ABB ACS 800 Series Benutzerhandbuch

ACS800

Application Guide

ACS800 Single Drive Common DC Configurations

Application Guide

3AFE64786555 REV E

EFFECTIVE: 03.12.2004

Table of contents

Introduction

Possible main supply connections

Step by step guide

Design

Power limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Allowed braking power and need for a brake resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Calculation of the allowed braking power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Internal brake chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

External brake chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Contactors, DC bus and brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Wiring

Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Powering the AC fans in R7 and R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Brake resistor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Connecting the contactor of the resistor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Phase loss guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

READY signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Wiring the READY signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Start-up

Appendix A Charging circuit capacity

Frame sizes R...R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Frame sizes R5...R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Appendix B Powering the AC fans of R7 and R8

Introduction

Connecting the DC buses of frequency converters together results in energy savings

and in some cases simplifies the connection to the main supply. With common DC

the braking energy of one converter can be used for the other converters and

motors.

Unequal current distribution and different charging methods cause difficulties to

common DC systems:

• Unequal current distribution is influenced by input cables, AC or DC chokes and

input bridges’ forward characteristics. If the voltage reduction over the supply

components mentioned is not the same with all converters, more current will flow

through the converter which has a lower voltage reduction. Factors which

influence the current distribution include temperature, tolerances of components

and in DC choke cases the input cable’s cross-sectional area and length.

• Charging methods vary depending on the converter size. Because of this in some

installations, the supplies of the frame sizes R2-R4 should be disconnected when

they are connected parallel with frame sizes R5-R8.

Note: The drive compliance with the EMC Directive on low voltage networks is

specified in the appropriate Hardware Manual. However, please notice that different

common DC configurations have not been tested according to the EMC

requirements of conducted and radiated emissions.

Possible main supply connections

Figure 1. Common DC connections. Cases a and b.

Figure 2. Common DC connections. Cases c, d1 and d2.

Cases b, c and d can be used when the total power taken from the main supply,

Pout.tot, is smaller than the drive power rating, Pcont.max, of the biggest converter.

R8 R7 R6

F8 F7 F6

R8 R8 R8

R6 R8 R7

F6 F7

R7 / R6 R7 R7 / R5

Possible main supply connections

Case a)

The most common set-up, where all converters are connected to the main supply.

When the charging circuits of the converters are different, this connection is not

always allowed. Table 1 shows when the connection cannot be used.

Case b)

Converters are identical and only one converter is connected directly to the main

supply.

Case c)

Converters are not identical and only the biggest converter is connected directly to

the main supply. The AC cables to the other converters are protected by

drive-specific fuses.

Case d1)

Converters are identical and only one converter is connected directly to the main

supply. The charging circuit of the connected converter is capable of charging the

whole DC bus.

Case d2)

Converters are not identical and only the biggest converter is connected to the main

supply. Charging circuit of the connected converter is capable of charging the whole

DC bus.

Note: If the charging circuit in case d1/d2 is not capable of charging the DC bus,

connection presented in case b/c must be used.

Note: With frame sizes R5...R8 the charging circuit in case d1/d2 might not be able

to withstand the three times larger charging energies. In this case the main supply

cable is wired to all of the input rectifiers as presented in case b/c.

Note: With ACS800-11 only connection presented in case d1/d2 is allowed.

Note: With ACS800-11 220 V units, the voltage drop over the charging resistor

during charging can generate a permanent undervoltage fault. Contact your local

ABB representative for help on designing the common DC configuration!

To determine whether it is possible to leave some converters unconnected to the

main supply see Appendix A Charging circuit capacity.

Step by step guide

1) Select the converters and preselect the main supply connection. See Possible

main supply connections and Appendix A Charging circuit capacity.

2) Check from Table 1 that the connection is possible.

3) Check by using equation 1 that the load does not exceed the total power limit

Pout.tot of the system. See Power limit.

4) Select the fuses, cables and possible contactors for the DC side. See Fuses,

Cables and Contactors, DC bus and brake circuit.

5) Calculate the braking power and determine whether the braking cycle can be

performed and whether an internal or an external brake chopper is needed. See

Allowed braking power and need for a brake resistor.

6) If resistor braking is needed, select the internal or external brake chopper, the

resistor and the contactor. See Internal brake chopper, External brake chopper and

Contactors, DC bus and brake circuit.

7) Set up the common DC system according to the wiring instructions. See Wiring.

8) If the input terminals of frame sizes R7 and R8 are left unconnected, make sure

that the AC fans are powered separately. See Appendix B Powering the AC fans of

R7 and R8.

9) Set the common DC system related parameter values. See Start-up.

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