Safety instructions What this chapter contains This chapter contains the safety instructions which you must follow when installing, operating and servicing the regen supply module. If ignored, physical injury or death may follow, or damage may occur to the regen supply module, drive, the motor, or driven equipment.
WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment. • The regen supply module is not field repairable. Never attempt to repair a malfunctioning regen supply module; contact your local ABB representative or Authorized Service Center for replacement. Safety instructions...
• Make sure that dust from drilling does not enter the regen supply module during the installation. Electrically conductive dust inside the regen supply module may cause damage or lead to malfunction. • Ensure sufficient cooling. WARNING! The printed circuit boards contain components sensitive to electrostatic discharge.
Start-up and operation These warnings are intended for all who plan the operation of the regen supply module, or start up or operate the regen supply module. WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment. •...
The flowchart refers to chapters/sections in this manual and other manuals. Compatibility The manual is compatible with ACSM1-204 (frame sizes A to D) and the corresponding WFU-xx regen filter modules. Intended audience This manual is intended for people who plan the installation, install, commission, use and service the regen supply module.
Technical data (page 69) and other technical data. Compatibility (page 37) If ACSM1-04 drives (frame sizes A-D) are not used: check compatibility of the drive and the regen supply Option manual (if optional equipment is module. included) Select the cables.
Inquiries Address any inquiries about the product to the local ABB representative, quoting the type code and the serial number of the unit. If the local ABB representative cannot be contacted, address inquiries to the manufacturing facility. About this manual...
FPBA-0x Optional PROFIBUS DP adapter for the ACSM1. Frame (size) Size of the regen supply module. This manual deals with ACSM1-204 frame sizes A, B, C or D. The frame size is marked on the regen supply module designation label.
Derating on page for more information. The ACSM1-204 either has an air-cooled heatsink, or is to be installed on a cold plate cooling element. The ACSM1-204 is available in several frame sizes depending on output power. All frame sizes use the same control unit (type JCU).
Analogue inputs regen filter module thermistor input Analogue outputs Drive-to-drive link Reserved (jumper must be placed) Control panel / Slot 3 for optional PC connection fieldbus adapter Memory unit connection Brake resistor connection Supply connection (through the filter module) The ACSM1-204...
WFU-xx regen filter module The WFU-xx regen filter module is an essential part of the ACSM1-204 regen supply module and it does not work without the filter. The regen supply module uses the filter to actively shape the AC line current to resemble sinusoidal waveform and to filter most of the current ripple at the switching frequency and higher frequencies.
Use a supply that meets the requirements given Connection to the regen supply module on page 72. Length: 1 m Connect to the power input terminal (U2, V2, W2 and PE) in the regen supply module The ACSM1-204...
Memory unit (JMU) containing the application program (see page 68) Mains input DC output Not in use L2 L3 UDC+ UDC- V1 W1 WFU-xx ACSM1-204 Rectifier – Capacitor bank Braking chopper Inverter V2 W2 V2 W2 JBR-xx braking resistor (optional) The ACSM1-204...
Description Braking chopper Conducts the energy generated by a decelerating motor from the DC bus to a braking resistor. The braking chopper is built in the ACSM1; braking resistors are external options. Braking resistor Dissipates the braking energy by converting it to heat.
Please note that the installation must, however, always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations.
Free space requirements The modules and their regen filter modules can be installed side by side. The main dimensions of the regen supply module as well as free space requirements are shown below. For more details, refer to the chapter Dimension drawings.
• allowed ambient temperature • cold plate specification (for ACSM1-204Cx-xxxx-x only). Make sure the air inlets and outlets are sufficient in size. Note that in addition to the power loss of the regen supply module and the WFU-xx regen filter module, the heat dissipated by cables and other additional equipment must also be ventilated.
Preventing the recirculation of hot air Cabinet (side view) AREA Main airflow out Air baffle plates COOL AREA Main airflow in Outside the cabinet Prevent hot air circulation outside the cabinet by leading the outcoming hot air away from the area where the inlet air to the cabinet is taken. Possible solutions are listed below: •...
Mechanical installation Contents of the package The regen supply module is delivered in a cardboard box. To open, remove any banding and lift the top off the box. Mechanical installation...
The box contains: • ACSM1-204 regen supply module, with factory-installed options • three cable clamp plates (two for power cabling, one for control cabling) with screws • screw-type terminal blocks to be attached to the headers on the JCU Control Unit and the power unit •...
Installation procedure Direct wall mounting of the regen supply module 1. Mark the locations for the four holes. The mounting points are shown in Dimension drawings. 2. Fix the screws or bolts to the marked locations. 3. Position the regen supply module onto the screws on the wall. Note: Only lift the regen supply module by its chassis.
Cold plate mounting (ACSM1-204Cx-xxxx-x, frames C and D only) For cold plate cooling characteristics, see page 71. 1. Determine the locations for the four fixing points on the cold plate. The fixing points of the regen supply module are shown in the dimension drawings on page (frame C) or (frame D).
Installation of the WFU-xx regen filter module 1. Mark the locations for the four holes. 2. Fix the screws or bolts to the marked locations. 3. Position the filter module onto the screws on the wall. Note: Only lift the filter module by its chassis.
ACSM1-04 drives (frame sizes A…D). Note: The ACSM1-204 regen supply module is not designed to be started under load. If the DC bus is loaded when the ACSM1-204 tries to start, the start attempt may fail.
• The regen supply module and regen filter module cannot prevent power flow from the grid to the DC bus and further to the ACSM1-04 drives. Even if the modulation of the ACSM1-204 regen supply module is stopped, the anti-parallel diodes of the inverter bridge in ACSM1-204 enable power flow to the DC bus and to the motor inverters.
Supply disconnecting device Install a hand-operated input disconnecting device (disconnecting means) between the AC power source and the regen supply module. The disconnecting device must be of a type that can be locked to the open position for installation and maintenance work.
The protective characteristics of circuit breakers depend on the supply voltage as well as the type and construction of the breakers. There are also limitations pertaining to the short-circuit capacity of the supply network. Your local ABB representative can help you in selecting the breaker type when the supply network characteristics are known.
Selecting the power cables General rules Dimension the power cables according to local regulations. • The cable must be able to carry the regen supply module load current. See the chapter Technical data for the rated currents. ° • The cable must be rated for at least 70 C (US: 75 °C [167 °F]) maximum permissible temperature of conductor in continuous use.
Power cables cross-section Cross-sections for mains supply connection cables (regen filter module) Min. cross section (L1, L2, L3) EN 60204-1* NEC** ACSM1-204 Filter (AWG) -07A0-4 WFU-01 -016A-4 WFU-02 -031A-4 WFU-11 -046A-4 WFU-21 -090A-4 WFU-22 Cross-sections for DC connection cables (regen supply module) Min.
Install the protective component as close to the inductive load as possible, not at the relay output. Varistor 230 VAC Relay output RC filter 230 VAC Relay output Diode 24 VDC Relay output Planning the electrical installation...
ABB. Control panel cable The cable connecting the control panel to the regen supply module must not exceed 3 metres in length. The cable type tested and approved by ABB is used in control panel option kits. Routing the cables Route the DC cabling away from other cable routes.
A diagram of the cable routing is below. Input cable DC Supply cable DC supply cable min 200 mm (8”) Regen Regen Control cables filter supply module module min 500 mm (20”) Braking resistor cable 90° AC supply min 300 mm (12”) cable AC/DC Supply cable min 300 mm (12”)
Electrical installation What this chapter contains This chapter describes the electrical installation procedure of the regen supply module. WARNING! The work described in this chapter may only be carried out by a qualified electrician. Follow the Safety instructions on the first pages of this manual. Ignoring the safety instructions can cause injury or death.
Power and control cable connection Power and control cable connection diagram UDC+ UDC– UDC+ UDC– WFU-xx ACSM1-204 ACSM1-04 control on/off Temperature Temperature sensor signal R– input supply Optional braking resistor (see chapter Resistor braking [page 83]) Notes: 1) Main contactor and fuses. Not included in the delivery.
Procedure For cabling drawings and tightening torques for each frame size, see pages to 53. 1. Frame sizes C and D only: Remove the two plastic connector covers at the top and bottom of the regen supply module. Each cover is fastened with two screws. 2.
Installation of power cable clamp plates Two identical power cable clamp plates are included with the regen supply module. The picture below depicts a frame size A regen supply module; the installation is similar with other frame sizes. Note: Pay attention to supporting the cables adequately within the installation enclosure especially if not using the cable clamps.
Connecting the control cables Control connections to the JCU Control Unit Notes: +24VI External power input *Total maximum current: 200 mA 24 V DC, 1.6 A WFU-xx cooling fan control Relay output WFU-xx temperature supervision 250 V AC / 30 V DC The wiring shown is for demonstrative purposes only.
Jumpers J1 – Determines whether Analogue input AI1 is used as a current or voltage input. Current Voltage J2 – Determines whether Analogue input AI2 is used as a current or voltage input. Current Voltage J3 – Drive-to-drive link termination. Must be set to the ON position when the regen supply module is the last unit on the link.
Control cable grounding The shields of all control cables connected to the JCU Control Unit must be grounded at the control cable clamp plate. Use four M4 screws to fasten the plate as shown below left. The plate can be fitted either at the top or bottom of the regen supply module.
Installation of options Options such as fieldbus adapters and I/O extensions are inserted into slots on the JCU Control Unit. See page for the available slots; see the appropriate option manual for specific installation and wiring instructions. Removing EMC and varistor screws from the regen filter module On IT (ungrounded) systems, and corner grounded TN systems, the EMC and varistor screws must be removed from the regen filter module.
Installation example The figure below shows power and control connections in an installation example. WFU-xx ACSM1-204 ACSM1-04 UDC+/UDC-/PE L1/L2/L3/PE DIO1 (X3: 14, 15) TH (X4: 8, 9) U2/V2/W2/PE 24 V DC Electrical installation...
The screws labeled VARISTOR (1 screw) and FILTER (2 screws) are removed from the regen filter module. The capacitors are reformed if stored over one year (ask local ABB representative for more information). The regen supply module is grounded properly.
Check The braking resistor (if present) is connected to R+/R-, and the terminals are tightened to specified torque. The external control connections to the JCU Control Unit are OK. There are no tools, foreign objects or dust from drilling inside the drive. The supply (input power) voltage cannot be applied to the output of the drive through a bypass connection.
Every 3 years if the ambient temperature is filter. higher than 40 °C (104 °F). Consult your local ABB Service representative for more details on the maintenance. On the Internet, go to www.abb.com/drives and select Drive Services – Maintenance and Field Services.
Heatsink The heatsink fins pick up dust from the cooling air. The regen supply module runs into overtemperature warnings and faults if the heatsink is not clean. In a normal environment, the heatsink should be checked annually, in a dusty environment more often.
If the regen supply module is operated in a critical part of a process, fan replacement is recommended once these symptoms start appearing. Replacement fans are available from ABB. Do not use other than ABB-specified spare parts. Fan replacement (Frames A and B) Detach the power cable clamp plate and terminal blocks.
Fan replacement (Frames C and D, ACSM1-204Ax-xxxx-x) To remove the fan, release the retaining clip (arrowed) carefully using a screwdriver. Pull the fan holder out. Disconnect the fan cable. Carefully bend the clips on the fan holder to free the fan.
Fan replacement (Frames C and D, ACSM1-204Cx-xxxx-x) Unfasten the fan holder by removing the two screws marked (1) in the drawing below. Pull the fan holder out and disconnect the wire plug (2). Remove the four screws (3) to release the fan from the holder. Use the spacers (4) to mount the new fan.
Replacing the cooling fan of the WFU filter To remove the fan, release the retaining clips (arrowed). Pull the fan holder out. Disconnect the fan cable. Carefully bend the clips on the fan holder to free the fan. Install a new fan in reverse order. Note: The airflow direction is bottom-to-top.
The DC capacitors must be reformed if the regen supply module has been stored for a year or more. See page for information on finding out the manufacturing date. For information on reforming the capacitors, contact your local ABB representative. Maintenance...
Other maintenance actions Transferring the memory unit to a new regen supply module When a regen supply module is replaced, the parameter settings can be retained by transferring the memory unit from the defective regen supply module to the new module.
Note: All values a re valid at an ambient temperature of 40 °C (104 °F) with default settings. Input connection (AC) Supply module type Frame 2max Filter type ACSM1-204xR… size (kVA) 400 V AC 480 V AC -07A0-4 WFU-01 14.7...
Derating The continuous output currents stated above must be derated if any of the following conditions apply: • the ambient temperature exceeds +40 °C (+104 °F) • the regen supply module is installed higher than 1000 m above sea level. Note: The final derating factor is a multiplication of all applicable derating factors.
2580 * Preliminary value or value not available yet Cold plate cooling characteristics (ACSM1-204Cx-xxxx-x only) The ratings stated at the beginning of this chapter are achieved provided that the hot-spot temperature of the cold plate is kept below 65 °C (140 °F) and that the regen supply module is installed according to the instructions in this manual.
The ACSM1-204Cx-xxxx-x has an internal fan to cool the circuit boards. The heat dissipation into air is approximately 200 W. Supply voltage requirements for the WFU-xx regen filter module fan No fan supply is included the delivery. Choose a supply according to the following requirements for supply voltage and current.
DC power ratings of regen supply modules are shown in the table below. Note: Do not use fuses with a higher current rating. IEC fuse UL fuse Supply module type Rated Rated current ACSM1- current Voltage Class current Voltage Class 204xx… -07A0-4...
Checking the charging capacity on page 38. Maximum DC cable length Maximum DC cable length between the supply module (ACSM1-204) and drive module (ACSM1-04) is 10 m. JCU Control Unit Power supply 24 V (±10%) DC, 1.6 A Supplied from the power unit of the regen supply module, or from external power supply through connector X1 (pitch 3.5 mm, wire size 1.5 mm...
For the regen supply module to start, both connections (OUT1 to IN1, and OUT2 to IN2) must be closed Control panel / PC Connector: RJ-45 connection (X7) Cable length < 3 m Efficiency Approximately 96% at nominal power level (combined value with ACSM1-204 and WFU- Technical data...
Cooling Method Internal fan, flow from bottom to top. Air-cooled heatsink, or cold plate mounting. Free space around the unit See chapter Planning the cabinet assembly. Degrees of protection IP20 (UL open type). See chapter Planning the cabinet assembly. Ambient conditions Environmental limits for the regen supply module are given below.
Part 5-1: Safety requirements. Electrical, thermal and energy Provisions for compliance: The final assembler of the machine is responsible for installing the ACSM1-204 in a cabinet that is protected to IP2X (IP3X for top surfaces for vertical access). Approval pending.
5. The regen supply module, regen filter module and drive(s) are installed on the same conductive back wall. 6. The regen supply module is used as a supply unit for motor ACSM1-04 drive(s), frame sizes A…D. Technical data...
5. The regen supply module, regen filter module and drive(s) are installed on the same conductive back wall. 6. The regen supply module is used as a supply unit for motor ACSM1-04 drive(s), frame sizes A…D. 7. Total motor cable length of drives connected to the DC bus does not exceed the following values: Max.
The regen supply module is intended to be incorporated into machinery to constitute machinery covered by Machinery Directive (98/37/EC) and does therefore not in every respect comply with the provisions of the directive. For more information, see the Declaration of Incorporation by ABB Drives (code 6884199).
Overload protection – The regen supply module provides overload protection in accordance with the National Electrical Code (US). Braking – The ACSM1-204 has an internal braking chopper. When applied with appropriately sized braking resistors, the braking chopper will allow the regen supply module to dissipate regenerative energy (normally associated with quickly decelerating a motor).
Braking resistor selection Pre-selected resistors are available from ABB as shown in the table below. If the listed resistor is not sufficient for the application, a custom resistor can be selected within the limits imposed by the internal braking chopper of the ACSM1-204. The following rules apply: •...
Contactor protection of regen supply module below. Chopper data / Resistor selection table The ratings apply at an ambient temperature of 40°C (104°F). Supply module Internal braking chopper Example braking resistor type ACSM1- brcont brmax pulse Type 204xx… (kW) (kW)
This is essential for safety since the regen supply module will not otherwise be able to interrupt the main supply if the chopper remains conductive in a fault situation. Below is a simple example wiring diagram. L1 L2 L3 Fuses ACSM1 U2 V2 W2 Resistor thermal switch Θ Resistor braking...
Braking circuit commissioning For more information, see the appropriate Firmware Manual. • Enable the braking chopper function. Please note that a braking resistor must be connected when the chopper is enabled • Switch off the overvoltage control of the regen supply module •...