G740 - Control Unit & Terminal Unit - RevB1 PDF
G740 - Control Unit & Terminal Unit - RevB1 PDF
COU
Training objectives
COU
ACS 5000
ACS 5000
Air Cooled
Unit
© ABB Ltd - 3 -
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 -
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
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) :
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
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
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) :
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
COU
ACS 5000
ACS 5000
Water Cooled
Unit
© ABB Ltd - 8 -
COU
ACS 5000W Control Unit & Terminal Unit
(=TEU) (=COU)
ACS 5000 Training -RevB1
Terminal Section
Supply cables for Motor cables
COU
ACS 5000W Terminal Unit
§ Mains cables can be connected to the cabinet
either from the top or through the bottom of the
cabinet
0°
+20°
diode bridge
phase 2
-20°
0°
diode bridge
ACS 5000 Training -RevB1
+20° phase 1
© ABB Ltd - 10 -
COU
ACS 5000W Control Unit
Circuit Breakers
Auxiliary Relays
ACS 5000 Training -RevB1
Auxiliary Transformer
© ABB Ltd - 11 -
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 -
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
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) :
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
COU
ACS 5000
ACS 5000
Air & Water Cooled
Control HW
ACS 5000 Training -RevB1
© ABB Ltd - 15 -
COU
ACS 5000A I/O Configuration
AF100 Bus
FieldBus (e.g. Profibus)
FieldBus (e.g. Modbus)
(=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 -
COU
ACS 5000W I/O Configuration
AF100 Bus
FieldBus (e.g. Profibus)
FieldBus (e.g. Modbus)
AMC
Position/ WCU
Speed Monitoring
encoder (*)
ACS 5000 Training -RevB1
Inverter/MCB/ Customer
E-Off/Charging I/Os (*)
© ABB Ltd - 17 -
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 -
COU
ACS 5000A Control HW Overview (Air Cooled)
Overriding Control System
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
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
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)
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
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
DriveWindow)
INT/PUB board CH7_S800
© ABB Ltd - 22 -
INT/PUB board
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 -
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.
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 -
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 -
COU
PEC-INT board
§ The PEC-INT board includes 2 optical modules with 6 transmitter
/receiver channels
PhaseV_LinkB
PhaseW_LinkA
Earth Fault Supervision from EAF-
ACS 5000 Training -RevB1
A1414 A1415
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 -
COU
ACS 5000A S800 I/O Configuration (Air cooled)
(CxPy) = Cluster x, Position y
AMC33
CH7
Standard Drive
ACS 5000 Training -RevB1
MCB Control
© ABB Ltd - 29 -
Air cooling
control
COU
ACS 5000W S800 I/O Configuration (Water cooled)
AMC33 (CxPy) = Cluster x, Position y
CH7
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 5 AI830
Position 6 AI830
Standard Drive
Related I/O Position 7 DI810/811
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
COU
S800 Modular I/O system
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
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
Bus
COU
S800 I/O Modules
COU
ACS 5000 Training -RevB1
© ABB Ltd - 37 -
I/O modules LED indication
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 -
COU
Gray encoder (Option)
receiver (Rx).
© ABB Ltd - 39 -
COU
Pulse encoder (Option)
COU
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.
ACS 5000 Training -RevB1
© ABB Ltd - 41 -
COU
Branching Unit (Option)
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.
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.
COU
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
The CDP control panel is the basic user interface for operating,
controlling and monitoring the converter.
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
© ABB Ltd - 45 -
COU
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)
ACS 5000 Training -RevB1
© ABB Ltd - 46 -
COU
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.
ACS 5000 Training -RevB1
© ABB Ltd - 47 -
COU
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)
ACS 5000 Training -RevB1
© ABB Ltd - 48 -
COU
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
© ABB Ltd - 49 -
COU
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)
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.
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)
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 -
COU
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),
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 - 53 -
ACS 5000 Training
Page 53