term current limit Rule of thumb Set to the rated AC current of the DSU module Peak current limit Rule of thumb Set to a value 3 4 times the rated AC current of the DSU module Check the settings of the relays for the emergency stop See the circuit diagrams circuit 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 See the circuit diagrams circuits delivered with the device Check that all breakers switches of the auxiliary circuits are open 2 Power Supply Board SDCS POW 1 inside the Diode Supply Unit module Check that the position o
34. n 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 section Pp max If the conditions mentioned above are not fulfilled the DC fuses of the connected inverter s may blow or the braking chopper may be damaged ACA 631 633 Diode Supply Sections V Safety Instructions vi ACA 631 633 Diode Supply Sections Table of Contents ACS 600 MultiDrive Manuals English Originals Safety Instructions ENEE EA ARA SAGE we AE iii General Safety Instructions awek Dd de lane oe eae bea ieee ia bee et Seah ie MA iii Starting DSU with a Braking Section usi po Sess te W EVO SS v Table of Contents Chapter 1 Introduction Overview of the Manual o oo ooooo GA 1 1 The Main Components of the Drive Overall View 1 1 DSU Technical and Ambient Requirements 1 2 DSU Main Circuit Operation siria aa papa a alte KWI 1 2 RRE EE E EE 1 4 Non Redundant 12 Pulse System 1 5 Redundant 12 pulse Supply LLL aaaaaa aaa aaa aaa ee ene eee a a ia 1 5 Voltages from the Supply Section to the Control Devices uaaaaaaaaaaaa eee 1 6 Chapter 2 Commissioning the Supply Section with DSU OVEMIOW 6 lara d wr NIAGARA RO Ga EE Ee Aziz id Se 2 1 Installation Check list ne R
35. ncluded 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 e DSU specific Safety Instructions DSU hardware and software descriptions e DSU commissioning Earth fault protection options Thyristor Supply Sections User s Manual TSU EN 64170597 e TSU operation basics TSU firmware description e TSU 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 System Application Program Control Panel use Software description Parameters of the System Application Program Fault tracing Terms Application Program Template EN 63700185 e Commissioning of the Drive Section Control Panel use Software description e Parameters Fault tracing e Terms Standard EN 61201441 e Control Panel use e Standard application macros with external control connection diagrams e Parameters of the Standard Application Program Fault tracing e Fieldbus control Note a separate Start up Gu
36. ned at the factory If further tuning is required see the RDH265 Operating Manual by Bender code TGH1249 This is an optional feature See the circuit diagrams delivered with the device if included IRDH 265 x Earth Fault Protection Based on a Summation Current Transformer Check the tripping level of the earth fault protection summation current transformer The current limit is set to 4 A at the factory lt can be changed via DDCS link For more information on the limit setting see Chapter 5 Software Description This is an optional feature See the circuit diagrams delivered with the device if included On load Checks Section The table below is a commissioning check list for the loaded Supply Action Check the correct operation of the current meters Check the correct operation of the emergency stop circuits Information This is an optional feature See the circuit diagrams delivered with the device This is an optional feature See the circuit diagrams delivered with the device ACA 631 633 Diode Supply Sections 2 7 Chapter 2 Commissioning the Supply Section with DSU ACA 631 633 Diode Supply Sections Chapter 3 Earth Fault Protection option Overview This chapter contains the description of the earth fault protection solutions available for ACS 600 MultiDrive and ACS ACC 607 627 units 0760 3 0930 5 0900 6 or above frequ
37. no Fault Logger on the board If the power supply for the board trips the current fault is lost 5 8 ACA 631 633 Diode Supply Sections Chapter 5 Software Description Fault and Alarm Table Table 5 1 Fault signals Definition of the faults Display code Fault word bit No Short circuit F 12 0 Over current F 02 1 Auxiliary under voltage F 01 2 Converter overtemperature F 04 3 Earth fault F 05 4 No converter fan acknowledge F 50 5 Type coding fault F 17 8 DDCS link communication error F 20 10 Not in sync F 31 13 Table 5 2 Alarm signals Definition of alarms Display code Alarm word bit No Converter overtemp alarm A 105 4 DDCS link communication alarm A 120 5 Mains under voltage alarm A 118 10 Net asymmetry alarm A117 11 Aux Under voltage alarm A 132 14 Uc ripple alarm A 116 15 Current asymmetry alarm A119 13 in REV C and later Fault and Alarm Logic Net Supply Undervoltage The firing pulses are inhibited when supply voltage is lt 60 of nominal voltage The nominal voltage level is chosen with the 8 way DIP switch S1 see Checks with No Voltage Connected in Chapter 2 Commissioning the Supply Section with DSU on the board No Undervoltage Alarm is indicated if the ON OFF status is OFF UnetAct_V al t 11 gt 12 d AlarmWord1 UNetMin60 NetUnderVoltage Or 60 12 25 ms 8 U J MainsOn BC bit 3 Figure 5 10 Uac undervol
38. nra a e AAA GEORGE 5 1 Software FUNCIONS ei EE 5 1 Measurements ze tre gea A a pilo ladina e al sa a e 5 2 AG Voltage Measurement ZA AE rl a e a KEG 5 2 Uc Voltage Measurement Zsa ico EE GS A rana nia 5 2 DC Current Measuremerit Aa ita ito UA SI aaa 5 3 PRC Calculation Lat a e e Lo rallo e DA a SE 5 3 Firing Angle Calculation aussi aa aa 5 3 CRT Uy sos oaz oh Gi os ta AS om da els 5 3 Control Logic and SAUS AI AA E d E 5 6 Local Remote Controles ts os ai is ZST bees 5 6 Digital INPUTS EE 5 6 Digial OUputsi true Palaia EE 5 6 Fault DIOSES tti cama Dod ae A A eR eke a tette 5 8 Fault and Alatm Table creta enlarge cei 5 9 Faulra d Alarm Logies 224 4230607 eee ote duale loved dk o 5 9 Net Supply Undervoltage i nao Bang Sa veer ee dea Lei bud 5 9 Auxiliary Voltage Supervision creto prada EA Ae Soe ene SESE 5 10 DC Link Shor Circuit Fest nun is o kod ita A elia age 5 10 G mtdct rACKN WIEJJE sata wita oi dra leia 5 11 Temperature SUPSIVISION veias barra a a wa ae twa kw agi 5 11 Earth Fault Curent e e ads da ada es aaa owi AE Sets 5 12 SYNCAFONISATON eg E A ob EEG AA BACA 5 13 Net Asymmetry Alarmi a To Sits a Cuero doe as fa ay 5 14 Uc Ripple Alarm air ra A a a A aja Dj ah ae ao 5 14 Current Asymmetry Alarm In REV C or later ueaaaaaaa aaa eee 5 14 DOCS Communication GO ie re cits e e Mee A 5 15 OVvercuinrerit Fault woal ls da arate as iy ete ae a ate Succi te ka ete ta 5 16 type Code Raul Abt Go
39. od 1 2 ACA 631 633 Diode Supply Sections Chapter 1 Introduction Ay ZNy iy IU UV v Em w Em o Lia SR ILd Figure 1 3 Half controlled rectifier bridge The conducting thyristors each carry the current for 120 This period involves one upper leg thyristor and one lower leg diode so the output voltage U consists of 60 sections of sequential line to line voltages 102 104 106 108 110 112 114 116 pisano 18 120 122 124 126 128 tims Figure 1 4 Diode Supply Unit voltages and currents in normal mode The six pulse function of a diode thyristor bridge is different from a six pulse thyristor bridge The firing angle can be controlled only with low discontinuous current This is why the charging is made with low steps starting from 170 There are two modes in the firing pulse control Charging mode and normal mode During charging mode a single pulse is given during each 120 period In normal mode the thyristors are fired twice during each 120 period see Figure 1 5 The firing angle is 0 in normal mode meaning that ACA 631 633 Diode Supply Sections 1 3 Chapter 1 Introduction the bridge operates as a 6 pulse diode bridge The Diode Supply Unit is only rectifying the voltage No braking power can be converted back to the network 360 dgr cycle 120 dgr cycle Vi V3
40. ply Sections Chapter 5 Software Description Bujuuny 8 aseajay powuny eudiy MOLWYSNAD 3SINd SONI peudiy ep 01 deg eudjy Xen D ONEHN zeydjy eydiy el lt LI LI 0028 cI lt ll CISHONEHN ep 09 GEGG9 eudiy Z 68 0068 0068 zi 28 0028 Losoneweyn IS 1INOIDLOYS LISHONEHN od 1E0 1ONEHN 0000LONEHN GLAN EE 334 AGH OSO via ela ea ca La lt 08 SNONOYHINAS ON asind ONAS ON MI AIAANS NIV LINOYIO LHOHS IN3YYNO HJAO Tas XVIN A OQUON SE8INI8NN A Die leos pvon 0000LONEHN Figure 5 7 Firing angle generation 5 5 ACA 631 633 Diode Supply Sections Chapter 5 Software Description Control Logic and Status Local Remote Control Digital Inputs Digital Outputs The DSU is controlled through digital inputs The rising edge of the signal activates the commands The Remote Control can be set by 8 way DIP switch S1 see Checks with No Voltage Connected in Chapter 2 Commissioning the Supply Section with DSU on the control board The overriding system can enable or disable the ON command given from digital I O The RESET command can be given for the overriding system via the DDCS link DI1 FAN amp MAIN_CON
41. ponse values An earth fault closes the measuring circuit An electronic evaluation circuit calculates the insulation resistance which is indicated on an LC display or an external ohmmeter after the response time The alarm actions depend on the electric connection for example ALARM1 may only give a warning and ALARM2 may trip the device ACA 631 633 Diode Supply Sections Further Information Current Transformer System Earthed Network Description In Case of an Earth Fault Chapter 3 Earth Fault Protection option Further information about the insulation monitoring device is available in the RDH265 Operating Manual code 1GH1249 published by the manufacturer BENDER companies In a system earthed network the neutral point of the supply transformer is earthed solidly L1 L2 L3 Transformer Supply Unit Inverter Units Ee lo x N L gt 0 Leakage Current Pal ze I i f I i ez Zb Moa 3 U N Figure 3 3 Current transformer system earthed network The earth fault protection in a system earthed network is based on a summation current transformer monitoring the sum of the three phase supply currents The transformer output is connected to the supply section Control Board NDSC In normal operation the current sum is approximately zero An earth fault leads to an unbalance in the 3 phase system and therefore to a current sum which i
42. red with an NTC sensor Current measurement is optional as this information is not needed in control The current transformer ratio for the software is defined by 8 way DIP switch S1 Earth fault measurement is optional A current transformer with trans formation ratio 400 1 A is to be connected to X1 pins 1 and 2 If an other type of earth fault indication is used Bender a digital signal of 24VDC can be connected to X1 pins 1 and 3 The gate pulses for the three thyristors of the DSU bridge are generated through pulse transformers 4 4 ACA 631 633 Diode Supply Sections Chapter 4 DSU Hardware Description Communication The communication to the overriding system is handled via a DDCC ASIC The board contains one communication channel The status of the channel is indicated by LEDs TXD RXD 7 Segment Display The status of the NDSC 1 board is shown on the 7 segment display one digit at a time See Fault and Alarm Table in Chapter 5 Software Description ACA 631 633 Diode Supply Sections 4 5 Chapter 4 DSU Hardware Description 4 6 ACA 631 633 Diode Supply Sections Program Revision Chapter 5 Software Description This software description is compatible with the Diode Supply Unit program revision 1 02 or later The Diode Supply Unit control program is stored in the PROM of the microcontroller on the NDCS 01 board Parameters cannot be changed The program revision code is visible on microcont
43. roller chip Software Functions ACA 631 633 Diode Supply Sections 5 6 DDCS in out e s e 2 2 Fan amp MainContAck DO1 DO2 DO3 DO4 Fault Display N gt DH Sequence lt sd Fault handling pa AS Seven segment OnOff S pie control display handling Reset J pis Faults Measurements DEE U Uc Ratio and are Firing pulse ay Ue UNetActV alphareference PunMode generator m IDC UcActScal handling Release EarthCurr gt V8 2 Bridge Temp d SE ee gt V5 2 Figure 5 1 Block diagram of DSU software 5 1 Chapter 5 Software Description Measurements AC Voltage Measurement 10 bit 0 1023 AVG UNet A 1 6 phase UNetAct_V UNetActAVG_V Ed time X BA 3 78 V 690 V U_CONSTANT_V ms 690 V U_AD_CONSTANT 773 U Supply VM e UNetLim60 X U NET UM 60 100 e Figure 5 2 AC voltage measurement Nominal AC voltage is chosen by 8 way DIP switch S1 on the control board NDSC see Checks with No Voltage Connected in Chapter 2 Commissioning the Supply Section with DSU Low voltage alarm is 60 of the network nominal voltage Uc Voltage Uc is the DC busbar voltage see Figure 1 3 in Chapter 1 Measurement Introduction The scaling is in accordance with the AC voltage 10bit
44. ructions stated in ACS 600 MultiDrive Safety and Product Information EN 63982229 or ACS ACC 607 Installation amp Start up Manual ACS ACC 607 units 630 to 3000 kW EN 61329005 must be followed when installing operating and servicing the frequency converters Study the complete safety instructions carefully General Safety The general safety instructions are given below These general Instructions instructions include only the main parts of the complete safety instructions The general safety instructions are intended for all work on the ACS 600 MultiDrive and the ACS ACC 607 630 to 3000 kW frequency converters In the text below they are collectively referred to as ACx 600 Neglecting these instructions can cause physical injury and death WARNING All electrical installation and maintenance work on the ACx 600 should be carried out by qualified electricians Any installation work must be done with the power off and power is not to be reconnected unless the installation work is complete Dangerous residual voltages remain in capacitors when the disconnecting device is opened Wait 5 minutes after switching off the supply before starting work Always ensure that the measured voltage between terminals UDC and UDC and frame is close to O 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 a
45. s greater than zero This current induces a current lo in the current transformer If exceeds the tripping limit set in the software of the converter the device is tripped The fault signal FO5 appears on the 7 segment display ACA 631 633 Diode Supply Sections 3 3 Chapter 3 Earth Fault Protection option 3 4 ACA 631 633 Diode Supply Sections Chapter 4 DSU Hardware Description DSU Control Unit The figure below shows the control unit connections SDCS POW 1 X37 X37 NDSC 01 Figure 4 1 Control unit connections for DSU Power Supply Board The SDCS POW 1 is a power supply board for the DSU control unit It SDCS POW 1 provides all necessary DC voltages for the NDSC 01 board The input voltage can be selected either to 230 VAC or 115 VAC or to 190 350 VDC The figure below shows the instructions for the selection of the AC input voltage ACA 631 633 Diode Supply Sections 4 1 Chapter 4 DSU Hardware Description Relay output 230 V 3A 220 230 V 115 V AC Supply Fuse m SWI1 Input voltage selection T3 15A 250V Backup supply for SDCS POW 1 These supports should be metallic SDCS POW 1 Encoder supply selection X5 X4 X3 A 5V 12V BE A BE A a
46. side 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 If an ACx 600 with the EMC Line Filter is installed to unearthed mains the mains will be connected to earth potential through the EMC filter of the ACx 600 This may cause danger or damage the unit Disconnect the EMC filter capacitors before connecting the ACx 600 to unearthed mains For detailed instructions on how to do this please contact your local ABB distributor WARNING Close switch fuses of all parallel connected inverters before starting the frequency converter Do not open the drive section fuse switches 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 WARNING Fans may continue to rotate for a while after the disconnection of the electrical supply WARNING Some parts like heatsinks of power semiconductors inside of cabinet remain hot for a while after the disconnection of the electrical supply ACA 631 633 Diode Supply Sections Safety Instructions Starting DSU with a If the drive is equipped with a Braking Section the following warning Braking Section applies WARNING Before power switch o
47. st be followed Negligence of the safety instructions can cause injury or death Installation Check list The installation must be checked before commissioning the Supply Section The table below refers the more detailed instruction Action Check that the mechanical and electrical installation of the frequency converter is inspected and OK Ensure that the insulation resistance of the assembly is checked according to the instructions given in the installation manual Ensure that the surroundings and inside of the cabinet are free from dust and loose objects like cable trimmings and other waste left from the installation Information For ACS 600 MultiDrive see ACS 600 MultiDrive Hardware Manual 63700118 For ACS ACC 607 627 see ACS ACC 607 627 Hardware Manual 61329005 Refer to installation check list Insulation Checks After the start the cooling air fans may suck nearby loose objects into the unit This might cause failure and damage the unit ACA 631 633 Diode Supply Sections 2 1 Chapter 2 Commissioning the Supply Section with DSU Checks with No The table below is a commissioning check list for the Supply Section Voltage Connected with no voltage connected Action Information position i e no voltage is or cannot be connected to the ACx 600 inadvertently Check WARNING Ensure that the disconnector of the supply transformer is locked to ope
48. t 12 pulse Supply Unit with hardware tripping The redundant 12 pulse supply enables the use of one half of the supply independently thus minimising the process downtime in case of failure Inspite of a failure in one of the unit the other units will continue operating as a 6 pulse supply Figure 1 8 12 pulse supply equipped with DSU modules ACA 631 633 Diode Supply Sections 1 5 Chapter 1 Introduction Voltages from the The inverter units convert auxiliary voltages 24 V from the DC Supply Section to the busbar The 24 V is required by the electronic boards for example Control Devices option modules and I O Supply for the Diode Supply Unit cooling air fan s is taken from main AC circuit through contactor and circuit breaker The 230 VAC for the digital inputs of the DSU board is taken from a protection switch The emergency stop information to the drive sections goes from 24 VDC power supply through an emergency stop relay 1 6 ACA 631 633 Diode Supply Sections Chapter 2 Commissioning the Supply Section with DSU Overview This chapter describes the commissioning of an ACx 600 Supply Section that is equipped with the Diode Supply Unit DSU out by a qualified electrician The Safety Instructions on the first pages A WARNING The work described in this chapter must only be carried of this manual and in the Safety and Product Information manual EN 3AFY 63982229 mu
49. tage alarm ACA 631 633 Diode Supply Sections 5 9 Chapter 5 Software Description Auxiliary Voltage The control system supervises two auxiliary voltage signals rvision indi ili SAREMO MPFS is the signal that indicates the status of the auxiliary voltages on the control board NDSC When this signal is low a fault is generated and the DSU trips MPFP is the supervision signal of the power supply board SDCS POW 1 When mains supply to the board fails the MPFP bit is set If DSU is running when MPFP is set a fault is generated and the DSU trips If the DSU is not running when MPFP is set only an alarm is indicated t H MPFS t 25 ms lo d FaultWord1 t PFailFact ae 1 HH 1 MPFP A es t 25ms TcR amp R LES Bc Bit12 CscRdyRef PFailWact AlarmWord1 amp Ooo o Figure 5 11 Auxiliary voltage fault alarm and tripping Table 5 3 Auxiliary voltage monitoring Supply voltage Undervoltage limit 5V 4 55V 15V 12 4V 15V 12 0V 24V 19V 48V 38V DC Link Short Circuit Test A short circuit test is carried out in the beginning of the charging In the test the thyristors are fired with 170 angle 15 times If the Uc voltage does not rise above the 2 limit during the short circuit test a fault is generated and the Diode Supply Unit trips Note Short circuit test does not ne
50. tivated and no DataSet message has been received Timeout RemoteSel watch dog SupervisionActive If there are no Data Set DDCSLinkFault i 8 messages during 2s S FaultWord1 FirstinMessage the output of the watch dog block DDCSLinkFault is set to ON state 9 R amp TcRes Lo g DDCSLinkWact men Figure 5 18 DDCC communication supervision ACA 631 633 Diode Supply Sections 5 15 Chapter 5 Software Description Overcurrent Fault Type Code Fault DDCS Communication Current measurement is optional The control system does not need the current value The nominal value of the transformers is set by the 8 way DIP switch S1 on the control board NDSC Overcurrent Fault is generated when the current value is three times the nominal value of the transformer ConCurrAct_A OverCurrLim 1 gt 12 s FaultWord1 3 CurrTrans_A TcRes Bc Bit0 Figure 5 19 Overcurrent fault and tripping The 8 way DIP switches S1 and S2 on the control board NDSC are configuring the control unit to the whole supply The 8 way DIP switches must be set during power off state The codes are read during the initialisation in power up The reading procedure is repeated until five successive readings are similar If the reading procedure is repeated more than 50 ti
51. vice Floating Network Description In Case of an Earth Fault In case of an earth fault a LED on the overvoltage relay illuminates Depending on the connection the overvoltage relay controls the main contactor or air circuit breaker open or generates a warning via the control board NDSC L1 L2 L3 Transformer Supply Unit Inverter Units DC Busbar BENDER ua Insulation I I Monitoring rt d Device z N db gt 0 Leakage Current Sa 7 A gt SE 8 7 Figure 3 2 Insulation monitoring device floating network The monitoring device is connected between the unearthed system and the equipotential bonding conductor PE A pulsating AC measuring voltage is superimposed on the system measuring principle Adaptive Measuring Pulse AMP is developed by BENDER patent pending The measuring pulse consists of positive and negative pulses of equal amplitude The period depends on the respective leakage capacitances and the insulation resistance of the system to be monitored The setting of the response values and other parameters can be carried out via the function keys The parameters are indicated on the display and stored in a non volatile memory after setting By using Bender s insulation monitoring device it is possible to set up two response values ALARM1 and ALARM2 Both values have their own alarm LED which illuminates if the reading is below these selected res
52. y Y urdd uay0919 u0 09 Buspouaiu DEN Jawsojsuos Ajdens uo 103909190 abpug apoig UONMS U1107 J8YDSJQ LION JeyD8JQ UIDN L 9 S H R l Aquoyjno ssasdxa nou seng Du 0 asnsojosip Jo sn uoqanpouday ule18u PSUIO UOD uonouojul ayy Ul puo zu wnoop siy ui slybu pp enjasal M ACA 631 633 Diode Supply Sections A 6 Ai HD ED PADDED 3AFY 61451544 R0325 EFFECTIVE 28 03 2001 EN ABB Industry Oy Drives P O Box 184 FIN 00381 HELSINKI FINLAND Telephone 358 10 22 2000 Telefax 358 10 22 22681

ABB ACS600 user manual

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