Control
ACS1000 Control
Hardware
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 1
ACS1000 Control Hardware
ACS1000 Control Overview
Standard Boards
Internal Option Modules
Fieldbus Adapter Summary
Control Panel CDP 312
AMC3 board
INT Board
EPS Board
VLSCD Board
ADCVI Board
OVVP Board
SCA Subprint
SVA Subprint
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 2
Control
ACS1000 Control Hardware
IOEC Board
GUSP Board
IGCT
Option module connection to AMC3
Pulse Encoder Interface (NTAC)
Profibus Adapter (NPBA)
Modbus Adapter (NMBA)
CS31 Adapter (NCSA)
Comparison ACS600-ACS1000
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 3
Control
ACS1000 Control Overview
Internal Connections
PANEL
14 DI
6 DO
2 AO
4 AI
IOEC 1
Fan Pump1
DO 1 ORD ON Fan / Pump 1
DI 1 Trip Fan / Pump 1
Service plus
Drive-Windows
Optional Break chopper
Interface
DI 4 DP Cool air SV trip
FOL
DO 2 ORD ON Fan / Pump 2
DI 2 Trip Fan / Pump 2
DI 5 L exp vessel low
Fan Pump2
Control
Electronic power
supply (incl. battery)
FOL
4
Sec. 1
FOL
Sec. 2
Gate Unit Power Supply
FOL
DDE
Aux Fan
DO 6 MCB ORD Trip (low active) aux.
DI 3 Trip aux. Fan
Battery is ON
Gate Drive units
Battery is OK
FOL
Earth isolation switch
Battery ON
DI 10 Earth isolation open
14
DDCS 3
RS485
DI 11 Earth isolation closed
ENABLE
TEST Battery
DO 4 Earth. Isolator Unlocked
FRONT DOOR
OPEN
CLOSED
DO 5 MCB-CLOSED
EARTH. I SOL .
UNLOCKED
LSD-1
AMC-3
DI 6 Pushbutton OFFLINE
UP Short circuit + (FOL)
DI 7 Pushbutton ONLINE
di / dt
PPCS
I filt A I filt C U dc1 U dc2
FCB
DI 8 DISABLE LOCAL
DI 9 Air filter supervision
PPCS
DDCS 2
DO 3 Order ON Motor Heater
I Inv A I Inv C Irerd
AMC-Tabelle
PPCC
LSD-2
EPLD
DI 12 Motor Heater trip
DOWN Short circuit + (FOL)
di / dt
PPCC
ADCVI
DI 13 External Trafo protection trip
Extern
Control und Macros
DI 14 External Motor protection Trip
PPCS 1
AO 1 Raw water control valve ref value
AO 2 TORQUE (Raw water control valve ref value 2 ??)
T
4..20mA
4..20mA
PT100
PT100
4..20mA
I Inv A I Inv C
DDCS 1
PPCC
Optional Fieldbus
Interace
Optional Tacho
Channel A and B
Iinv A
Filter Over-current (FOL)
14 DI
6 DO
2 AO
4 AI
AI 1 Motor WDG Temp U
AI 2 Motor WDG Temp V
AI 3 Motor WDG Temp W
Ifilt C
DC-Overvoltage
Iinv C
Inverter-Overcurrent(FOL)
I Rerd1
MCB
OVPP
open MCB FOL
DC-Overvoltage (FOL)
Intermediate link
overvoltage
Emergency-OFF fol
Macros
Ifilt A
PPCC
Irerd1
IOEC 2 (adr = A)
4..20mA
4..20mA
DDCS 2
DDCS 0
PPCS 3
AI 4 Reference Value 2 Manual
PT100
PPCS 2
AI 2 P coolant
AI 3 Conductivity
4..20mA
External Connections
AI 1 T coolant or T air beef heat sink
(OPTION if needed)
4..20mA
DO 6 MCB order close
U dc1
U dc2
DO 5 MCB order open (low active)
Main circuit breaker
U dc1
U dc2
PPCC
I filt A I filt C U dc1 U dc2
OR
DI 9 MCB open
10
11
12
13
Synch. M1
Synch. M2
Synch. M3
Order ON Output Isolator
Order ON Input Isolator
Input isolator open
Input isolator closed
Output isolator closed
External water cooling alarm
El. Door interlock
BRG Temp NDE actual value
temperature breakchopper trip (> max2)
1
5
DI 2 Forward / Reverse (Manual)
Output isolator open
External water cooling trip
14 DI
6 DO
2 AO
4 AI
IOEC 4
temperature breakchopper alarm (> max1)
Input voltage unbalanced
Motor cooler trip
External motor protection Alarm
BRG Temp DE actual value
DI 1 Start / stop (Manual)
Motor cooler Order ON
AO 2 Current
AO 1 Speed
Vibration SV Trip
4..20mA
Vibration SV Alarm
4..20mA
AI 4 Reference Value 1 Auto
14 DI
6 DO
2 AO
4 AI
Overspeed Trip
A
rpm
4..20mA
Motor Cooling Trip
DO 4 Trip
REMOTE
CONTROL
Motor Cooling Alarm
Oil temp Trip or Trafo winding temp trip
DO 3 Alarm
Buchholz alarm
DO 2 Running
ALARM
Oil level Alarm
RUNNING
T RIP
Oil temp alarm or Trafo winding temp alarm
IOEC 3
DO 1 Ready
Bucholz trip
DI 11 MCB Not available
READY
AI 1 oil temp./ Trafo winding temp. -actual value
DI 10 MCB closed
CUSTOMER
CONTACTS
9 10 11 3 4 5
12 13 14 6
14
DI 3 (macro depending)
DI 6 (macro depending)
DI 7 Remote MCB order close
DI 8 Process_stop
TRANSFORMER
Protection
DI 12 Remote Reset
DI 13 Remote MCB order open
5 DI and 1 AI
DI 14 Emergency-OFF
Intern
MOTOR
Protection
7 DI , 1 DO and 2 AI
Input Voltage
DI 4 (macro depending)
DI 5 (macro depending)
FREE
External
water
cooling
break
chopper
Output
Isolator
Synch. for
PUMP Appl
Input
Isolator
OPTIONS
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 4
FREE
Standard Boards
AMC3 Application and Motor Control Board
NAMC
INT Main Circuit Interface Board
Gate amplifiers with GCTs (x14)
EPS Electronic Power Supply + 2 x GUPS
IOEC Standard I/O Board (2 pcs)
ADCVI,OVVP, VLSCD Meas. & Protection Boards
CDP 312 : CONTROL PANEL
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 5
Control
Internal Option Modules
IOEC3, I/O Extension Board
IOEC4, I/O Extension Board
NTAC2, Pulse encoder
NAIO-02 , Analog IO Extension module
NDNA-01, DeviceNet adapter
NCSA-01, CS31 adapter
NIBA-01, Interbus S adapter
NPBA-02, Profibus adapter
NMBA-01, Modbus adapter
NMBP-01, Modbus plus adapter
NAFA-01, AF100 Fieldbus
Others
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 6
Control
Fieldbus Adapter Summary
Adapter
Protocol
Size of
Link
Transmission
Speed
Control
Original
Vendor
NPBA-02
Profibus-DP
31 stations
9.6...1500 kBit
Siemens
NCSA-01
ABB Procontic
CS31
22 stations
187.5 kBaud
ABB
247 stations
1.2...19.2 kBaud
AEG
NMBA-01 1) Modicon Modbus
1)
NMBP-01
Modbus+
64 stations
1 MBaud
AEG
NDNA-01
DeviceNet
63 stations
125...500 kBaud
Allen-Bradley
NIBA-01 1)
Interbus-S
32 stations (!)
500 kBaud
Phoenix
1)
Ability to Read and Write ACS1000 parameters in the groups 1 to 99.
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 7
Control Panel CDP 312
1 L 1242 rmp I
SPEED 1242 rmp
CURRENT 76 A
POWER 55 %
ACT
PAR
FUNC
DRIVE
ENTER
LOC
REM
RESET
REF
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 8
Control
Mounted on converter door
Local operation of drive
Monitoring actual and reference values
Macros and parameter settings
Fault memory monitoring
Parameter up/down load
RS485 connection with AMC3 board
Control Panel CDP 312
Control
Panel
Display
Status Line
1 L 1242 rmp I
SPEED 1242 rmp
CURRENT 76 A
POWER 55 %
ACT
PAR
FUNC
DRIVE
ENTER
Control
Panel
Keypad
LOC
REM
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 9
RESET
REF
Control
Mode Selection Keys
Up & Double up Arrows,
Enter,
Down & Double Down Arrows
Local/Remote, Reset,
Reference, Start
Forward, Reverse, Stop
LINK B INT1 PPCS1
BOOT EPROM
JTAG / OnCE Connector
DSP processor
RAM
FLASH
LINK A INT0 PPCS0
24Vdc power supply
CH5 DDCS5
CH4 DDCS4
CH3 DDCS3
CH2 DDCS2
CH1 DDCS1
CH0 DDCS0
RS485 bus for panel
Rx
Tx
Rx
Tx
Rx
Tx
Rx
Tx
Rx
Tx
Rx
Tx
CH6 DDCS6
CH7 DDCS7
5conthw1.ppt / Version A / 1998-05-08 / Page 10
Rx
Rx
ABB Industrie AG
Drive Products / IUS
Tx
Tx
Tx
ASIC
Rx
Tx
Rx
LEDs
Control
AMC3 Board
AMC3 Board
(PPCS-PROTOCOL)
IOEC Board
FIELD BUS
APC 2
LINK A
INT Board
CH0
INT0
D3TXD
D3RXD
TXD
RXD
GND
CLK
CLK
+24V_RS
ICMC0-ASIC
A0-15
D0-23
A0-15
D0-23
ICMC1-ASIC
+5V
+3.3V
DGND
+24V_RS
+5V_RS
AGND
CH1
OSCILLATOR
32 MHz
TXD
RXD
D3TXD
D3RXD
D2TXD
D2RXD
D1TXD
D1RXD
D0TXD
D0RXD
+5V_RS
PANEL & BUS INTERFACE
POWER_FAIL
CH2
1 2 3 4 5 6
TRANS
FAULT
X17
CH3
D2TXD
D2RXD
INT1
MASTER /
FOLLOWER
CH4
D1TXD
D1RXD
CH5
DRIVE
WINDOWS
CH6
(PPCS-PROTOCOL)
D0TXD
D0RXD
LINK B
INT Board
TACHO
CH7
FIBER OPTIC LINKS
(DDCS-PROTOCOL)
CONTROL
PANEL
BA+
AGND
+24V_RS
FIBER OPTIC LINKS
(DDCS-PROTOCOL)
Control
CONTROL BUS
GAL
ADDRESS BUS
POWER
RESET
DGND
PROM
32k*8
5V / 3.3V
DATA BUS
FLASH
2048k*8
GND
REAL
TIME
CLOCK
+24V
GND
X14 1 2 3 4
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 11
SRAM
SRAM
SRAM
512k*8 512k*8 512k*8
DSP
56303
OnCE
AMC3 Board
Control
Auxiliary power- on
Auxiliary power 27V for
boards from EPS- board
AMC- board PROM
Purpose
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 12
Color
Description
Red
Green
R
M
Green Power OK
T1&T2
(Traffic)
S0-3
(State display)
Control panel
CDP 312
loading
F
M
T1
S3
S2
Fault
(State.display mode)
Program loading
FLASH--> RAM
7...10 seconds
Red
Green
Yellow
Yellow
Yellow
Green
R
P
T2
S1
S0
Green
Green
Yellow
Yellow
Yellow
Illuminated, when booting up the AMC3
Illuminated, when booting up the AMC3
Software implemented. Not used .
turned on when DDCS-channels 0 (T1)
Yellow LED:s
(APC 2 Field bus) and 3 (T2) (Drive windows)
are receiving data. Hardware implemented.
Yellow
Software implemented. Not used
AMC3 Board
Control
AMC3 Application Motor Controller
AMC3 handles all motor & drive information and status,
motor model, torque and flux calculations, SW protection,
SW tripping levels
AMC3 communicates with the IEOC & INT boards through the
DDCS (Distributed Drive Control System) and
PPCS (Power Plate Control System) channels
Fast DSP 56303 (Digital Signal Processor), 66 MHz
Status indication by Leeds
MMI interface to ABB Support Tool, Drives Windows,
CDP312 Panel, Field buses
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 13
AMC3 Board
Fast SRAM memory 512 x 24 bits (Variables)
Flash memory 2048 k x 8 bit (subprint)
Program code , initial values of SW and parameters
RS485 interface for Modbus communication (panel)
8 DDCS communication channels, 4 MBPS
2 PPCS communication channels, 8 MBPS
Watchdog
Boot-PROM
Galvanically isolated 27VDC power supply
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 14
Control
AMC3 Board
Control
Contents of different memories
SRAM memory: Variables (SW are loaded after booting)
Flash memory: Program code , initial values of SW and
parameters
Boot-PROM:
Booting code for AMC3 board
Replacement of AMC3 board
1)
Change the flash from the old AMC3 board
to the new AMC3 board
2)
Change the AMC3 board with programmed Flash and
download application parameters to Flash the memory
Attention: Check compatibility of FLASH SW with EPLD SW
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 15
A404
TX_AMC0
A541
RX_ADCVI1
A531
RX_ADCVI2
A209
RX_SPARE4
A403
RX_AMC0
FOL
FOL
A210
OVC_M
A592
TX_ADCVI2
FOL
FOL
FOL
A202
OVV_ZK
A302
TX_ADCVI1
FOL
FOL
A201
RX_SPARE3
A551
RX_ADCVI0
FOL
FOL
A204
OVV_ULS2
A402
TX_ADCVI0
FOL
FOL
A203
OVV_ULS1
A303
RX_AMC1
FOL
FOL
A207
PWF_GUSP1
A208
PWF_GUSP2
A304
TX_AMC1
FOL
FOL
A206
RX_SPARE2
LINK E LINK D LINK C LINK B LINK A
FOL
FOL
FOL
A641
OVVP
Control
FOL
A205
RX_SPARE1
INT Board
2x27Vdc
supply
from EPS
X1
FOL
FOL
3 2 1
Control
connector
to EPS
A591
X201
V591
V568
.
.
.
.
.
.
V561
V103
5V
PPCC
FLEX 10K40
V641
PPCC
FOL
FOL
FOL
FOL
FOL
FOL
FOL
FOL
FOL
FOL
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 16
A724
MCBOFF
A712
GUBC1
A713
GUBC2
A593
TX_SPARE1
A594
MCBOFF1
A723
GUP2
A714
GUBC3
A715
GUBC4
A722
GUP1
FOL
FOL
A804
GU10
A814
GU11
A815
GU12
FOL
FOL
FOL
A805
GU9
FOL
A803
GU6
A813
GU7
A705
GU8
FOL
A703
GU5
FOL
A812
GU3
A704
GU4
FOL
A702
GU1
FOL
Green LED V103 lights when internal 5V is OK
Green LED V113 lights when redundant secured 5V for critical function is OK
Red LED V591 lights when EPLD is on booting from A591
Red LED V641 lights when DC overvoltage occurred. (Resetting by aux. power)
FOL
A802
GU2
SR
V113
5V save
Gnd
INT Board
Control
14 gate units
Overvoltage limit (OVVP)
Current limit (Inverter)
Voltage limits +Uls
Voltage limits -Uls
Voltage limits IL
Power fail GUSP1
Power fail GUSP2
Spare
Spare
Spare
Spare
LINK C PPCS - ADCVI0
4 brake chopper
gate units
FORX
FORX
FORX
OVVP - DELAY
AND LATCH
FOTX
FOTX
FOTX
FOTX
FOTX
FOTX
FOTX
FOTX
FOTX
FOTX
FOTX
FOTX
FOTX
FORX
FOTX
FORX
FORX
HARDWIRED
LOGIC
FORX
DRIVER
FORX
FOTX
FORX
FOTX
FORX
FOTX
FORX
FORX
FORX
BOOT-EPROM
EPLD
FLEX 10K40
PPCC
PPCC
+ 5V/3A
GENERAL
DC
FOTX
5conthw1.ppt / Version A / 1998-05-08 / Page 17
FORX
PPCS - AMC 3 LINK B
FOTX
FORX
ABB Industrie AG
Drive Products / IUS
PPCS - AMC3 LINK A
Osz.
FORX
6 galvanic inputs
2 galvanic outputs
MCB_OFF to IOEC1
MCB_OFF1to IOEC2
Spare
FOTX
FOTX
LINK E PPCS - ADCVI2
FOTX
FOTX
FOTX
LINK D PPCS - ADCVI1
FOTX
FOTX
EPS_MAIN_OK
EPS_CTP_OK (+-20V)
EPS_BAT_OK
EPS_BAT_IS_ON
EPS_I_GUSP1
EPS_I_GUSP2
EPS_BAT_TEST (OUTPUT)
EPS_BAT_ON (OUTPUT)
DC
SUPPLY
0V
ORING
NETWORK
+ 5V/1A
SECURED
DC
DC
+
24 V DC
24 V DC
+
INT Board
Control
INT : INTerface board
Control of IGCTs via optic links (also optional Braking
Chopper)
contains EPLD chip for selection of optimum voltage
switching, also for protections
Measurement interface between the current and voltage
measuring board ADCVI to AMC3 Board
Communicates with AMC3 via optic links, receives torque,
flux and sector information from AMC3 Board
Protection signals from ADCVI, GUSPs, OVPP and
VLSCD1/VLSCD2 boards to EPLD and AMC3 Board
Control of EPS (Electronic Power Supply)
MCB control signals through IOEC1 and IOEC2 boards
Galvanically isolated 27VDC power supply
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 18
INT Board
- 12 fiber optic outputs to inverter
- 2 fiber optic outputs to protection igcts
- 4 fiber optic outputs to braking chopper
- 2 fiber optic outputs to IOEC2 board for MCB
- 7 fiber optic inputs for protection
- Galvanic connection to EPS
- 2 PPCS channels for communication with AMC3
- 3 PPCS channels for communication with ADCVI
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 19
Control
EPS Board
Control
EPS ( KU C720 )
R26
2
R24
6
Gr. LED +/- 20V OK
Yel. LED GUSP1 I>1,5A
Yel. LED GUSP2 I >1,5A
V307
V171
V174
V111
V183
Gr. LED 27V supply OK
Gr. LED Battery connected
V186
Yel. LED Battery test on
V177
F101
F113
F112
F109
F110
F111
F108
F107
F106
F105
F104
F103
F102
X101_3
F114
F2
F1
TP101
32VAC
INPUT
X6_3
X6_2
X6_1
X101_4
1 2 3
1 2 3 4
1 2 3 4 5 6
1 2 3 4 5 6
1 2 3 4 5 6
1 2 3 4 5 6
X8
X9
X1
X2
X3
X4
X51
X5
27VDC CONTROL
27VDC
27VDC
27VDC
24VAC 24VAC
E_ISOL 3A INT (1) 3A IOEC3 3A IOEC4 3A SIGNALS
INPUT POWER
RELAIS 3A IOEC 1,2 3A INT (2) 3A GUSP1 10A OVVP 3A BETWEEN
CONDUCT. DC_AC 3A AMC3 3A GUSP2 10A NTAC 3A INT&EPS
MEASUR.. 3A
1 2 3 4
X7
+-20VDC
ADCVI
27VDC output voltage is adjusted with trimmer R262 at factory and maximum output current is limited to 18A with R246
Green battery polarity LED lights when positive wire from battery is put on test pin TP101. F114 is 20A fuse for batteries
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 20
EPS Board
Control
BATTERY 2 * 12V / 6 Ah
575V
480V
400V
32V
DC
AUX.
MAINS
BATTERY MANAGEMENT & INTERFACE
DC
DC
DC
24V AC
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 21
+20V 0V -20V
27V 0V
BTEST
BBATON
MTEST
MBATON
MLGON
MPNON
MIGUSP1
MIGUSP2
EPS Board
Control
EPS : electronic power supply
- Supply for all electronic boards AMC3, INT, ADCVI, OVPP,
GUPS1 and GUPS2 (27 VDC)
- Battery back-up (2 x 12VDC, 6 ah) for 10 minutes keep
IGCTs conducting to avoiding self-excitation
- Battery control (on-off) and supervision (battery test function)
- Supply for external relays (24VAC)
- Auxiliary power failure information to AMC3 via INT
- Galvanically isolated 32 & 24VAC power supply from T1
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 22
EPS Board
Electronic power supply inputs
- 3 x 32 VAC, 50/60 hz from aux. Transformer
- 3 x 24 VAC, 50/60 hz from aux. Transformer
(output to external relays and contactors)
- 24 VDC (2 x 12 V) from battery
Electronic power supply outputs
- 14 x 27 VDC, max 16 A for boards and GUSP
- +20 VDC, max 45 W for ADCVI board
- 24 VAC, 50/60 hz, max 50 VA for external relays
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 23
Control
VLSCD Board
Control
VLSCD
Rectifier
bridge
Vls1
+
+
Ia
Inverter
bridge
Motor
NP +
Ib
Vls2
VLSCD
Optical fiber to INT board
Z2
HFBR 1528
R5
VLSCD
Z3
LS choke
LS choke
R1
R2
C1
Z1
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 24
R3
R4
VLSCD Board
Control
VLSCD : Voltage Level Short-Circuit Detection
- Short-circuit detection in the inverter power stage
- Detection is based on the measurement of voltage across the
commutation reactors
- Separate protection for + and - parts of the inverter
- Optical signal informs when commutation is going on in
inverter
If signal lasts too long (over 10us) -> short-circuit indication
If signal does not appear every 50ms, when inverter operates
with sufficient load current -> VLSCD fault detection
- short circuit in output terminals detected by currentmeasuring transducers (overcurrent)
Caution: VLSCD board is at intermediate DC potential
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 25
ADCVI Board
Control
NP
PPCC
ASIC
CH 0
PPCC
ASIC
CH 2
SVA
VOLTAGE ADJUST
X3
Iw
X4
Iuf
PPCC
ASIC
CH 1
INSULATION
Iu
X6
SCA Iwf
X7
-15V
CURRENT ADJUST
Ignd
X8
+15V
-DCBUS
PE
CH 0
A8
A1
TX RX
LINK C
CH1
A9 A2
A6
TX RX
TX RX
TX TX
IOC INVERTER / FILTER OVERCURRENT
DCOV DC OVERVOLTAGE
POWER SUPPLY OK LEDs +5V +15V AND -15V
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 26
X1 -
+5V
CH 2
A10 A3
LINK D LINK E
+
+
+
+
+
A4
PE
IOC DCOV
CURRENT
TRANSDUCERS
ADCVI BOARD
+DCBUS
POWER
+ SUPPLY
+/- 20V
ADCVI Board
5M
Control
5M
+DCBUS
NP
+
-
-DCBUS
voltage adjust
1 +20V
2
3 -20V
IUinverter
RANGE
ADJUST
+DC
FILTER
/ -DC
DCBUS NOMINAL =
IWinverter
X4
( 4kV or 3.3kV or 2.4kV )
x
2 x 1.045
IUinv, IWinv, Ignd/5.33
A4
IUfilter
R
C
RANGE
ADJUST
1 +20V
2 IW filter
3 -20V
X7
1 +20V
Iearth
2
3 -20V
current adjust
X6
AGND
COMMUNICATION
&
DATA TRANSFER
IUinv.
FILTER
IWinv. PPCC ASIC
+DC CHANNEL 0
Temp
OVER LIMITS
SUPERVISION
A6
DCOV 129% DCBUS
( nominal)
IOC 220% Iinverter
( nominal)
A8
LINK C
A1
IUfil
SCA
X8
1 +20V
0V
2
3 -20V
AGND
SVA
AGND
1 +20V
2
3 -20V
DIFFERENTIAL
MEASURING
1 +20V
2
3 -20V
X3
power
supply
burden
resistors
AGND
Temperature
Sensor
Earth
+15V
-15V
+5V
X1
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 27
AGND
IWfil. PPCC ASIC
-DC CHANNEL 1
LINK D
0V
A2
-10C ....+ 76C
Ignd
0V
0V
0V
DGND
A9
PPCC ASIC
CHANNEL 2
A10
LINK E
A3
ADCVI Board
Control
ADCVI : analogue-digital current-voltage interface
- Measuring of converter DC voltage (DC+ and DC-)
- HW protection of DC overvoltage
- Measuring of converter currents (2 inverter output currents,
2 filter currents and earth current)
- HW overcurrent protection for inverter
- Temperature measurement of by PTC
- 3 PPCC communication channels to interface board
(measured current and voltage values)
- Fiber optic links to trip inverter in overcurrent and overvoltage
- SCA subprint make current adaptation
- SVA subprint make voltage adaptation
Caution:
ADCVI board is connected to intermediate DC potential
via high ohmic resistors
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 28
OVVP Board
5M
5M
5M
5M
NP
-DC
5M
5M
ELECTRONICS
SVA
SUBPRINT
+DC
Control
-15V OK
OVP
+15V OK
power 27VDC
OVVP OVERVOLTAGE PROTECTION AGAINST SELF EXITATION
POWER SUPPLY OK LEDS FOR -15V AND 15V
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 29
OVVP Board
Control
OVVP BOARD
SVA SUBPRINT
5M
5M
+DCBUS
47K5
+DCBUS
+
+
-
+
+
5M
DCBUS NOMINAL =
+
+DC
( 4kV or 3.3kV or 2.4kV )
x
2 x 1.045
COMPARATOR
139%DCBUS
( nominal)
NP
-
47K5
NP
5M
DIFFERENTIAL
MEASURING
OPTICAL TRANSMITTER
+
-
+
-DC
-DCBUS
5M
-DCBUS
COMPARATOR
47K5
5M
+15V
+27V
DC
AGND
-15V
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 30
DC
FROM
EPS
GND
OVVP Board
Control
OVVP : overvoltage protection board
- Supervises DC overvoltage against self-excitation
- Fiber optic output to trip the MCB in case of overvoltage
(Self-excitation)
- Powered separately by EPS
- SVA subprint make voltage adaptation
Caution: OVVP board is connected to intermediate DC potential
via
high ohmic resistors
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 31
SCA Subprint
Control
SCA : Subprint Current Adjust
- SCA subprint adjust different current ranges (17)
- SCA subprint is used together with ADCVI board.
- ADCVI board is common for all power ranges and SCA
has to be selected in order to adjust current measuring.
40 - 50 mm
5
1
8
4
X1
X2
5
1
TW O
8 POLE CONNECTORS
SCA 5140A
X3
4 8
ABB INDUSTRIE AG
HIEE YYYXXXA
8
4
UF CXXYYAE
40 - 60mm
1 5
SCA Subprint
8 POLE CONNECTOR
10mm
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 32
ADCVI BOARD
COMPONENT SIDE
SCA Subprint
POWER TYPE
AND CURRENT
TRANSFORMER TYPE
3823A
ES300 (motor & filter)
3833A
ES300 (motor & filter
3840A
ES300 (motor & filter)
5123A
ES500 (motor & filter)
5133A
ES500 (motor & filter)
5140A
ES300 (motor & filter)
6823A
ES500 (motor & filter)
6833A
ES500 (motor & filter)
6840A
ES500 (motor & filter)
6823W
ES500 (motor & filter)
6833W
ES500 (motor & filter)
6840W
ES500 (motor & filter)
9123WR
ES2000 (motor & filter)
9133WR
ES2000 (motor & filter)
9140WR
ES1000 (motor & filter)
9133W
ES2000 (motor & filter)
9140W
ES1000 (motor & filter)
Control
Inverter nominal
current / Measuring
range
190Arms
570Apeak
150Arms
450Apeak
115Arms
345Apeak
335Arms
1005Apeak
270Arms
810Apeak
190Arms
570Apeak
440Arms
1320Apeak
360Arms
1080Apeak
250Arms
750Apeak
650Arms
1950Apeak
500Arms
1500Apeak
380Arms
1140Apeak
920Arms
2760Apeak
700Arms
2100Apeak
580Arms
1740Apeak
920Arms
2760Apeak
750Arms
2250Apeak
Filter nominal
current / measuring
range
190Arms /
570Apeak
150Arms
450Apeak
115Arms
345Apeak
335Arms
1005Apeak
270Arms
810Apeak
190Arms
570Apeak
440Arms
1320Apeak
360Arms
1080Apeak
250Arms
750Apeak
650Arms
1950Apeak
500Arms
1500Apeak
380Arms
1140Apeak
920Arms
2760Apeak
700Arms
2100Apeak
580Arms
1740Apeak
920Arms
2760Apeak
750Arms
2250Apeak
Earth current
SAP Code
RFB resistance
3BHL2953R0001
15.78
0.5W
20.00
0.5W
26.087
0.33W
22.39
0.33W
27.78
1W
15.79
0.5W
17.045
0.5W
20.8333
0.4W
30.00
0.33W
11.54
0.5W
15
0.5W
19.74
0.4W
8.15
0.8W
10.71
0.8W
12.93
0.5W
8.15
0.8W
10.0
0.7W
(measuring range =
56.25% Iinv)
ES-300
107A 84.21 / 0.3W
ES-300
84.4A 106.7 / 0.2W
ES-300
64.7A 139.13 / 0.15W
ES-300
188.44A 47.76 / 0.5W
ES-300
151.88A 59.26 / 0.5W
ES-300
107A 84.2 / 0.3W
ES-300
247.5A 36.36 / 0.7W
ES-300
202.5A 44.44 / 0.5W
ES-300
140.625A 64 / 0.33W
ES-300
365.6A 24.61 / 0.85W
ES-300
281.25A 32 / 0.6W
ES-300
213.75A 42.1 / 0.5W
ES-300
517.5A 17.4 / 1W
ES-300
394A 22.86 / 0.9W
ES-300
326.25A 27.58 / 0.75W
ES-300
517.5A 17.4 / 1W
ES-300
421.9A 21.33 / 1W
3BHL2953R0002
3BHL2953R0003
3BHL2953R0004
3BHL2953R0005
3BHL2953R0006
3BHL2953R0007
3BHL2953R0008
3BHL2953R0009
3BHL2953R0010
3BHL2953R0011
3BHL2953R0012
3BHL2953R0013
3BHL2953R0014
3BHL2953R0015
3BHL2953R0016
3BHL2953R0017
table 1: Nominal and Maximal currents for each power type
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 33
SVA Subprint
Control
SVA : Subprint Voltage Adjust
- SVA subprint adjust the interface boards OVVP and
ADCVI to the different voltages ( 4k16V / 3k3V / 2k4V)
ATTENTION:
4K16V
2K4V
soldering
bridges
4K16V
3K3V
2K4V
4K16V
3K3V
2K4V
In order to get the correct identification (part number and code),
the adjusting of the subprint to the right voltage has to be made in
ABB Industrie AG CH-5300. ABB will deliver the subprint with the
correct adjust and part number to all distributor centers worldwide.
ABB INDUSTRIE AG
CODE
PART NUMBER
3K3V
SVA BOARD (SOLDERING SIDE)
10 mm
The differential voltage measuring is performed by voltage dividers
with high voltage resistors and very precise operational amplifiers.
The different types of SVA subprint are provided by connecting two
soldering points soldering side of the board) in order to perform the
right voltage divider of the wished voltage.
Inverter type
Line voltage Motor voltage
2400 Vac
3300 Vac
4160 Vac
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 34
2400Vac
3300Vac
4160Vac
Voltages
Maximal measuring
type
voltage range
0 - 2425 Vdc
SVA2K4
0 - 3475 Vdc
SVA3K3
0 - 4200Vdc
SVA4K16
IOEC Board
Control
Setting of analog inputs is made by dip switches
AI_ 20mA AI_ 10V
ON
OFF
Current input 4-20mA
OFF
ON
Voltage input 0-10V
ON
ON
Current input, wrong amplification
OFF
OFF
Voltage input, wrong amplification
IOEC board address has to be selected by node address
switch: IOEC1->2, IOEC2->4, IOEC3->6, IOEC4->8
Node address Solder joint for
switch
direct MCB_OFF
X6
1
V740
Gnd
V504
V514
V107
V524
V534
V544
V117
V127
V137
V147
V157
V177
V187
V197
V207
V217
V227
V237
V554
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 35
X31-1
X32-1 X31-2
X32-2 X31-3
X32-3 X31-4
X32-4 X31-5
X32-5 X31-6
X32-6 X31-7
X32-7
X11-1
X11-2
X11-3
X11-4
X11-5
X11-6
X11-7
X11-8
X11-9
X11-10
X12-1
X12-2
X12-3
X12-4
X12-5
X12-6
X12-7
X12-8
X12-9
X12-10
X13-1
X13-2
X13-3
X13-4
X13-5
X13-6
X13-7
X13-8
X13-9
X13-10
X26-1
X26-2
X26-3
X25-1
X25-2
X25-3
X24-1
X24-2
X24-3
X23-1
X23-2
X23-3
X22-1
X22-2
X22-3
X21-1
X21-2
X21-3
1
2
3
4
ON
ON
AI1
AI1
AI2
AI2
V726
20mA
10V
20mA
10V
A451
AI3
AI3
AI4
AI4
A405
MCBOFF
1
2
3
4
A403
TX_DDCS
20mA
10V
20mA
10V
RX_DDCS
V167
V402
IOEC Board
Control
6 DO
14 DI
>1
>1
MCB - DO
2 AO
I
U
I
U
4 AI
10V
DC
DC
FORX
24V
A
DC
24 V DC
D
+15V
DC
BIO
- 15V
FORX
IOCC
+ 5V
DC
PWM1
PWM2
Node adr.
Reset Osz.
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 36
MCB_OFF
Uref
DC
FOTX
DDCS1
IOEC Board
Control
IOEC = Input-Output Electronic Card
Analog and digital interface of the converter:
-14 Digital inputs, 230 VAC / 20 ...160VDC
- 6 Digital outputs, max. switching voltage:
120 VDC/ 250 VAC, max. currents: 24 VDC 8 A ,
125 VDC 0.4 A , 250 VAC 8 A
- 4 Analog inputs, 4-20 mA or 0-10 V, 10 bit 0,25% +-30mV
- 2 Analog outputs, 4-20 mA , 12 bit 0,25% +-0,1mA ,
Load max.250 ohm.
Optical DDCS link for communication (4 Mbit/s)
Converter has 2 IOEC boards as standard , 2 optional
Interrogation voltage 24Vdc+-20% limited to 180mA by PTC
can be supplied from IOEC board
IOEC is monitored by SW
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 37
IOEC Board
Control
Isolation levels of i/os:
- DI: input-input 2300VAC , input-logic 1350VAC ,
Input-ground 1350 VAC
- Do:
4000 vac
- AI: input-input 350VAC 60 hz , input-logic 350 VAC 60 hz ,
input-ground 350VAC 60 hz
- AO:
output-output 350VAC 60 hz , output-logic 350VAC 60 hz
,
output-ground 350VAC 60 hz
Status indication leds for power supply green V740 , for
interrogated supply green V726 , for communication fault red
V402 and for digital inputs and outputs yellow leds
If soldering pads are soldered together, DO5 and DO6 will be
deactivated and controlled via fiber optical MCB_OFF input.
(Light: DO5 and DO6 relay outputs on, no light: relays off)
Caution: risk of external voltage
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 38
GUSP Board
Control
GUSP1
EPS
Sub-board 1
GU
Power supply
22.4 ....28.4V
Sub-board 2
GU
Sub-board 3
GU
Sub-board 4
GU
Sub-board 5
GU
Sub-board 6
GU
Sub-board 7
GU
Main
board
GUSP2
CONNECTION OF GATE UNITS
( 20 Volt + 0.5 Volt, 4A )
GALVANIC ISOLATION BETWEEN SUB-BOARDS
GALVANIC ISOLATION BETWEEN LOW AND MIDDLE VOLTAGE SIDE
Main-board
Sub-boards
From supply
22.4 . . 28.4 V
X1:4 (0V)
X1:3 (+24V)
20 Volt
Filter
15 Volt Supply
Monitoring
signal for
INT-board
A1
Chopper
controlled
supply
transformer
for sub-boards
20 Volt
Control
Monitoring
ISOLATION TRANSFORMER
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 39
Short circuit 0 Volt
Protection
GUSP Board
GUSP: gate unit supply power
- GUSP = main board + transformer + sub-boards (7pcs)
- Powering of igcts
- Isolation transformer separates inverter potential from
supply voltage (27VDC) by EPS
- In self-excitation, both power supplies have battery
back-up for 10 minutes to keep motor short-circuited
- Fiber optic link to control electronics to indicate fault.
Fault indication -> no solid light come on case of switching
loss (one or both primary windings) or supply under
21,5vdc
- Indication leds in sub-board
Caution: sub-boards of GUSP and transformer secondary are at
inverter potential (medium voltage)
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 40
Control
GUSP Board
Control
Sub-board has two indications LED
Yellow LED
Green LED
light
State of control sub-board
light
Output state operate correctly, no over load
weak light
blink
Output state operates correctly, over load /
short circuit in output: output voltage has
dropped under 10V, sub-board will try
continually switch in.
no light
light
LED or serial resistance defect
no light
no light
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 41
Supply voltage loss or control sub-board defect
IGCT
Control
IGCT = GCT + Gate Driver
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 42
IGCT
Control
Inverter and protection IGCTs (6 types) for air cooled types:
38/51/68mm/4,5kv for 2,3kv and 3,3kv units
38/51/68mm/6,0kv for 4,0kv units
Gate unit is integrated with the GCT, each GCT has its own
gate unit
Gate unit is fed by GUSP (20vdc +-0,5V)
Fiber optic link to INT (interface) card to receive
commands of GCT switching (receive light -> turn on the
GCT)
Separate channels for turn-on, continuous gate current
and turn off
LED status indications only in GUSP sub-board
Caution: gate unit and cables between GU- and GUSP
board are at inverter potential (medium voltage)
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 43
IGCT
Control
GATE UNIT
20V DC
Supply
From EPS
Turn
on
circuit
Gate
Turn
off
circuit
Cathode
Logic,
Monitoring
Control signal
(Light)
Rx
From INT
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 44
IGCT
Control
Fault behavior of gate unit
Cause
Effect to Gate Unit
Reaction of Gate Unit
GCT is switched too fast Under voltage on capacitors
or turn off circuit of Gate of Gate Unit
Unit is in short circuit
1. If a turn-off pulse is not possible, the following
a turn on pulse is ignored.
2. When requirements for a turn off pulse are again
fulfilled a switching signal can be executed.
No supply or too low supply
voltage
1. If a turn-off pulse is not possible, the following
turn on pulse is ignored.
2. When requirements for a turn off pulse are again
fulfilled a switching signal can be executed.
loss of GUSP
3. If VGU falls below 10V. This is detected as
a short circuit between the gate and the cathode.
Short circuit impedance must be very small and
that state must stand 5 minutes
Auxiliary supply or
cooling fan
Six Gate Units will be turned on
(0-Vector). This state will remain
15 minutes without inverter
cooling. Surface temperature
of heat sinks can be 60C in the
beginning and falls to ambient
temperature of inverter in time
constant about 3 minutes.
Other loss of Gate Unit
Undefined effect
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 45
Gate Unit must hold this load.
Undefined Reaction. Switching circuit of the Gate
Unit is protect against fault propagate by GUSP.
Option module connections to AMC3
ACS 1000
AMC 3
NTAC-02
Pulse encoder
NMFA-01
Master Field Bus
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 46
Control
Pulse Encoder Interface (NTAC)
CONNECTIONS
Supply
Earthings
Tacho
Fiber optic link
+24V
0V
24
15
Control
24/15
+V
-V
X2
SETTINGS
See Installation and Start-up Guide
Node address
TXD
NTAC-02
PULSE
ENCODER
INTERFACE
PARAMETERS IN ACS1000
See Users Manual
Activation P75.03
Parameters in group 50
.
.
.
RXD
X1
A+
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 47
A-
B+
B-
Z+
Z-
SH
PE
Profibus Adapter (NPBA)
CONNECTIONS
Supply
Earthings
PROFIBUS bus cable
Fiber optic link
Control
PE
+24V
X2
RXD
0V
SH
SHF
DG
D(N)
D(P)
SETTINGS
See Installation and Start-up Guide
Bus termination
TXD
PARAMETERS IN ACS1000
See Users Manual
Activation P75.04
Parameters in group 51
.
.
.
PROFIBUS
ADAPTER
MASTER
BUS
TERMINATION
MSG
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 48
ON
OFF
DDCS
INDICATION LEDs
NPBA-01
Modbus Adapter (NMBA)
CONNECTIONS
Supply
Earthings
MODBUS bus cable
Fiber optic link
SETTINGS
See Installation and Start-up Guide
Bus termination
PARAMETERS IN ACS1000
See Users Manual
Activation P75.04
Parameters in group 51
.
.
.
INDICATION LEDs
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 49
Control
CS31 Adapter (NCSA)
CONNECTIONS
Supply power
Earthings
CS 31 bus cable
Fiber optic link
Control
PE
X2
SH
SHF
DG
D(N)
RXD
SETTINGS
See Installation and Start-up Guide
Bus termination
TXD
CS 31
ADAPTER
PARAMETERS IN ACS1000
See Users Manual
Activation P75.04
Parameters in group 51
.
.
.
DDCS
BUS
TERMINATION
UART
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 50
ON
OFF
ERROR
INDICATION LEDs
NCSA-01
D(P)
Comparison ACS600-ACS1000
Main Motor Control
ACS600
ACS1000
Motor Control Board
NAMC1
AMC3
Digital Signal Processor 40 Mhz
66 Mhz
Communication DDCS
8 channels
4 channels
Communication PPCS
Control
2 channels
RAM memory
3 x 128 k
1 x 512 k
Flash memory
512k
2M
Controlling inverter
2 level (8 switching
positions)
3 level (27 switching
positions)
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 51
Comparison ACS600-ACS1000
Standard I/O Boards
ACS600
ACS1000
I/O Board
1x NIOC-01
2 x IOEC
Number of DI
6 pcs
14 pcs
Number of DO
3 pcs
6 pcs
Number of AI
3 pcs
4 pcs
Number of AO
2 pcs
2 pcs
ABB Industrie AG
Drive Products / IUS
5conthw1.ppt / Version A / 1998-05-08 / Page 52
Control
