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ABB ACS850 Application Manual

Common dc configuration
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ACS850
Common DC configuration application guide

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Summary of Contents for ABB ACS850

  • Page 1 ACS850 Common DC configuration application guide...
  • Page 3 ACS850 Common DC configuration application guide 3AUA0000073108 REV A EN EFFECTIVE: 22.3.2010 © 2010 ABB Oy. All rights reserved.

  • Page 5: Safety Instructions

    Safety instructions Chapter overview WARNING! All electrical installation and maintenance work on the drive should be carried out by qualified electricians only. Never work on the drive, the braking chopper circuit, the motor cable, or the motor when input power is applied to the drive. After disconnecting the input power, always wait for 5 minutes to let the intermediate circuit capacitors discharge before you start working on the drive, control cabling, motor, or motor cable.
  • Page 6 Safety instructions...

  • Page 7: Table Of Contents

    Table of contents Safety instructions ..........................5 Chapter overview ............................. 5 Table of contents............................ 7 Introduction to the manual ........................10 Compatibility............................10 Intended audience..........................10 Categorization according to the frame size .................... 10 Drive modules documentation........................ 10 Common DC configurations........................ 12 Introduction.............................
  • Page 8 External DC supply ..........................24 Frame sizes A…D ......................... 25 Frame sizes E0, E and G ......................25 Supply units other than ACS850 ....................25 Mains choke selection ..........................25 Mains choke data..........................26 Single AC input ..........................26 Multiple AC input..........................26 Harmonic distortion..........................
  • Page 9 Table of contents...

  • Page 10: Introduction To The Manual

    Drive modules documentation This guide contains only common DC related technical items for the ACS850 drive modules. For complete documentation, see the table below. If there are deviations in the given data between this guide and other manuals, then the document with the latest date (Effective: xx.yy.20zz) will apply.
  • Page 11 Introduction to the manual...

  • Page 12: Common Dc Configurations

    Common DC configurations Introduction Drive modules can be connected together via DC terminals to have a so called common DC configuration. Within common DC, the drives with regenerative power from the motor can via DC link feed the other drives that are on the motoring mode. The major benefits with this kind of connection are the following: Energy saving due to a reduced need for the supply side power.

  • Page 13: Configuration Steps

    Sample configuration 2 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.
  • Page 14 Configuration step Related section Define the common DC power profile • DC link power versus time for Power requirements each axis • average and maximum total motoring power • average and maximum total regenerative power Select the drive module(s) to be connected to the AC supply Supply unit selection •...

  • Page 15: Common Dc Configuration

    Common DC configuration Power ratings for DC connection The power unit diagram with related power ratings is shown in the following figure. UDC+ UDC- Frames A, B, C and D UDC+ UDC- Frames E0, E and G rec,ave Average rectifier power P rec,ave is the maximum average DC power that the input bridge of a drive can supply.

  • Page 16: Chokes, Braking Choppers And Charging Circuits

    ACS850 Type rec,ave rec,max 03A0-5, 03A6-5, 04A8-5, 06A0-5 08A0-5 010A-5 014A-5, 018A-5 10.8 13.5 025A-5, 030A-5, 035A-5 20.5 25.7 044A-5, 050A-5 29.2 36.5 061A-5, 078A-5, 094A-5 52.9 66.2 103A-5 61.0 77.1 144A-5 85.3 90.1 166A-5 98.2 103.6 202A-5 119.3 133.9 225A-5 133.3...

  • Page 17: Dc Link Power P

    Drive Drive Drive DC link power P of motoring axis dc,mot is the power supplied to the DC terminals to get the required mechanical dc,mot motoring power on the motor shaft. P is higher than the shaft power, because it dc,mot also covers the losses in the drive and motor.

  • Page 18: Peak Motoring Power P Mot,Max

    Average motoring power P mot,ave is the average of the motoring DC link power over the whole cycle. This power mot,ave is taken from the AC supply. For long load cycles, P should be determined over mot,ave the worst-case 3 minutes time window. Peak motoring power P mot,max is the positive peak power in the power profile.

  • Page 19: Supply Unit Selection

    Supply unit selection DC link power supplied via the drive The DC link power can be supplied via a suitable drive module for the common DC system. The drive module will be selected based on P and P requirements, mot,ave mot,max and charging circuit capacity requirements.
  • Page 20 The DC buses of three converters ACS850-04-08A0-5, 4.7 kW, (A); ACS850-04-035A- 5, 20.5 kW, (C) and ACS850-04-035A-5, 20.5 kW, (C) are connected together. The input terminals of the 3 kW converter are left unconnected. k = 0.5 when two frame C´s...

  • Page 21: Checking The Charging Capacity

    In frame sizes E0, E and G, the charging circuit is in parallel with the input bridge and the charging circuit(s) of the drive(s) are connected to the supply charge of all the capacitor banks. The charging circuit data for each drive module is shown in the following table. ACS850 Type 03A0-5, 03A6-5, 04A8-5, 06A0-5 21.7 08A0-5 16.5...

  • Page 22: Multiple Ac Input

    R values (R ,…) are the charging resistances of each drive module. The following condition must be fulfilled: > R • If the condition cannot be fulfilled, more than one drive module must be connected to the AC supply. Multiple AC input Define R as in the previous case.

  • Page 23: Frame Sizes A

    where the U is the line to the line supply voltage. The charging time is generally about 0.3 s (U > 95% U ) with the drive modules. Frame sizes A…D In frame sizes A-D the charging resistor is in series with the DC capacitors and all DC buses are charged via their own resistors despite of the main supply connection.

  • Page 24: External Dc Supply

    Example 1 The DC buses of three converters ACS850-04-103A-5 (E0), ACS850-04-0202A-5 (E) and ACS850-04-430A-5 (G) are connected together. The main supply voltage is 400 V. The total charging energy of the capacitors is = 1/2 · (2400 µF + 4700 µF + 8600 µF) · (1.35 · 400V) ·...

  • Page 25: Frame Sizes A

    AC fan in frame Supply units other than ACS850 When some other type of supply unit than ACS850 is used, its DC voltage compatibility with the drive units must be checked in addition to the earlier described items (see...

  • Page 26: Mains Choke Data

    Mains choke data Data for the mains chokes is listed in the table below. Drive types not listed below have a built-in choke as standard. Frame Choke type µ ACS850 03A0-5, 03A6-5 CHK-01 6370 04A8-5, 06A0-5, 08A0-5 CHK-02 4610 11.4...

  • Page 27: Harmonic Distortion

    Harmonic distortion If there are requirements for harmonic distortion level, a mains choke (CHK-xx) is typically needed in ACS850 frames A and B. Other drive types have a choke as standard. Total harmonic distortion is about 40…45%, when a choke is used according to default selection.

  • Page 28: Common Dc Capacitance

    The energy demand from the supply is then reduced. DC link capacitance Each drive module has its own capacitor bank. The capacitance value of each drive size is given in the table below. ACS850 Type ACS850 Type µ µ 03A0-5, 03A6-5...

  • Page 29: Resistor Braking

    The available energy capacity now depends on the criteria for the U and the actual dc,lim DC link voltage supplied into the common DC system. The selection of the value for depends on the common DC system configuration and its general requirements. dc,lim Here are the common alternatives for the U based on the drive module DC voltage...

  • Page 30: Braking Power Ratings

    DC link voltage of the drive reaches 780 V. The maximum braking power rating for each drive module is achieved at 840 V. The braking chopper data of the drive modules is shown in the following table. ACS850 br,cont br,max...

  • Page 31: Multiple Braking Choppers

    Multiple braking choppers In case two or more braking choppers of drive modules are active in the common DC system, the same conditions as above must still be fulfilled. < • cont < • ,max ,max Where P ratings are now calculated from the individual ratings as follows: ×...

  • Page 32: Braking Resistor Types

    The resistance R of each individual braking resistor must be at least R • br(i) br,min according to the braking chopper data of the drive module in question. The resistance value R of each individual braking resistor should also fulfil the •...

  • Page 33: Selection Of Ac Supply Fuses

    Selection of AC supply fuses The standard selection table for the AC supply fuses in the single drive configuration can be found in the relevant hardware manual. That selection guideline can be used when the AC supply line current of the drive module(s) connected to the AC supply is according to the table.

  • Page 34: Emc

    ACS850-04 Fuse Type 03A0-5, 03A6-5, 04A8-5, 06A0-5, 08A0-5 010A-5 014A-5, 018A-5 025A-5, 030A-5 035A-5, 044A-5, 050A-5 061A-5, 078A-5, 094A-5, 103A-5 144A-5, 166A-5 202A-5, 225A-5 260A-5 290A-5 430A-5 521A-5 1000 602A-5 1250 693A-5, 720A-5 1600 The compliance of the drive modules with the EMC directive is specified in the relevant hardware manual for the single drive configuration.

  • Page 35: Cables

    Cables • Select the input power cables as described in the appropriate drive Hardware Manual. The cross-sectional area of the DC cables must be the same as the cross-sectional area of the AC side cables. • If screened DC cables are used, ground the screen at the other end only. •...

  • Page 36: Drive Module Settings

    JCU connectors XPOW:2 and XRO:2 (from left to right) JCU connectors XD24:1 and XDI:A (from left to right) Drive module settings Note: The parameter settings mentioned below apply to ACS850 Standard Application Program. It is recommended to set parameter 99.05 MOTOR CTRL MODE to DTC and to •...

  • Page 37: General Technical Data

    Disable fault function “Cross connection” (par. 30.08), if the external DC supply • (other than ACS850 drive module) is used General technical data DC voltage limits All drive modules have their own terminals for the DC connection. Different limit values in drive modules related to the DC voltage level are defined in the table below.

  • Page 38: Powering The Ac Fan In Frame G

    DC voltage control: the overvoltage and undervoltage control of the DC link voltage • level are enabled by default. Then the drive modules will limit the motoring and generating torque, if there is a need to keep the DC link voltage within the control limits.

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