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
©2009 ABB Oy.
All rights reserved.
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
M
~3
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
M
~3
3
3
2
1
2
3
4
5
6
7
33
2
2
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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.
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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
PE
WFU-xx
L1 L2 L3
L1 L2 L3
U2 V2 W2 PE U2 V2 W2 PE
U1 V1 W1 UDC+UDC-
R+ R-
M
~3
U1
V1 W1 PE
ACSM1-04
U2 V2 W2 PE
U1 V1 W1 UDC+UDC-
R+ R-
PE
1)
2)
4)
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)
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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).
1
2
3
4
5
6
2
1
4
56
1
4
56
2
3
1
56
4
2
UDC+ UDC- UDC+
Lb/
UDC+
La/
La/ Lb/
2
2
2
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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)
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Quick installation and start-up guide – ACSM1-204 9
Default I/O connection diagram
Notes:
*Total maximum current: 200
mA
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
X1
External power input
24 V DC, 1.6 A
+24VI 1
GND 2
X2
Relay output
250 V AC / 30 V DC
2 A
NO 1
COM 2
NC 3
X3
+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
X4
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
X5
Drive-to-drive link termination J3
Drive-to-drive link. B 1
A2
BGND 3
X6
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)
J1
J3
J2
Order of terminal
headers and jumpers
X4.8
X4.9
WFU
2
X3.14
X3.15
WFU
1
24 V DC
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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)
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