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G740 - Control Unit & Terminal Unit - RevB1 PDF

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0% found this document useful (0 votes)
364 views53 pages

G740 - Control Unit & Terminal Unit - RevB1 PDF

Uploaded by

srmohapatra5086
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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ABB ACS 5000 Training

ACS 5000 Service & ACS 5000


Commissioning
Control Unit &
Course G740
Terminal Unit
ACS 5000 Training -RevB1
© ABB Ltd - 1 -

© ABB Ltd Page 1


ABB ACS 5000 Training

COU
Training objectives

Upon completion of this part the student will be able to


handle the hardware including:
n Control HW (Air and Water Cooled drive)
n PCBs (Printed Circuit Boards)
n Interface to overriding system
n S800 I/O modules
n Various option modules
n Auxiliary supply concept
ACS 5000 Training -RevB1
© ABB Ltd - 2 -

© ABB Ltd Page 2


ABB ACS 5000 Training

COU
ACS 5000

ACS 5000
Air Cooled

Control Unit & Terminal


ACS 5000 Training -RevB1

Unit
© ABB Ltd - 3 -

© ABB Ltd Page 3


ABB ACS 5000 Training

COU
ACS 5000A Control Unit & Terminal Unit
§ All control devices are mounted inside the COU cabinet (=A11).
§ Terminal section for transformer and motor cables
ACS 5000 Training -RevB1
© ABB Ltd - 4 -

Responsible for most of the converter control, monitoring and


protection tasks:
§ Control for inverter
§ Current control for the excitation system
§ Controlling and monitoring motor (INU)
§ Control and monitoring of trafo and MCB
§ Control and monitoring of the water cooling system (control
HW for ACS 5000 cooling is installed on inside of WCU
cabinet)
§ Local operation with CDP 312R panel and push buttons on
the control cabinet door

© ABB Ltd Page 4


ABB ACS 5000 Training

COU
ACS 5000A Control Unit

Optional
customer I/Os

S800 I/O
AMC- board on the top modules
PEC-INT board below

Auxiliary Relays

24V power
ACS 5000 Training -RevB1

Charging Transformer supplys


© ABB Ltd - 5 -

Responsible for most of the converter control, monitoring and


protection tasks:
§ Control for inverter
§ Current control for the excitation system
§ Controlling and monitoring motor (INU)
§ Control and monitoring of trafo and MCB
§ Control and monitoring of the cooling system
§ Local operation with CDP 312R panel and push buttons on
the control cabinet door

© ABB Ltd Page 5


ABB ACS 5000 Training

COU
ACS 5000A Earth Fault Supervision
§ The earth fault protection is done by supervision of the voltage over
the common mode filter
ACS 5000 Training -RevB1
© ABB Ltd - 6 -

The only setting element on the board is the DIL switch. The
selectable detection levels are (The voltage over Rn) :

Switch setting Switching


threshold

1 2 3 4
OFF OFF OFF ON ± 500 V
OFF OFF ON OFF ± 660 V
OFF ON OFF OFF ± 825 V
ON OFF OFF OFF ± 1150 V

Check right settings from project related electrical diagrams.

© ABB Ltd Page 6


ABB ACS 5000 Training

COU
ACS 5000A Earth Fault Supervision
§ The earth fault protection is done by supervision of the voltage over
the common mode filter: If an earth fault occurs this voltage is
increasing
§ In normal operation the EAF board is sending light. If the voltage over
the common mode filter is increasing over a certain limit (adjusted by
the serial resistor), the light is switched off. Via fibre-optic link this is
communicated to control. In this case the drive trips and open MCB

star point of EMC-filter


3.3M
ACS 5000 Training -RevB1

EAF

power ground
© ABB Ltd - 7 -

The only setting element on the board is the DIL switch. The
selectable detection levels are (The voltage over Rn) :

Switch setting Switching


threshold

1 2 3 4
OFF OFF OFF ON ± 500 V
OFF OFF ON OFF ± 660 V
OFF ON OFF OFF ± 825 V
ON OFF OFF OFF ± 1150 V

Check right settings from project related electrical diagrams.

© ABB Ltd Page 7


ABB ACS 5000 Training

COU
ACS 5000

ACS 5000
Water Cooled

Control Unit & Terminal


ACS 5000 Training -RevB1

Unit
© ABB Ltd - 8 -

© ABB Ltd Page 8


ABB ACS 5000 Training

COU
ACS 5000W Control Unit & Terminal Unit
(=TEU) (=COU)
ACS 5000 Training -RevB1

Terminal Unit for


© ABB Ltd - 9 -

Terminal Section
Supply cables for Motor cables

© ABB Ltd Page 9


ABB ACS 5000 Training

COU
ACS 5000W Terminal Unit
§ Mains cables can be connected to the cabinet
either from the top or through the bottom of the
cabinet

-20° diode bridge


phase 3

+20°

diode bridge
phase 2

-20°

diode bridge
ACS 5000 Training -RevB1

+20° phase 1
© ABB Ltd - 10 -

© ABB Ltd Page 10


ABB ACS 5000 Training

COU
ACS 5000W Control Unit

S800 I/O modules

PEC-INT- AMC- board


board

Circuit Breakers
Auxiliary Relays
ACS 5000 Training -RevB1

Auxiliary Transformer
© ABB Ltd - 11 -

Responsible for most of the converter control, monitoring and


protection tasks:
§ Control for inverter
§ Current control for the excitation system
§ Controlling and monitoring motor (INU)
§ Control and monitoring of trafo and MCB
§ Control and monitoring of the water cooling system (control
HW for ACS 5000 cooling is installed on inside of WCU
cabinet)
§ Local operation with CDP 312R panel and push buttons on
the control cabinet door

© ABB Ltd Page 11


ABB ACS 5000 Training

COU
ACS 5000W Control Unit
(=COU 0)
§ All control devices are mounted inside the
COU cabinet (=COU 0).
§ Terminal section for motor cables
§ Behind the control box of the COU is the
location of the EMC filter.

(=COU 3)
I
u_ph_mot u
I

(=COU 2)
I
u_ph_mot v
I

(=COU 1)
I
u_ph_mot w
I
ACS 5000 Training -RevB1
© ABB Ltd - 12 -

Responsible for most of the converter control, monitoring and


protection tasks:
§ Control for inverter
§ Current control for the excitation system
§ Controlling and monitoring motor (INU)
§ Control and monitoring of trafo and MCB
§ Control and monitoring of the water cooling system (control
HW for ACS 5000 cooling is installed on inside of WCU
cabinet)
§ Local operation with CDP 312R panel and push buttons on
the control cabinet door

© ABB Ltd Page 12


ABB ACS 5000 Training

COU
ACS 5000W EMC- and CM-filter
Limited dv/dt by EMC filter output
dv/dt=500V/us
Transient overshoot=500V

Emc filter
phase u u_ph_mot u
4000V/1380us I
I

phase v u_ph_mot v
I
I

phase w u_ph_mot w
I
I

1800V/1376us
ACS 5000 Training -RevB1
© ABB Ltd - 13 -

power ground

Common mode voltages and currents


§ Definition: In time domain the three phase voltages (created by
certain switching states) can be separated into a common mode
and a symmetrical part.
§ The common mode voltage is defined as: uCM = (ua + ub + uc) / 3
§ The symmetrical three phase system is defined as:
ua sym = ua - uCM
ub sym = ub - uCM
uc sym = uc – uCM
§ Common mode currents are created by the common mode voltage
which is applied to parasitic stray capacitance such as:
§ Parasitic cable capacitance between phase conductor and
screen
(or ground).
§ Parasitic motor capacitance between windings and housing.
§ Parasitic main transformer capacitance between secondary
winding system and screen (and also housing).
§ Residual common mode currents are dependant on common mode
voltage gradient and on the coupling of the DC-link neutral point to
ground.
§ By installing a dv/dt and grounding filter, common mode
currents
are limited, controlled and damped
§ A ground filter decouples multiple inverter units on a common
© ABB Ltd Page 13
DC
ABB ACS 5000 Training

COU
ACS 5000W Earth Fault Supervision
§ If measured voltage is above
defined limit, the optical output signal
of EAF-board turns OFF and the INT-
board of 1st Inverter detects an
earth fault.
ACS 5000 Training -RevB1
© ABB Ltd - 14 -

The only setting element on the board is the DIL switch. The
selectable detection levels are (The voltage over Rn) :

Switch setting Switching


threshold

1 2 3 4
OFF OFF OFF ON ± 500 V
OFF OFF ON OFF ± 660 V
OFF ON OFF OFF ± 825 V
ON OFF OFF OFF ± 1150 V

Check right settings from project related electrical diagrams.

© ABB Ltd Page 14


ABB ACS 5000 Training

COU
ACS 5000

ACS 5000
Air & Water Cooled

Control HW
ACS 5000 Training -RevB1
© ABB Ltd - 15 -

© ABB Ltd Page 15


ABB ACS 5000 Training

COU
ACS 5000A I/O Configuration
AF100 Bus
FieldBus (e.g. Profibus)
FieldBus (e.g. Modbus)

Service Tools (*)


(e.g. DriveWindow)

(=COU)
Fieldbus CDP312R
Adapters (*) Control Panel

AMC

Position/
Speed
encoder (*)
ACS 5000 Training -RevB1

Inverter/MCB/ Customer
E-Off/Charging I/Os (*)
© ABB Ltd - 16 -

(*) Optional Equipment


M

§ If the overriding control system is not based on the AF100 bus,


interfacing is achieved with field bus adapters.
§ Field bus adapters are standard devices and are part of the ACS
product family

© ABB Ltd Page 16


ABB ACS 5000 Training

COU
ACS 5000W I/O Configuration
AF100 Bus
FieldBus (e.g. Profibus)
FieldBus (e.g. Modbus)

Service Tools (*)


(e.g. DriveWindow)

(=LSU) (=INU) (=COU) (=WCU)


Fieldbus CDP312R
Adapters (*) Control Panel

AMC

Position/ WCU
Speed Monitoring
encoder (*)
ACS 5000 Training -RevB1

Inverter/MCB/ Customer
E-Off/Charging I/Os (*)
© ABB Ltd - 17 -

(*) Optional Equipment


M

§ If the overriding control system is not based on the AF100 bus,


interfacing is achieved with field bus adapters.
§ Field bus adapters are standard devices and are part of the ACS
product family

© ABB Ltd Page 17


ABB ACS 5000 Training

COU
Interface to overriding system
§ ACS 5000 can be connected to ABB Advant automation series and to
most standard process automation systems available on the market
§ Below two the most commonly used connections with Advant:
§ AMC is connected to AC80 via DDCS link. AC80 processor can also
fulfil control tasks.
§ AMC is connected to the AF100 bus via field bus adapter. Adapter is
only for the data exchange between ACS 5000 and a higher control
system

Fieldbus

(=COU)
Advant Fieldbus
Controller Adapter
ACS 5000 Training -RevB1

CH4 CH0

AMC board
© ABB Ltd - 18 -

§ If the overriding control system is not based on the AF100 bus,


interfacing is achieved with field bus adapters.
§ Field bus adapters are standard devices and are part of the ACS
product family

© ABB Ltd Page 18


ABB ACS 5000 Training

COU
ACS 5000A Control HW Overview (Air Cooled)
Overriding Control System

PC S800 Drive I/O S800 Drive I/O


Cluster 1 Cluster 3
DI DO DI DO DI DO DI DO
TB820 8 8 8 8 TB820 8 8 8 8
Fieldbus NDBU-95 *) 1 1 1 2 1 1 1 2
CDP312R Adapter Branching Unit 0 0 0 0 0 0 0 0

To CIU 1
To CIUs/ To CIUs/
AMC Ch3
AMC Ch4
CH0 CH3 CH7 CH4
AMC- 33
CH1
XD C903 *) Note! Only if EXU
X102

64
NTAC-02 GRB
OEI MCB Control
ACS 5000 Training -RevB1

XV C904 From earth fault


X4 supervision EAF

RX511
RX501

RX503

RX505

TX512
(Filter in COU)
PEC INT MAIN
© ABB Ltd - 19 -

PPCC A

PPCC B

U V W
TX402
RX401
TX404
RX403

TX406
RX405
TX408
RX407

TX410
RX409
TX412
RX411
From diode bridge
Supervision EAF
(LSU Phases)
INU Phase U INU Phase V INU Phase W

© ABB Ltd Page 19


ABB ACS 5000 Training

COU
ACS 5000W Control HW Overview (Water Cooled)
Overriding Control System

PC
S800 Drive I/O
DI DO DI DO
TB820 8 8 8 8
Fieldbus NDBU-95 1 1 1 2
CDP312R Adapter Branching Unit 0 0 0 0

To WCU I/O
To EXU CCB (if exist)

CH0 CH3 CH7 Exists if no BCU


AMC- 33
OEI
CH1
XD C903
To discharging
X102
HV relays
From BCU
64 VLSCD
NBIO-21 NTAC-02 GRB
OEI MCB Control
ACS 5000 Training -RevB1

XV C904 From earth fault


X4 supervision EAF

RX511
RX501

RX505

TX512
RX503

(Filter in COU)
PEC INT MAIN
© ABB Ltd - 20 -

PPCC A

PPCC B

U V W
TX402
RX401
TX404
RX403

TX406
RX405
TX408
RX407

TX410
RX409
TX412
RX411
From diode bridge
Supervision EAF
(LSU Phases)
INU Phase U INU Phase V INU Phase W

© ABB Ltd Page 20


ABB ACS 5000 Training

COU
AMC- board
n AMC-33 (Application and Motor Control board) handles all motor & drive
information and status, motor model, torque and flux calculations, SW
protection, SW tripping levels etc.
n Program code, initial values of SW and parameters
n 8 DDCS (Distributed Drive Control System) communication channels, 1-4
MBPS
n 2 PPCS (Power Plate Communication System) communication channels, 8
MBPS
2 PPCS channels
ACS 5000 Training -RevB1
© ABB Ltd - 21 -

8 DDCS channels

AMC3-board
§ Located on swing frame inside the COU module
§ Communicates with:
§ Overriding controllers (via advant or field bus adapters)
§ I/O devices
§ Converter and excitation controller interfaces
§ Service and commissioning tools (DriveWindow, DriveDebug)
§ CDP 312R Control panel (RS-485 link)
§ Communication between AMC33 and other control boards is carried
out
via optical links by using the PPCS and DDCS serial communication
protocols which are specially designed for the fiber optic data transfer
§ Customer interfaces are standardized:
§ Fieldbus adapters as an interface with different automation
systems
§ S800 I/O modules as an interface with transformer, MCB,
motors
etc.
§ Encoders for position and speed monitoring (optional)
§ CDP 312R panel for local drive operation
§ DrivesWindow interface for operation, monitoring, setting
parameters etc.
© ABB Ltd Page 21
ABB ACS 5000 Training

COU
AMC- board
X14 - 24Vdc power
§ Serial communication supply
protocols tailored for
X17 - RS485 bus panel
data transfer via fiber
optic cables, namely with: CH0_Overriding system

§ Converter and excitation CH1_GRAY/NTAC


control interfaces
§ Higher-level process control CH2_MF link
systems via advant or CH3_Drive monitoring
fieldbus adapters, Fieldbus
Interfaces CH4_AC80 (option)
§ I/O devices, S800 I/O CH5_CCB-board (EXU)
Modules
§ Service tools (e.g. CH6_PFF board
ACS 5000 Training -RevB1

DriveWindow)
INT/PUB board CH7_S800
© ABB Ltd - 22 -

INT/PUB board

© ABB Ltd Page 22


ABB ACS 5000 Training

COU
AMC- board
n Status indication by LEDs
F (red) : Illuminated when booting up
R (green) : Not used
R P T2 S1 S0 M (green) : Illuminated when booting up
P (green) : Power OK
T1 (yellow) : Flash when DDCS-channel 0 (from
F M T1 S2 S3
overriding system) is receiving data
T2 (yellow) : Flash when DDCS-channel 3
(DriveWindow) is receiving data
S0-S4 (yellow) : Not Used
ACS 5000 Training -RevB1
© ABB Ltd - 23 -

© ABB Ltd Page 23


ABB ACS 5000 Training

COU
AMC- board
The control software is organized into the following functional groups
§ Operating system software (AMCOS)
§ Rectifier and inverter control software
§ Fixed application software
§ FCB application software for project-specific functions

FlashPROM replacement :
White dot must be located on
this position !
ACS 5000 Training -RevB1
© ABB Ltd - 24 -

Software
§ After the replacement of the flash memory for some reason, it is
important to download correct SW package and parameter settings
to the flash memory before running the unit
§ The safest way to download the SW is to use empty spare flash. In
case of something goes wrong at least the original flash with the
original SW and parameter settings still exist.

© ABB Ltd Page 24


ABB ACS 5000 Training

COU
PEC-INT
§ The branching and modulation PEC-INT is connected with the AMC33 via
the adapters XD C903 AE and XV C904 AE and thus needs to be located
in a control unit.
§ The main functions are:
§ Main modulator
§ Communication with all three INU’s
§ Interface to DSP including measurements, inverter status, control
references, etc.
ACS 5000 Training -RevB1
© ABB Ltd - 25 -

© ABB Ltd Page 25


ABB ACS 5000 Training

COU
PEC-INT board
Six LED’s are foreseen directly on the board, to indicate the status of the
PEC-INT.

F(ault)
R(un)
P(ower)
S(upervisor)
T(ransmission)
A(ctivity)
ACS 5000 Training -RevB1
© ABB Ltd - 26 -

LED Color Description


No.

1 Red Fault, free usable FPGA output J4 V601

2 Green Light = Run. The FPGA firmware is loaded and


the hardware id is recognised correctly. The
DONE pin on the FPGA signals high after the
configuration is done. This LED follows the
common OPCoDe convention and cannot be
redefined. V602
3 Green Light = Power Ok. The signal is formed by the
power supply supervision of the power supply
after the EMC filter. This LED follows the
common OPCoDe convention and cannot be
redefined. V603
4 Green Supervisor, free usable FPGA output J3 V604

5 Yellow Transmission, free usable FPGA output J2


V605

6 Yellow Activity, free usable FPGA output J1 V606

© ABB Ltd Page 26


ABB ACS 5000 Training

COU
PEC-INT board
§ The PEC-INT board includes 2 optical modules with 6 transmitter
/receiver channels

LSU diode supervision phase U


PhaseU_LinkA

LSU diode supervision phase V


PhaseU_LinkB

LSU diode supervision phase W


PhaseV_LinkA

PhaseV_LinkB

PhaseW_LinkA
Earth Fault Supervision from EAF-
ACS 5000 Training -RevB1

board (Filter in COU)


PhaseW_LinkB
MCB Open
© ABB Ltd - 27 -

A1414 A1415

© ABB Ltd Page 27


ABB ACS 5000 Training

COU
OEI - board
§ Used for tripping MCB as fast as possible in case of time critical faults
§ Direct interface between PEC INT-board and S800 I/O
§ “Low active” optical trip signal from PEC INT board
§ When tripping OEI disconnects “MCB order close”, “/ MCB order
open” and “/ MCB order trip” from ground level (see picture below)
ð MCB opens
ACS 5000 Training -RevB1
© ABB Ltd - 28 -

© ABB Ltd Page 28


ABB ACS 5000 Training

COU
ACS 5000A S800 I/O Configuration (Air cooled)
(CxPy) = Cluster x, Position y
AMC33
CH7

CLUSTER 1 TB820 CLUSTER 3 TB820

Position 1 DI810 Position 1 AI820


Position 2 DO810 Position 2 DI810
Position 3 DI810 Position 3 AO820
Position 4 DO820 Position 4 DO820

Position 5 DI810 Position 5 AI830


Position 6 DO820 Position 6 AI830
Position 7 DO820 Position 7 DI810

Standard Drive
ACS 5000 Training -RevB1

Optional Customer Interface


Related I/O
Par.: 75.06 ... 75.10

MCB Control
© ABB Ltd - 29 -

Air cooling
control

© ABB Ltd Page 29


ABB ACS 5000 Training

COU
ACS 5000W S800 I/O Configuration (Water cooled)
AMC33 (CxPy) = Cluster x, Position y
CH7

CLUSTER 1 TB820 CLUSTER 2 TB820 CLUSTER 3 TB820 NBIO- 21


Fast I/O

Position 1 External
DI810 Position 1 DI810 Position 1 AI820 Excitation Control
Position 2 DO810 Position 2 DO820 Position 2 DI810/811 (Option RMD)

Position 3 DI810 Position 3 AI810 Position 3 AO820


Position 4 DO820 Position 4 DO820

Position 5 AI830
Position 6 AI830
Standard Drive
Related I/O Position 7 DI810/811

MCB Control WCU Control Optional Customer Interface


PAR:75.05 Par.: 75.06 ... 75.10
ACS 5000 Training -RevB1
© ABB Ltd - 30 -

© ABB Ltd Page 30


ABB ACS 5000 Training

COU
S800 modules
§ Internal and external I/O signals are connected to the converter control
system by standard ABB Advant S800 I/O modules.
§ The I/O modules are installed in the COU and WCU.
§ The external I/O signals are connected to terminals inside the COU and
are internally wired to their I/O modules.
ACS 5000 Training -RevB1
© ABB Ltd - 31 -

General

§ ACS 5000’s internal HW I/O signals connected to S800 are


signals
to/from WCU, push buttons, charging circuit, earthing isolator,
module temperatures etc.
§ ACS 5000’s external HW I/O signals connected to S800 are
signals
to/from main supply transformer, MCB, motor, automation etc.
§ S800 is a modular automation system which consists of peripheral
I/O stations and communicates with the AMC33 board via DDCS
link (TB820)
§ S800 modules are located in the COU and WCU

© ABB Ltd Page 31


ABB ACS 5000 Training

COU
S800 Modular I/O system

TB 820 ModuleBus Modem Digital I/O Module Analog I/O Module


ACS 5000 Training -RevB1

TU 830 Module Termination Unit TU 831 Module Termination Unit


© ABB Ltd - 32 -

© ABB Ltd Page 32


ABB ACS 5000 Training

COU
ModuleBus optical modem
§ TB820 ModuleBus Modem provides a fiber optic serial interface to the
AMC33 board of INU using standard DDCS protocol. Internal co-
ordination between S800 modules is achieved with an internal bus
(Module bus).
§ One TB820 ModuleBus Modem can control up to twelve S800 modules.
When more than twelve S800 modules are needed, extra TB820
ModuleBus are connected on serial loop.

AMC-33 (channel 7)
ACS 5000 Training -RevB1

Terminal Unit
Terminal Unit
Terminal Unit MTU831
MTU830
MTU830
Terminal Bus
© ABB Ltd - 33 -

TB820

(Optical fiber)

X4

X5

AMC-33

X4
Ch7

(Optical fiber)
X5

© ABB Ltd Page 33


ABB ACS 5000 Training

COU
ModuleBus Optical Modem
§ The Modulebus has an electrical and an optical interface which are
logically the same bus. A maximum of twelve I/O modules can be
connected to the electrical Modulebus and up to seven clusters can
be connected to the fiber optic Modulebus expansion.
ACS 5000 Training -RevB1
© ABB Ltd - 34 -

TB820 Description:
§ The unit includes an isolated power converter that generates a
short
circuit proof +5V supply for the TB820 and connected I/O
modules.
§ TB820 also contains the Modulebus interfaces, LED indicators and
one screwdriver maneuvered rotary switch for the Modulebus
I/O cluster address (1-7).
§ The Modulebus has an electrical and an optical interface which are
logically the same bus. A maximum of twelve I/O modules can be
connected to the electrical Modulebus and up to seven clusters
can
be connected to the fiber optic Modulebus expansion.
§ The fiber-optical interface is intended for local distribution of I/O
clusters and where more than 12 I/O modules per station are
required, however not more than 24 I/O modules per station.
LED Indicators:
§ R(un) LED: Green indicates that TB820 is operational.
§ F(ault) LED: Red indicates a fault condition. Reset and
communication errors on the electrical ModuleBus turns the LED
on.
§ P(owok) LED: Green indicates that the DC/DC converter
generates
a valid +5V dc.
© ABB Ltd § ORx1 and ORx2 traffic LEDs: Yellow (blinking) indicates that the Page 34
TB820 is receiving data on the two optical ModuleBus channels
ABB ACS 5000 Training

COU
Module Termination Unit
§ Module Termination Units (MTU), are the sockets which are used for housing
I/O modules. Two different types are available for ACS 5000

§ TU830 for all 24 VDC, mA modules

§ TU831 for relay output modules (230


V a.c./d.c.)
ACS 5000 Training -RevB1
© ABB Ltd - 35 -

§ Each MTU can accommodate one I/O module which contains


interface on each side for the Module bus
§ Passive unit
§ Expands the internal bus in increment
§ Mounted on standard DIN rails, grounding is achieved with a metal
clip spring

§ Mechanical locking tab


§ Activate/Deactivate I/O-module when replaced,
i.e. protects multipole contact from damage
§ Locks I/O module to MTU

Bus

§ MTU keying code (mechanical key protection)


§ Protects module for damage when replaced

© ABB Ltd Page 35


ABB ACS 5000 Training

COU
S800 I/O Modules

Available I/O modules:


§ Digital Input Module DI 810 (24VDC)
§ Digital Output Module DO 810 (24VDC)
§ Digital Output Module DO 820 (230VDC/VAC)
§ Analog Input Module AI 810 (0 or 4 – 20mA, 0 or 2 – 10V)
§ Analog Input Module AI 820 ( -20mA – 20mA, 0 or 4 –
20mA, -5V - +5V, 0 or 2 – 10V)
§ Analog Input Module AI 830 (RTD)
§ Analog Ouput Module AO 820 (-20mA – 20mA, 0 or 4 –
20mA, -5V - +5V, 0 or 2 – 10V)
ACS 5000 Training -RevB1
© ABB Ltd - 36 -

© ABB Ltd Page 36


ABB ACS 5000 Training

COU
ACS 5000 Training -RevB1
© ABB Ltd - 37 -
I/O modules LED indication

© ABB Ltd Page 37


ABB ACS 5000 Training

COU
Fieldbus adapters (Option)
§ Fieldbus interfaces are used for the serial, bidirectional communcation
between the converter and a higher-level process control system.
§ Using fieldbus interfaces, the converter can be controlled and status
messages, reference and actual values can be transmitted.
§ All common fieldbuses including:
§ AF100
§ Profibus
§ Modbus
§ Interbus S
§ DeviceNet
§ Many others...
ACS 5000 Training -RevB1
© ABB Ltd - 38 -

Communication with the AMC3 controller is accomplished with


datasets,each containing 3 x 16 bit integers. Each dataset contains a
standardized set of process data. The content of the datasets must
be programmed accordingly in the remote process controller.

© ABB Ltd Page 38


ABB ACS 5000 Training

COU
Gray encoder (Option)

§ The LD GRB-01 is a Gray-coded absolute


encoder interface, used for fast and accurate
measurement of the absolute position of a rotor
via a position encoder terminal.

§ The communication with the encoding


terminal is done over a 24V electrical
interface. This interface can be either
parallel or serial. The LD GRB-01 can
also deliver analog signals to a speed
monitoring instrument and a pulse encoder.

§ The communication with the controller platform AMC-33 is done


over an optical DDCS interface with one sender (Tx) and one
ACS 5000 Training -RevB1

receiver (Rx).
© ABB Ltd - 39 -

A frequently used example of an application for the Grey encoder is


when it is connected between a SCYC 55830 (Tacho terminal board)
and an AMC-3 (Application & Motor control board).
In some applications also NTAC (Pulse encoder interface) is
connected to pulse outputs.

© ABB Ltd Page 39


ABB ACS 5000 Training

COU
Pulse encoder (Option)

§ The Pulse Encoder Interface Module (NTAC)


offers an interface for a digital pulse encoder
connection. A pulse encoder should be used if
accurate speed or position (angle) feedback from
the motor shaft is required.

§ Two output channels, marked 1 and 2 or A and B,


are 90° (electrical) apart from each other. When
rotated clockwise, most encoders – but not all – have
channel 1 leading channel 2.
ACS 5000 Training -RevB1
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Fast I/O (Option)

§ The NBIO-21fast I/O –Module contains two fast analog inputs. This
allows a fast modification of the control speed –and / or torque
reference value via external analog inputs. The function can be
disabled or activated independently by parameter. The function is
implemented on the 2ms time level.
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Branching Unit (Option)

§ The NDBU-95 branching units are used for


distributing a DDCS-protocol control link

§ Using NDBU branching units, the usual ring topology


of a DDCS link can be replaced with a star topology,
which is useful to ensure uninterrupted
communication in case one unit on the ring fails or
must be shut down for maintenance.

§ NDBU-95 have one input channel (MSTR) and nine


output channels (CH0 to CH8). All channels on the
NDBU-95 have 10 MBd components.
ACS 5000 Training -RevB1
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Power Supply (X1)


The NDBU-85/95 requires a supply voltage of 24 V d.c. ±10%. The
connection is protected by means of fuse F1 and is galvanically
isolated from earth and the logic circuitry.

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ABB ACS 5000 Training

COU
Branching Unit (Option)
The NDBU units are configured using the jumpers and DIP switches on the circuit
board, which can be accessed by removing the cover of the metal housing.

§ Address (S1)
This switch represents the address as a binary number.

§ Communication Mode (X13)


Jumper X13 (MODE) on the NDBU-95 is set according to
the communication mode used. The default setting is
DDCS/DRIVEBUS.

§ Transmission Speed (X12)


Jumper X12 sets the transmission speed of the NDBU unit.
The setting must match the transmission speed of the
connected equipment.
ACS 5000 Training -RevB1
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Diagnostic LEDs
The diagnostic LEDs on the circuit board of the NDBU unit can be
viewed through the holes in the metal housing.
Each fibre optic channel has two LEDs labelled TXD and RXD. These
indicate messages being transmitted (TXD) or received (RXD). In
normal operation, these LEDs should be flashing continuously on all
channels that are in use.
The +5V OK LED indicates that the logic circuitry of the NDBU is
receiving its supply voltage of 5 V. This LED should be illuminated
when the NDBU is powered.

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Local Control
Control Panel
§ used to start and stop the motor
§ displays status messages of the
converter
§ displays alarm and fault messages
§ used to reset alarm and fault messages

Illuminated Pushbuttons
Alarm / Fault Lamp § OFF opens the main circuit
§ ALARM: flashing light breaker
§ Fault: permanent light § ON charges the DC link and
closes the
Emergency off Switch
§ Main circuit breaker
ACS 5000 Training -RevB1

§ prevents starting when


actuated at standstill Emergency off Reset button
§ main circuit breaker opens
© ABB Ltd - 44 -

and DC link discharges


§ when actuated during operation

The CDP control panel is the basic user interface for operating,
controlling and monitoring the converter.

When the Emergency off pushbutton is pressed during operation, the


following happens:
§ The main circuit breaker opens.
§ The drive coasts down.
§ The message Emergency Off comes up on the control panel
display.

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ABB ACS 5000 Training

COU
Local Control panel
§ An AMC controller is always connected to a
control panel which is mounted on the front of
the corresponding COU.
§ The control panel serves as a basic user
interface for monitoring, control and operation
and changing of parameters.
§ The communication of the AMC controller
with the control panel is accomplished via a
RS-485 link.
§ Same panel than in ACS1000, ACS6000
ACS 5000 Training -RevB1
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ACS 5000A Auxiliary concept (Air Cooled)
The total auxiliary power demand of the converter includes
§ Auxiliary power for the cooling fans and the charging unit (short time
demand)
§ Control power for the control hardware and the gate units.
Depending on the requirements for safe shutdown and the use of the ride-
through functions of the converter the control power must be supplied
separately and backed up by an uninterruptible power supply (UPS).

§ 3 phase supply
§ 3 phase supply and separate UPS with AC output (single phase)
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ACS 5000A No safe line
§ If no uninterruptible power supply is required, the internal auxiliary
backup capacitor for control enables a short-term energy supply of
0.5 s ... 3 s.
§ The total auxiliary power is fed to the converter by a 3 phase supply
with voltages between 380 and 480 VAC.
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ACS 5000A AC safe line
§ External 1-phase UPS supply (110 / 120 or 230 VAC, 50 or 60 Hz)
plus external 3-phase AC supply (same conditions as in the no safe
line concept)
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ACS 5000W Auxiliary concept (Water cooled)
The total auxiliary power demand of the converter includes
§ Auxiliary power for the cooling pumps and the charging unit(short time
demand)
§ Control power for the control hardware and the gate units.
Depending on the requirements for safe shutdown and the use of the ride-
through functions of the converter the control power must be supplied
separately and backed up by an uninterruptible power supply (UPS).

§ 3 phase supply
§ 3 phase supply and separate UPS with AC output (single phase)
§ 3 phase supply and separate UPS with DC output
ACS 5000 Training -RevB1
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ACS 5000W No safe line
§ If no uninterruptible power supply is required, the internal auxiliary
backup capacitor for control enables a short-term energy supply of
0.5 s ... 3 s.
§The total auxiliary power is fed to the converter by a 3 phase supply with
voltages between 380 and 690 VAC.
380 - 690 VAC (No Safe Line)

=LSU =INU =INU 2 (Option) =COU =WCU

28 VDC 28 VDC 28 VDC 28 VDC 28 VDC 28 VDC


10 x 30...40 VDC

10 x 30...40 VDC

10 x 30...40 VDC

10 x 30...40 VDC

10 x 30...40 VDC

10 x 30...40 VDC
M M
2 x 24 VDC
2 x 27 VDC

2 x 24 VDC
2 x 27 VDC

2 x 24 VDC
2 x 27 VDC

2 x 24 VDC
2 x 27 VDC

2 x 24 VDC
2 x 27 VDC

2 x 24 VDC
2 x 27 VDC

24/48 VDC

24 VDC
Charging
ACS 5000 Training -RevB1

Unit
© ABB Ltd - 50 -

The following voltage levels are required: 380 - 690 VAC, 3 phase,
for control and gate unit supply as well as for cooling pumps and
capacitor bank unit charging.

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ABB ACS 5000 Training

COU
ACS 5000W AC safe line
§The control power is fed to the converter separately from the 3 phase
supply and backed up by a UPS.
§ UPS voltage levels: 110 / 230 VAC (AC Safe Line)

380 - 690 VAC


110 / 230 VAC from ext. UPS (AC Safe Line)
=LSU =INU =INU 2 (Option) =COU =WCU

28 VDC 28 VDC 28 VDC 28 VDC 28 VDC 28 VDC


10 x 30...40 VDC

10 x 30...40 VDC

10 x 30...40 VDC

10 x 30...40 VDC

10 x 30...40 VDC

10 x 30...40 VDC
M M
2 x 24 VDC
2 x 27 VDC

2 x 24 VDC
2 x 27 VDC

2 x 24 VDC
2 x 27 VDC

2 x 24 VDC
2 x 27 VDC

2 x 24 VDC
2 x 27 VDC

2 x 24 VDC
2 x 27 VDC

24/48 VDC

24 VDC
Charging
ACS 5000 Training -RevB1

Unit
© ABB Ltd - 51 -

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ABB ACS 5000 Training

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ASC 5000W DC safe line
§The control power is fed to the converter separately from the 3 phase
supply and backed up by a UPS.
§ UPS voltage levels: 110 / 220 VDC (DC Safe Line),

380 - 690 VAC


110 / 220 VDC from ext. UPS (DC Safe Line)
=LSU =INU =INU 2 (Option) =COU =WCU

28 VDC 28 VDC 28 VDC 28 VDC 28 VDC 28 VDC


10 x 30...40 VDC

10 x 30...40 VDC

10 x 30...40 VDC

10 x 30...40 VDC

10 x 30...40 VDC

10 x 30...40 VDC
M M
2 x 24 VDC
2 x 27 VDC

2 x 24 VDC
2 x 27 VDC

2 x 24 VDC
2 x 27 VDC

2 x 24 VDC
2 x 27 VDC

2 x 24 VDC
2 x 27 VDC

2 x 24 VDC
2 x 27 VDC

24/48 VDC

24 VDC
Charging
ACS 5000 Training -RevB1

Unit
© ABB Ltd - 52 -

© ABB Ltd Page 52


© ABB Ltd
ACS 5000 Training -RevB1
ABB

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ACS 5000 Training

Page 53

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