ABB ACSM1-204 Installation manual

ACSM1

Quick Installation and Start-up Guide

ACSM1-204 Regen Supply Module

English . . . . . . . . . . . . . . . 3

Appendix. . . . . . . . . . . . . 13

3AUA0000060576 REV A

Effective: 2009-10-05

ACSM1-204 Quick Quide.book Page 1 Tuesday, October 6, 2009 11:02 AM

List of related manuals in English

REGEN SUPPLY MODULE MANUALS Code (EN)

ACSM1-204 Regen Supply Modules Hardware Manual 3AUA0000053713

ACSM1-204 Regen Supply Modules Firmware Manual 3AUA0000052174

ACSM1-204 Quick Installation and Start-up Guide 3AUA0000060576

WFU-xx Regen Filter Module Quick Installation Guide 3AUA0000055334

DRIVE MODULE MANUALS Code (EN)

ACSM1-04 (0.75 to 45 kW) Drive Modules Hardware Manual 3AFE68797543

ACSM1-04 (0.75 to 45 kW) Drive Modules Quick Installation Guide 3AFE68797551

ACSM1-04 (55 to 110 kW) Drive Modules Hardware Manual 3AFE68912130

ACSM1-04/04Lx (55 to 160 kW) Drive Modules Quick Installation

Guide

3AFE68971853

ACSM1-04LC (55 to 132 kW) Liquid-Cooled Drive Modules

Hardware Manual

3AUA0000022083

ACSM1-04 Drive Modules System Engineering Manual 3AFE68978297

OPTION MANUALS Code (EN)

FCAN-01 CANopen Adapter Module User's Manual 3AFE68615500

FDNA-01 DeviceNet Adapter Module User's Manual 3AFE68573360

FPBA-01 PROFIBUS DP Adapter Module User's Manual

ACSM1 Fieldbus Control with FPBA-01 PROFIBUS DP Adapter

Module and ABB AC500 PLC Application Guide

3AUA0000049359

FSCA-01 RS-485 Adapter Module User’s Manual 3AUA0000044530

FENA-01 Ethernet Adapter Module Hardware Manual 3AUA0000022986

FENA-01 Ethernet Adapter Module Modbus/TCP Protocol Manual 3AUA0000022989

FENA-01 Ethernet Adapter Module Ethernet/IP Protocol Manual 3AUA0000033371

FIO-01 Digital I/O Extension User's Manual 3AFE68784921

FIO-11 Analog I/O Extension User's Manual 3AFE68784930

FIO-01 Digital I/O Extension Quick Guide 3AFE68784981

FIO-11 Analog I/O Extension Quick Guide 3AFE68784999

Manual downloads: www.abb.com/drives > Document Library

ACSM1-204 Quick Quide.book Page 2 Tuesday, October 6, 2009 11:02 AM

Quick installation and start-up guide – ACSM1-204 3

Quick installation and start-up guide – ACSM1-204

About this guide

This guide contains very basic information about the mechanical and electrical

installation, and start-up of the ACSM1-204 regen supply module.

System overview

The ACSM1 regen supply feeds power to ACSM1-04 drive modules. The regen

supply can also feed braking power back to the supply network. The regen supply

consists of a regen filter module (WFU-xx) and regen supply module (ACSM1-204).

The regen filter module is always needed in the system to operate the regen supply

module.

Applicability

This manual applies to the ACSM1-204 regen supply module (frame sizes A to D).

For instructions on installing the regen filter module, see WFU-xx Regen Filter

Module Installation Guide and ACSM1-204 Regen Supply Modules Hardware

Manual.

Compatibility

ACSM1-204 modules are compatible with ACSM1-04 drives (frames A-D).

Input power line

No. Description

1 Main disconnector

2 Fuses

3 Main contactor

4 WFU-xx regen filter module.

5 ACSM1-204 regen supply module

6 ACSM1-04 drive module(s)

7ACmotor

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4 Quick installation and start-up guide – ACSM1-204

Related documents

For a list of related documents in English, see the inside of the front cover.

Safety instructions

WARNING! All electrical installation and maintenance work on the regen

supply module should be carried out by qualified electricians only.

WARNING! Never work on the regen supply module or regen filter module

when input power is applied to the drive system. Always ensure by measuring

that no voltage is present.

WARNING! Do not use the regen supply module without a regen filter

module.

Planning the installation

• The ACSM1-204 is an IP20 (UL open type) regen supply module to be used in a

heated, indoor controlled environment. The regen supply module must be

installed in clean air according to enclosure classification. Cooling air must be

clean, free from corrosive materials and electrically conductive dust. See the

Hardware Manual for detailed specifications.

• The maximum ambient air temperature is 40 °C (104 °F) at rated current. The

current is derated for 41 to 55 °C (104 to 131 °F). See the Hardware Manual for

more information on derating.

• The regen supply module is suitable for use in a circuit capable of delivering not

more than 100,000 rms symmetrical amperes, 480 V maximum.

• The cables located within the motor circuit must be rated for at least 75 °C

(167 °F) in UL-compliant installations.

• The input cable must be protected with fuses or circuit breakers. The DC cable

must be protected with DC fuses. Suitable IEC and UL fuses are listed in the

Technical data section of ACSM1-204 Regen Supply Modules Hardware Manual.

For suitable circuit breakers, contact your local ABB representative.

• For installation in the United States, branch circuit protection must be provided in

accordance with the National Electrical Code (NEC) and any applicable local

codes. To fulfill this requirement, use the UL classified fuses.

• For installation in Canada, branch circuit protection must be provided in

accordance with Canadian Electrical Code and any applicable provincial codes.

To fulfill this requirement, use the UL classified fuses.

ACSM1-204 Quick Quide.book Page 4 Tuesday, October 6, 2009 11:02 AM

Quick installation and start-up guide – ACSM1-204 5

Mechanical installation

Fasten the regen supply module to the mounting base using screws through the four

mounting holes. Frame A and B can be mounted onto a DIN rail, but it is

recommended to fasten the modules to the mounting base also by two screws

through the lower mounting holes.

Fasten the regen filter module as instructed in WFU-xx Regen Filter Module

Installation Guide.

Installing the power cables

Connection diagram

Connection procedure

Cabling examples are presented on page 7. Tightening torques are presented on

page 8and at appropriate points in the text. For power cable connections in an

installation example, see Appendix on page 13.

• Attach the terminal blocks included to the regen supply module.

•Frame sizes C and D only: Remove the two plastic connector covers at the top

and bottom of the regen supply module. Each cover is held by two screws.

• On IT (ungrounded) systems and corner-grounded TN systems, remove the

screw labeled VAR located close to the supply terminals. Also, remove the screws

ACSM1-204

WFU-xx

L1 L2 L3

U2 V2 W2 PE U2 V2 W2 PE

U1 V1 W1

UDC+UDC-

R+ R-

V1 W1 PE

ACSM1-04

U2 V2 W2 PE

U1 V1 W1

UDC+UDC-

R+ R-

Input power line

No. Description

1 Main disconnector and fuses (switch fuse)

2 Main contactor

3DCfuses

4 Brake resistor (optional)

3) 3)

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6 Quick installation and start-up guide – ACSM1-204

labeled VARISTOR (1 screw) and FILTER (2 screws) in the regen filter module

(under the cover).

• Fasten the two cable clamp plates included with the regen supply module, one at

the top, one at the bottom. The clamp plates are identical.

• Strip the DC cable and resistor cable (if present) so that the cable shields are bare

at the cable clamps. Connect the ends of the cable shields to the ground terminals

using cable lugs. Cover visible bare shield with insulating tape.

• Connect the DC cable and resistor cable to the appropriate terminals.

• Tighten the cable clamps onto the bare cable shields of DC cable and resistor

cable.

• Connect the AC supply conductors and PE conductor to the appropriate

terminals.

• Tighten the cable clamp onto the AC supply conductors and PE conductor, or tie

the conductors to the clamp with a cable tie.

•Frame sizes C and D only: Cut suitable slots on the edges of the connector

covers to accommodate the cables. Refit the covers.

• Connect the filter temperature monitoring cable of the WFU-xx regen filter module

to the thermistor input (X4:8, 9) in the regen supply module.

• Connect the fan control cable of the WFU-xx regen filter module to

DIO1 (X3:14, 15) in the regen supply module.

Frames A and B:1.5 N·m (13 lbf·in)

Frames C and D: 3 N·m (25 lbf·in)

1.5 N·m (13 lbf·in)

ACSM1-204 Quick Quide.book Page 6 Tuesday, October 6, 2009 11:02 AM

Quick installation and start-up guide – ACSM1-204 7

Cabling examples

U1 V1 W1

U2 V2 W2 R+R-

UDC+UDC-

U2 V2 W2

U1 V1 W1

R- R+

Frame size A Frame size B

Frame sizes C and D

Cable clamp on bare shield.

Bare shield. Cover with insulating tape.

Screw lug detail:

Connection to the drive modules.

Connection to the regen filter module.

Strain relief: draw conductors under clamp

or tighten conductors to clamp with cable

tie.

Connection to the brake chopper (optional).

UDC+ UDC- UDC+

Lb/

UDC+

La/

La/ Lb/

ACSM1-204 Quick Quide.book Page 7 Tuesday, October 6, 2009 11:02 AM

8 Quick installation and start-up guide – ACSM1-204

Recommended wire sizes

Filter unit mains supply cable

DC cable

Tightening torques

Installing the control cables

Wiring the main contactor connection

Equip the installation with a main contactor that opens if the regen supply module

trips on a fault.

Regen supply module

frame size

Wire size Wire size (AWG)

A1.5…4mm

215 … 12

B 2.5 … 6 mm213 … 10

C10…70mm

27 … 2/0

D25…70mm

23 … 2/0

Regen supply module

frame size

Wire size Wire size (AWG)

A1.5…4mm

215 … 12

B4…6mm

212 … 10

C10…70mm

27 … 2/0

D35…70mm

22 … 2/0

Regen supply module

frame size

Power terminals (supply and

braking resistor cables)

Screw lug

(Allen screw)

N·m (lbf·in) N·m (lbf·ft)

A 0.5 … 0.6 (4.4 … 5.3) N/A

B 1.2 … 1.5 (10.6 … 13.3) N/A

C or D 3 (25) 15 (11)

Regen supply module

frame size

PE/Ground

terminals

Power cable

clamps

Power connector

covers

N·m (lbf·in) N·m (lbf·in) N·m (lbf·in)

A 1.5 (13) 1.5 (13) N/A

B 1.5 (13) 1.5 (13) N/A

C or D 3 (25) 1.5 (13) 3 (25)

ACSM1-204 Quick Quide.book Page 8 Tuesday, October 6, 2009 11:02 AM

Quick installation and start-up guide – ACSM1-204 9

Default I/O connection diagram

Notes:

*Total maximum current: 200

Wire sizes and tightening

torques:

X2: 0.5 … 2.5 mm2 (24…12

AWG). Torque: 0.5 N·m (5 lbf·in)

X3, X4, X5, X6:

0.5 … 1.5 mm2(28…14 AWG).

Torque: 0.3 N·m (3 lbf·in)

1) WFU-xx cooling fan control

2) WFU-xx temperature

supervision

External power input

24 V DC, 1.6 A

+24VI 1

GND 2

Relay output

250 V AC / 30 V DC

2 A

NO 1

COM 2

NC 3

+24 V DC* +24VD 1

Digital I/O ground DGND 2

Digital input 1: Stop/start (EXT2) DI1 3

Digital input 2: EXT1/EXT2 DI2 4

+24 V DC* +24VD 5

Digital I/O ground DGND 6

Digital input 3: Fault reset DI3 7

Digital input 4: Force stop DI4 8

+24 V DC* +24VD 9

Digital I/O ground DGND 10

Digital input 5: Not connected DI5 11

Digital input 6: Not connected DI6 12

+24 V DC* +24VD 13

Digital I/O ground DGND 14

Digital I/O 1: Fan control signal (output) DIO1 15

Digital I/O 2: Running (output) DIO2 16

+24 V DC* +24VD 17

Digital I/O ground DGND 18

Digital I/O 3: Fault (output) DIO3 19

Reference voltage (+) +VREF 1

Reference voltage (–) -VREF 2

Ground AGND 3

Analogue input 1: Not connected AI1+ 4

AI1- 5

Analogue input 2: Not connected AI2+ 6

AI2- 7

AI1 current/voltage selection J1

AI2 current/voltage selection J2

Thermistor input TH 8

Ground AGND 9

Analogue output 1 (current) AO1 (I) 10

Analogue output 2 (voltage) AO2 (U) 11

Ground AGND 12

Drive-to-drive link termination J3

Drive-to-drive link. B 1

BGND 3

Not in use. Both circuits must be closed

with jumpers for the regen supply

module to start.

OUT1 1

OUT2 2

IN1 3

IN2 4

Control panel connection X7

Memory unit connection X20

X3 (4 × 4-pole,

1 × 3-pole)

X2 (3-pole)

X1 (2-pole)

X4 (1 × 7-pole,

1 × 2-pole,

1 × 3-pole)

X5 (3-pole)

X6 (4-pole,

orange)

Order of terminal

headers and jumpers

X4.8

X4.9

WFU

X3.14

X3.15

WFU

24 V DC

ACSM1-204 Quick Quide.book Page 9 Tuesday, October 6, 2009 11:02 AM

10 Quick installation and start-up guide – ACSM1-204

Default connections

Make the following connections on the control unit before attempting to start up the

regen supply module:

•X3:14, 15 Fan control signal. The fan control cable must be connected.

Note: A 24 V DC supply must be connected to the WFU-xx filter.

•X4:8, 9 Thermistor input. The filter temperature monitoring cable must be

connected.

•X6:1, 3 and X6:2, 4 Not in use. Both circuits must be closed with jumpers

(included in delivery).

Connection procedure

The clamp plate can be fastened at the top or the bottom of the JCU Control Unit.

0.7 N·m

(6.2 lbf·in)

Use shrink

tubing or tape to

contain strands

If shielded

cable is in use,

remove outer

jacket of cable

at clamp to

expose cable

shield.

1.5 N·m

(13 lbf·in)

ACSM1-204 Quick Quide.book Page 10 Tuesday, October 6, 2009 11:02 AM

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