ABB ACSM1 Hardware Manual
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ABB ACSM1 Hardware Manual

Regen supply modules
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ACSM1
Hardware Manual
ACSM1-204 Regen Supply Modules (5.3 to 61 kW)

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  • Page 1 ACSM1 Hardware Manual ACSM1-204 Regen Supply Modules (5.3 to 61 kW)
  • Page 3 ACSM1-204 Regen Supply Modules (5.3 to 61 kW) Hardware Manual 3AUA0000053713 REV A EN EFFECTIVE: 2009-12-11 © 2009 ABB Oy. All Rights Reserved.

  • Page 5: Safety Instructions

    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.

  • Page 6: Installation And Maintenance Work

    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...
  • Page 7 • 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.

  • Page 8: Start-Up And Operation

    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. •...

  • Page 9: Table Of Contents

    The ACSM1-204 ........
  • Page 10 DIN rail mounting (Frames A and B only) of the regen supply module ....34 Cold plate mounting (ACSM1-204Cx-xxxx-x, frames C and D only) ....35 Installation of the WFU-xx regen filter module .
  • Page 11 Fan replacement (Frames A and B) ..........63 Fan replacement (Frames C and D, ACSM1-204Ax-xxxx-x) ......64 Fan replacement (Frames C and D, ACSM1-204Cx-xxxx-x) .
  • Page 12 Braking choppers and resistors with the ACSM1-204 ........
  • Page 13 Frame size C (for cold plate mounting) ..........94 Frame size D (air-cooled module) .
  • Page 14 Table of contents...

  • Page 15: About This Manual

    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.

  • Page 16: Contents

    The ACSM1-204 describes the regen supply module. Planning the cabinet assembly guides in planning the installation of the regen supply module into a user-defined cabinet.

  • Page 17: Installation And Commissioning Flowchart

    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.

  • Page 18: Inquiries

    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...

  • Page 19: Terms And Abbreviations

    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.
  • Page 20 About this manual...

  • Page 21: The Acsm1-204

    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).

  • Page 22: Layout (Frame A Shown)

    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...

  • Page 23: Wfu-Xx Regen Filter Module

    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.
  • Page 24 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...

  • Page 25: Main Circuit And Control Interfaces

    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...

  • Page 26: Operation

    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.

  • Page 27: Planning The Cabinet Assembly

    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.

  • Page 28: Free Space Requirements

    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.
  • Page 29 • 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.

  • Page 30: Preventing The Recirculation Of Hot Air

    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: •...

  • Page 31: Mechanical Installation

    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...
  • Page 32 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 •...

  • Page 33: Delivery Check And Regen Supply Module Identification

    The ACSM1-204 is to be mounted in an upright position. The wall the module is to be mounted on must be even, of non-flammable material and strong enough to carry the weight of the module.

  • Page 34: Installation Procedure

    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.

  • Page 35: Cold Plate Mounting (Acsm1-204Cx-Xxxx-X, Frames C And D Only)

    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).

  • Page 36: Installation Of The Wfu-Xx Regen Filter Module

    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.

  • Page 37: Planning The Electrical Installation

    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.

  • Page 38: Checking The Charging Capacity

    AC. Due to this, the charging capacity of the supply module(s) has to be checked. The ACSM1 drive and supply modules in frame sizes A-D have a charging circuit in series with the capacitor bank.

  • Page 39: Supply Connection

    • 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.

  • Page 40: Supply Disconnecting Device

    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.

  • Page 41: Circuit Breakers

    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.

  • Page 42: Selecting The Power Cables

    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.

  • Page 43: Power Cables Cross-Section

    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.
  • Page 44 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...

  • Page 45: Selecting The Control Cables

    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.

  • Page 46: Control Cable Ducts

    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”)

  • Page 47: Electrical Installation

    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.

  • Page 48: Power And Control Cable Connection

    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.

  • Page 49: Procedure

    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.

  • Page 50: Installation Of Power Cable Clamp Plates

    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.

  • Page 51: Power Cable Connection - Frame Size A

    Power cable connection – frame size A DC Supply cable Cable clamp on bare shield 1.5 N·m (13 lbf·in) Below cable clamp, cover bare shield with insulating tape 1.5 N·m (13 lbf·in) 0.5 … 0.6 N·m (4.4 … 5.3 lbf·in) 0.5 …...

  • Page 52: Power Cable Connection - Frame Size B

    Power cable connection – frame size B DC Supply cable Cable clamp on bare shield 1.5 N·m (13 lbf·in) Below cable clamp, cover bare shield with insulating tape 1.5 N·m (13 lbf·in) UDC+UDC- 1.2 … 1.5 N·m (10.6 … 13.3 lbf·in) 1.5 N·m (13 lbf·in) Above cable clamp, cover bare shield with insulating tape...

  • Page 53: Power Cable Connection - Frame Sizes C And D (Connector Covers Removed)

    Power cable connection – frame sizes C and D (connector covers removed) DC Supply cable Screw lug detail 3 N·m Cable clamp on bare Below cable clamp, cover (25 lbf·in) shield 1.5 N·m (13 lbf·in) bare shield with insulating 15 N·m (11 lbf·ft) tape UDC+ 15 N·m...

  • Page 54: Connecting The Control Cables

    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.

  • Page 55: Jumpers

    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.

  • Page 56: Control Cable Grounding

    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.

  • Page 57: Installation Of Options

    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.

  • Page 58: Installation Example

    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...

  • Page 59: Installation Checklist

    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.
  • Page 60 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.

  • Page 61: Maintenance

    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.

  • Page 62: Heatsink

    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.

  • Page 63: Cooling Fan

    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.

  • Page 64: Fan Replacement (Frames C And D, Acsm1-204Ax-Xxxx-X)

    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.

  • Page 65: Fan Replacement (Frames C And D, Acsm1-204Cx-Xxxx-X)

    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.

  • Page 66: Replacing The Cooling Fan Of The Wfu Filter

    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.

  • Page 67: Replacing The Wfu-Xx Filter Capacitor (Wfu-21 And Wfu-22)

    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...

  • Page 68: Other Maintenance Actions

    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.

  • Page 69: Technical Data

    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...

  • Page 70: Derating

    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.

  • Page 71: Dimensions And Weights

    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.

  • Page 72: Supply Voltage Requirements For The Wfu-Xx Regen Filter Module Fan

    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.

  • Page 73: Dc Cable Fuses

    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...

  • Page 74: Ac Input (Supply) Connection

    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...

  • Page 75: Efficiency

    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...

  • Page 76: Cooling

    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.

  • Page 77: Applicable Standards

    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.

  • Page 78: Ce Marking

    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...

  • Page 79: Compliance With En 61800-3 (2004), Category C3

    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.

  • Page 80: Compliance With The Machinery Directive

    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).

  • Page 81: Ul Checklist

    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).
  • Page 82 Technical data...

  • Page 83: Resistor Braking

    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: •...

  • Page 84: Chopper Data / Resistor Selection Table

    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)

  • Page 85: Resistor Installation And Wiring

    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...

  • Page 86: Braking Circuit Commissioning

    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 •...

  • Page 87: Dimension Drawings

    Dimension drawings What this chapter contains Dimension drawings of the ACSM1-204 and related accessories are shown below. The dimensions are given in millimetres and [inches]. Dimension drawings...

  • Page 88: Frame Size A

    Frame size A Dimension drawings...
  • Page 89 Dimension drawings...

  • Page 90: Frame Size B

    Frame size B Dimension drawings...
  • Page 91 Dimension drawings...

  • Page 92: Frame Size C (Air-Cooled Module)

    Frame size C (air-cooled module) Dimension drawings...
  • Page 93 Dimension drawings...

  • Page 94: Frame Size C (For Cold Plate Mounting)

    Frame size C (for cold plate mounting) Dimension drawings...

  • Page 95: Frame Size D (Air-Cooled Module)

    Frame size D (air-cooled module) Dimension drawings...

  • Page 96: Frame Size D (For Cold Plate Mounting)

    Frame size D (for cold plate mounting) Dimension drawings...

  • Page 97: Regen Filter Module (Types Wfu-01 And Wfu-02)

    Regen filter module (types WFU-01 and WFU-02) Dimension drawings...

  • Page 98: Regen Filter Module (Types Wfu-21 And Wfu-22)

    Regen filter module (types WFU-21 and WFU-22) Dimension drawings...

  • Page 99: Braking Resistors (Type Jbr-Xx)

    Braking resistors (type JBR-xx) Dimension drawings...
  • Page 100 Dimension drawings...
  • Page 102 ABB Oy AC Drives P.O. Box 184 FI-00381 HELSINKI FINLAND Telephone +358 10 22 11 +358 10 22 22681 Internet http://www.abb.com...

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Acsm1-204

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