ABB ACSM1 Series User manual

ACSM1
Hardware Manual
ACSM1-204 Regen Supply Modules (5.3 to 61 kW)

ACSM1-204 Regen Supply Modules
(5.3 to 61 kW)
Hardware Manual
3AUA0000053713 REV A EN
EFFECTIVE: 2009-12-11
©2009 ABB Oy. All Rights Reserved.

Safety instructions
5
Safety instructions
What this chapter contains
This chapter contains the safety instructions which you must follow when installing,
operating and servicing the regen supply module. If ignored, physical injury or death
may follow, or damage may occur to the regen supply module, drive, the motor, or
driven equipment. Read the safety instructions before you work on the unit.
Note: Also read the safety instructions for the drive.
Use of warnings and notes
There are four types of safety instructions used in this manual:
Dangerous voltage warning warns of high voltage which can cause
physical injury and/or damage to the equipment.
General warning warns about conditions, other than those caused by
electricity, which can result in physical injury and/or damage to the
equipment.
Electrostatic discharge warning warns of electrostatic discharge which
can damage the equipment.
Hot surface warning warns of component surfaces that may become
hot enough to cause burns if touched.

Safety instructions
6
Installation and maintenance work
These warnings are intended for all who work on the regen supply module.
WARNING! Ignoring the following instructions can cause physical injury or death, or
damage to the equipment.
Only qualified electricians are allowed to install and maintain the regen
supply module.
•Never work on the regen supply module when input power is applied. After
disconnecting the input power, always wait for 5 minutes to let the intermediate
circuit capacitors and WFU-xx regen filter module capacitors discharge before
you start working on the regen supply module.
Always ensure by measuring with a multimeter (impedance at least 1 Mohm)
that:
1. There is no voltage between terminals L1, L2 and L3 and the ground.
2. There is no voltage between terminals U2, V2 and W2 and the ground.
3. There is no voltage between terminals UDC+ and UDC– and the ground.
4. There is no voltage between terminals R+ and R– and the ground.
•Do not work on the control cables when power is applied to the regen supply
module or to the external control circuits. Externally supplied control circuits
may carry dangerous voltages even when the input power is switched off.
•Do not make any insulation or voltage withstand tests on the regen supply
module.
•If a regen supply module or WFU-xx regen filter module whose varistors are not
disconnected is installed on an IT power system (an ungrounded power system
or a high resistance grounded [over 30 ohms] power system), the regen supply
module will be connected to earth potential through the varistors. This may
cause danger or damage the regen supply module.
•If a regen supply module or WFU-xx regen filter module whose built-in varistors
are not disconnected is installed on an corner-grounded TN system, the regen
supply module will be damaged.
Notes:
•Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V)
may be present on the terminals of the relay output(s) of the regen supply
module.
WARNING! Ignoring the following instructions can cause physical injury or death, or
damage to the equipment.
•The regen supply module is not field repairable. Never attempt to repair a
malfunctioning regen supply module; contact your local ABB representative or
Authorized Service Center for replacement.

Safety instructions
7
•Make sure that dust from drilling does not enter the regen supply module during
the installation. Electrically conductive dust inside the regen supply module may
cause damage or lead to malfunction.
•Ensure sufficient cooling.
WARNING! The printed circuit boards contain components sensitive to electrostatic
discharge. Wear a grounding wrist band when handling the boards. Do not touch
the boards unnecessarily.

Safety instructions
8
Start-up and operation
These warnings are intended for all who plan the operation of the regen supply
module, or start up or operate the regen supply module.
WARNING! Ignoring the following instructions can cause physical injury or death,
or damage to the equipment.
•Pressing the STOP button in the control panel or sending an external stop
signal does not disconnect the power feed from the regen supply module to the
intermediate circuit because the diodes in the supply module conduct
electricity even when no control signals are given.
•Do not control the regen supply module with an AC contactor or disconnecting
device (disconnecting means); instead, use the control panel or external
commands via the I/O board of the regen supply module or a fieldbus adapter.
The maximum allowed number of charging cycles of the DC capacitors (i.e.
power-ups by applying power) is one per two minutes. The maximum total
number of chargings is 100000 for frame sizes A and B, 50000 for frame sizes
C and D.
Notes:
•When the control location is not set to local, the stop key on the control panel
will not stop the regen supply module.
WARNING! The surfaces of regen supply module system components become hot
when the system is in use.

Table of contents
9
Table of contents
Safety instructions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table of contents
About this manual
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Categorization according to the + code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
The ACSM1-204
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
The ACSM1-204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Layout (Frame A shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
WFU-xx regen filter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Main circuit and control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Planning the cabinet assembly
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Cabinet construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disposition of the devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Grounding of mounting structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cooling and degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Preventing the recirculation of hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Outside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cabinet heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Table of contents
10
Mechanical installation
Contents of the package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Delivery check and regen supply module identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Direct wall mounting of the regen supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
DIN rail mounting (Frames A and B only) of the regen supply module . . . . . . . . . . . . . . . . . 34
Cold plate mounting (ACSM1-204Cx-xxxx-x, frames C and D only) . . . . . . . . . . . . . . . . . . . 35
Installation of the WFU-xx regen filter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Braking resistor installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Planning the electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
ACSM1-04 drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Other drive types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Checking the charging capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Single AC input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Supply connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Main contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Thermal overload and short circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Thermal overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Protection against short-circuit in the supply cable or the regen supply module . . . . . . . . . . 40
Operating time of the fuses and circuit breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Circuit breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Protection against short-circuit in the DC cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Protection of the WFU-xx regen filter module against thermal overload . . . . . . . . . . . . . . . . 41
Ground fault protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Power cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Power cables cross-section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Protecting the relay output contacts and attenuating disturbances in case of inductive loads . . . . 43
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Table of contents
11
Regen supply module and WFU-xx regen filter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Braking resistor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Power and control cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Power and control cable connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Installation of power cable clamp plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Power cable connection – frame size A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Power cable connection – frame size B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Power cable connection – frame sizes C and D (connector covers removed) . . . . . . . 53
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Control connections to the JCU Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
External power supply for the JCU Control Unit (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Drive-to-drive link (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
X6 (not in use) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Control cable grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Installation of options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Removing EMC and varistor screws from the regen filter module . . . . . . . . . . . . . . . . . . . . . . . . . 57
Installation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Installation checklist
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Maintenance
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Fan replacement (Frames A and B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Fan replacement (Frames C and D, ACSM1-204Ax-xxxx-x) . . . . . . . . . . . . . . . . . . . . . . . . . 64
Fan replacement (Frames C and D, ACSM1-204Cx-xxxx-x) . . . . . . . . . . . . . . . . . . . . . . . . . 65
Replacing the cooling fan of the WFU filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Replacing the WFU-xx filter capacitor (WFU-21 and WFU-22) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Reforming the DC capacitors of the regen supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Other maintenance actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Transferring the memory unit to a new regen supply module . . . . . . . . . . . . . . . . . . . . . . . . 68
The 7-segment display on the JCU Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Technical data
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Regen supply module ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Input connection (AC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Output connection (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Table of contents
12
Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Regen supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Regen filter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Cooling characteristics, noise levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Cold plate cooling characteristics (ACSM1-204Cx-xxxx-x only) . . . . . . . . . . . . . . . . . . . . . . 71
Supply voltage requirements for the WFU-xx regen filter module fan . . . . . . . . . . . . . . . . . . . . . . . 72
AC supply cable fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
DC cable fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
AC input (supply) connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
JCU Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Compliance with EN 61800-3 (2004), category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Compliance with EN 61800-3 (2004), category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Compliance with EN 61800-3 (2004), category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Compliance with the Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
C-Tick marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Compliance with IEC 61800-3 (2004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
U.S. patents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Resistor braking
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Braking choppers and resistors with the ACSM1-204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Braking choppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Braking resistor selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Chopper data / Resistor selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Resistor installation and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Contactor protection of regen supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Braking circuit commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Dimension drawings
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Frame size A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Frame size B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Frame size C (air-cooled module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

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13
Frame size C (for cold plate mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Frame size D (air-cooled module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Frame size D (for cold plate mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Regen filter module (types WFU-01 and WFU-02) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Regen filter module (types WFU-21 and WFU-22) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Braking resistors (type JBR-xx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Table of contents
14

About this manual
15
About this manual
What this chapter contains
This chapter describes the intended audience and contents of this manual. It
contains a flowchart of steps in checking the delivery, installing and commissioning
the regen supply module. The flowchart refers to chapters/sections in this manual
and other manuals.
Compatibility
The manual is compatible with ACSM1-204 (frame sizes A to D) and the
corresponding WFU-xx regen filter modules.
Intended audience
This manual is intended for people who plan the installation, install, commission, use
and service the regen supply module. Read the manual before working on the regen
supply module. The reader is expected to know the fundamentals of electricity,
wiring, electrical components and electrical schematic symbols.
This manual is written for readers worldwide. Both SI and imperial units are shown
wherever appropriate.
Categorization according to the frame size
Some instructions, technical data and dimensional drawings which concern only
certain frame sizes are marked with the symbol of the frame size A, B, C or D. The
frame size is marked on the regen supply module designation label.
Categorization according to the + code
The instructions, technical data and dimensional drawings which concern only
certain optional selections are marked with + codes, e.g. +L500. The options
included in the regen supply module can be identified from the + codes visible on the
type designation label of the regen supply module. The + code selections are listed
in chapter The ACSM1-204 under Type code.

About this manual
16
Contents
The chapters of this manual are briefly described below.
Safety instructions give safety instructions for the installation, commissioning,
operation and maintenance of the regen supply module.
About this manual lists the steps in checking the delivery and installing and
commissioning the regen supply module and refers to chapters/sections in this
manual and other manuals for particular tasks.
The ACSM1-204 describes the regen supply module.
Planning the cabinet assembly guides in planning the installation of the regen supply
module into a user-defined cabinet.
Mechanical installation instructs how to place and mount the regen supply module.
Planning the electrical installation instructs on the cable selection, the protections
and the cable routing.
Electrical installation instructs on how to wire the regen supply module.
Installation checklist contains a list for checking the mechanical and electrical
installation of the regen supply module.
Maintenance lists periodic maintenance actions along with work instructions.
Technical data contains the technical specifications of the regen supply module, e.g.
the ratings, sizes and technical requirements, provisions for fulfilling the
requirements for CE and other markings.
Dimension drawings contains the dimensional drawings of the regen supply module
and connected equipment.

About this manual
17
Installation and commissioning flowchart
Task See
Identify the frame size of your regen supply module:
A, B, C or D.
Identify the WFU-xx regen filter module rating.
Technical data: Regen supply module ratings
(page 69)
Technical data: Derating (page 70)
Plan the installation.
Check the ambient conditions, input ratings, output
ratings againts required load power, cooling air flow,
and other technical data.
If ACSM1-04 drives (frame sizes A-D) are not used:
check compatibility of the drive and the regen supply
module.
Select the cables.
Planning the cabinet assembly (page 27)
Planning the electrical installation (page 37)
Technical data (page 69)
Compatibility (page 37)
Option manual (if optional equipment is
included)
Unpack and check the units.
Check that all necessary optional modules and
equipment are present and correct.
Only intact units may be started up.
Mechanical installation: Contents of the
package (page 31)
If the converter has been non-operational for
more than one year, the converter DC link
capacitors need to be reformed. Ask ABB for
more information.
Check the installation site. Mechanical installation: Before installation
(page 33)
Technical data (page 69)
If the regen supply module is about to be connected
to an IT (ungrounded) system, check that the
screw(s) labeled VAR are removed from both the
regen supply module and the regen filter module.
Also, check that screw(s) labeled EMC are removed
from the filter.
Safety instructions: Installation and
maintenance work (page 6)
Electrical installation: Removing EMC and
varistor screws from the regen filter module
(page 57)
Install the regen supply module, regen filter module,
main contactor, disconnector and fuses in a cabinet.
Mechanical installation: Installation procedure
(page 34)
Route the cables. Planning the electrical installation: Routing the
cables (page 45)

About this manual
18
Inquiries
Address any inquiries about the product to the local ABB representative, quoting the
type code and the serial number of the unit. If the local ABB representative cannot
be contacted, address inquiries to the manufacturing facility.
Check the insulation of the supply cable, the DC
output cable, and the resistor cable (if present).
Electrical installation: Checking the insulation of
the assembly (page 47)
Connect the power cables.
Connect the control and the auxiliary control cables.
Electrical installation: Power and control cable
connection:(page 48) and Connecting the
control cables:(page 54)
For optional equipment:
Resistor braking (page 83)
Manuals for any optional equipment
Check the installation. Installation checklist (page 59)
Commission the regen supply module. Appropriate Firmware Manual
Commission the braking chopper if required. Resistor braking (page 83)
Operating the regen supply module: start, stop, etc. Appropriate Firmware Manual
Task See

About this manual
19
Terms and abbreviations
Term/Abbreviation Explanation
ACSM1-204 Regen supply module.
EMC Electromagnetic Compatibility.
FIO-01 Optional digital I/O extension for the ACSM1.
FIO-11 Optional analogue I/O extension for the ACSM1.
FCAN-0x Optional CANopen adapter for the ACSM1.
FDNA-0x Optional DeviceNet adapter for the ACSM1.
FENA-0x Optional Ethernet/IP adapter for the ACSM1.
FPBA-0x Optional PROFIBUS DP adapter for the ACSM1.
Frame (size) Size of the regen supply module. This manual deals with ACSM1-204
frame sizes A, B, C or D. The frame size is marked on the regen supply
module designation label.
I/O Input/Output.
JCU The control unit of the regen supply module. The JCU is installed on top of
the power unit. The external I/O control signals are connected to the JCU,
or optional I/O extensions mounted on it.
JMU The memory unit attached to the control unit of the regen supply module.
WFU-xx Regen filter module used with ACSM1-204.

About this manual
20