ACS800

Application Guide
ACS800 Common DC System
 ACS800 Common DC System

Application Guide

3AFE 64786555 REV C

EN
EFFECTIVE: 12.09.2003

2003 ABB Oy. All Rights Reserved.

 5

Table of contents

Introduction

Possible main supply connections

Step by step guide

Design
Power limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Allowed braking power and need for a brake resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Calculation of the allowed braking power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Internal brake chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
External brake chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Contactors, DC-bus and brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Wiring
Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Powering the AC-fans in R7 and R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brake resistor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Connecting the contactor of the resistor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Phase loss guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Start-up

Appendix A When one charging circuit is enough

Appendix B Powering the AC-fans of R7 and R8

6
 1

Introduction

Connecting the DC-buses of frequency converters together results in energy savings

and in some cases simplifies the connection to the main supply. With common DC
the braking energy of one converter can be used for the other converters and
motors.
Unequal current distribution and different charging methods cause difficulties to
common DC-systems:
Unequal current distribution is influenced by input cables, AC- or DC-chokes and
input bridges forward characteristics. If the voltage reduction over the supply
components mentioned is not the same with all converters, more current will flow
through the converter which has a lower voltage reduction. Factors which
influence the current distribution include temperature, tolerances of components
and in DC-choke cases the input cables cross-sectional area and length.
Charging methods vary depending on the converter size. Because of this in some
installations, the supplies of the frame sizes R2-R4 should be disconnected when
they are connected parallel with frame sizes R5-R8.

Note: The common DC-application is not tested according to the EMC requirements
of conducted and radiated emissions.

Note: The maximum number of converters in the common DC-system is three.

Introduction
2

Possible main supply connections

F8 F7 F6 F8 F8

R8 R7 R6 R8 R8 R8

- + - + - + - + - + - +

M M M M M M
3~ 3~ 3~ 3~ 3~ 3~

Figure 1. Common DC-connections. Cases a and b.

F6 F8 F7 F7

R6 R8 R7 R7 / R6 R7 R7 / R5

- + - + - + - + - + - +

M M M M M M
3~ 3~ 3~ 3~ 3~ 3~

Figure 2. Common DC-connections. Cases c, d1 and d2.

Cases b, c and d can be used when the total power taken from the main supply,
Pout.tot, is smaller than the drive power rating, Pcont.max, of the biggest converter.

Possible main supply connections

 3

Case a)
The most common set-up, where all converters are connected to the main supply.
When the charging circuits of the converters are different, this connection is not
always allowed. Table 1 shows when the connection cannot be used.
Case b)
Converters are identical and only one converter is connected directly to the main
supply.
Case c)
Converters are not identical and only the biggest converter is connected directly to
the main supply. The AC-cables to the other converters are protected by drive-
specific fuses.
Case d1)
Converters are identical and only one converter is connected directly to the main
supply. The charging circuit of the connected converter is capable of charging the
whole DC-bus.
Case d2)
Converters are not identical and only the biggest converter is connected to the main
supply. Charging circuit of the connected converter is capable of charging the whole
DC-bus.

Note: If the charging circuit in case d1/d2 is not capable of charging the DC-bus,
connection presented in case b/c must be used.

Note: With frame sizes R5-R8 the charging circuit in case d1/d2 might not be able to
withstand the three times larger charging energies. In this case the main supply
cable is wired to all of the input rectifiers as presented in case b/c.

Table 3 in Appendix A When one charging circuit is enough lists the allowed drive
combinations when only one charging circuit is enough.

Possible main supply connections

4

Step by step guide

1) Select the converters and preselect the main supply connection. See Possible
main supply connections.
2) Check from Table 1, Power correction factors, that the connection is possible.
3) Check by using equation 1 that the load does not exceed the total power limit,
Pout.tot, of the system. See Power limit.
4) Select the fuses, cables and possible contactors for the DC-side. See Fuses,
Cables and Contactors, DC-bus and brake circuit .
5) Calculate the braking power and determine whether the braking cycle can be
performed and whether an internal or an external brake chopper is needed. See
Allowed braking power and need for a brake resistor.
6) If resistor braking is needed, select the internal or external brake chopper, the
resistor and the contactor. See Internal brake chopper, External brake chopper and
Contactors, DC-bus and brake circuit .
7) Set up the common DC-system according to the wiring instructions. See Wiring.
8) If the input terminals of frame sizes R7 and R8 are left unconnected, make sure
that the AC-fans are powered separately. See Appendix B Powering the AC-fans of
R7 and R8.
9) Set the common DC-system related parameter values. See Start-up.

Step by step guide

 5

Design

Power limit
Total output power limit of the common DC-system can be calculated with
equation 1.

P out.tot = P 1cont.max + k P 2cont.max + k P 3cont.max (equation 1)

Pout.tot is the instantantaneous power limit of the installation. P1cont.max is the lowest
and P3cont.max the highest drive power rating of the three converters.
Only converters, which are connected to the main supply, are used for the power
limit calculations.
The power correction factor, k, for each combination can be found from Table 1.
When all three converters are connected to the main supply, the least efficient power
correction factor is chosen from table 1, i.e. the smallest factor. See Example1 and
Example2.
Table 1. Power correction factors
ACS 800
R2-R3 R4 R5-R6 R7-R8

R2-R3 k=0.5 NO NO NO
R4 NO k=0.7 k=0.7 C k=0.7 C
R5-R6 NO k=0.7 C k=0.7 k=0.6
R7-R8 NO k=0.7 C k=0.6 k=0.7

Explanations of Table 1:
NO: The supply of the smaller converter MUST not be connected, because the
converters have different input chokes. Frame sizes R2-R3 have DC-chokes and
frame sizes R4-R8 AC-chokes.
C: If both converters are connected to the main supply, the DC-links MUST be
connected together via contactor because the converters have different charging
circuits. In R2-R4 the charging resistors are in series with the DC-capacitors and in
R5-R8 the charging resistor is in parallel with the input bridge. The DC-contactors
are switched on after all of the DC-links are charged and the converters are in the
READY state.

Note: The Pout.tot value is higher if the smallest converter is not connected to the
main supply.

Design
6

Example1
The DC-buses of three converters ACS800-0004-5, 2.2 kW, R2; ACS800-0025-5,
18.5 kW, R3 and ACS800-0025-5,18.5 kW, R3 are connected together. The input
terminals of the 2.2 kW converter are left unconnected. According to Table 1, k = 0.5
when two R3s are connected to the main supply, therefore Pout.tot is

P out.tot = 18.5kW + 0.5 18.5kW = 27.75kW

Example2
The DC-buses of three converters ACS800-0050-5, 37 kW, R5; ACS800-0140-5,
110 kW, R6 and ACS800-0320-5, 250 kW, R8 are connected together. All three
converters are connected to the main supply. According to Table 1, k = 0.7 when R5
and R6 are connected to the main supply and k = 0.6 when R6 and R8 are
connected to the main supply. The worst case is chosen for the calculations, i.e.
k = 0.6, therefore Pout.tot is

P out.tot = 37kW + 0.6 110kW + 0.6 250kW = 253kW

Fuses
Use fuses listed in the appropriate Hardware Manual for input cable protection.
The recommendations for obligatory DC-side semiconductor fuses, aR-fuses, are
listed in Table 2. Use 690 VAC rated fuses for 230-500 V converters and 1000 VAC
rated fuses for 690 V converters. The aR-fuses protect the converter against short
circuits in other converters. Because of the complicated fault current paths the
selectivity of the fuses cannot be guaranteed in all conditions.
aR-fuses must be installed on both DC-wires.

Design
 7

Table 2. Recommended DC-side aR-fuses.

I/A I/A I/A
ACS800-01-0003-3 R2 20 ACS800-01-0009-3 R2 40 ACS800-01-0009-5 R2 25
ACS800-01-0004-3 R2 20 ACS800-01-0004-5 R2 20 ACS800-01-0011-5 R2 40
ACS800-01-0005-3 R2 20 ACS800-01-0005-5 R2 20
ACS800-01-0006-3 R2 25 ACS800-01-0006-5 R2 20
ACS800-01-0011-3 R3 50 ACS800-01-0020-3 R3 63 ACS800-01-0020-5 R3 50
ACS800-01-0016-3 R3 50 ACS800-01-0016-5 R3 50 ACS800-01-0025-5 R3 63
ACS800-01-0025-3 R4 63 ACS800-01-0011-7 R4 25 ACS800-01-0030-7 R4 63
ACS800-01-0030-3 R4 63 ACS800-01-0016-7 R4 32 ACS800-01-0040-7 R4 80
ACS800-01-0030-5 R4 63 ACS800-01-0020-7 R4 40
ACS800-01-0040-5 R4 63 ACS800-01-0025-7 R4 63
ACS800-01-0040-3 R5 100 ACS800-01-0050-5 R5 100 ACS800-01-0050-7 R5 100
ACS800-01-0050-3 R5 125 ACS800-01-0060-5 R5 125 ACS800-01-0060-7 R5 100
ACS800-01-0060-3 R5 160 ACS800-01-0070-5 R5 125 ACS800-01-0070-7 R6 125
ACS800-01-0070-3 R6 315 ACS800-01-0100-5 R6 315 ACS800-01-0100-7 R6 160
ACS800-01-0100-3 R6 315 ACS800-01-0120-5 R6 315 ACS800-01-0120-7 R6 200
ACS800-01-0120-3 R6 400 ACS800-01-0140-5 R6 400
ACS800-02-0080-2 R7 400 ACS800-02-0210-3 R7 550 ACS800-02-0170-7 R7 350
ACS800-02-0100-2 R7 500 ACS800-02-0170-5 R7 400 ACS800-02-0210-7 R7 400
ACS800-02-0120-2 R7 550 ACS800-02-0210-5 R7 500 ACS800-02-0260-7 R7 400
ACS800-02-0140-3 R7 400 ACS800-02-0260-5 R7 550
ACS800-02-0170-3 R7 500 ACS800-02-0140-7 R7 350
ACS800-02-0260-3 R8 800 ACS800-02-0400-5 R8 1000 ACS800-02-0400-7 R8 700
ACS800-02-0320-3 R8 1000 ACS800-02-0440-5 R8 1250 ACS800-02-0440-7 R8 800
ACS800-02-0400-3 R8 1250 ACS800-02-0490-5 R8 1250 ACS800-02-0490-7 R8 900
ACS800-02-0440-3 R8 1600 ACS800-02-0550-5 R8 1600 ACS800-02-0550-7 R8 900
ACS800-02-0490-3 R8 1600 ACS800-02-0610-5 R8 1600 ACS800-02-0610-7 R8 1000
ACS800-02-0320-5 R8 800 ACS800-02-0320-7 R8 700

Design
8

Cables
Select the input power cables as described in the Hardware Manual. The cross-
sectional area of the DC-cables must be the same as the cross-sectional area of
the AC-side cables.
If screened DC-cables are used, ground the screen at the other end only.
The lengths of the supply cables must not differ more than 15%. This applies
especially to converters equipped with DC-chokes.
Maximum length of the DC-cables between two converters is 50 m.
If the system consists of three converters, the DC-links must be connected in an
external terminal box. Do not use the terminals of one of the converters for this
purpose.

Design
 9

Allowed braking power and need for a brake resistor

1. For each drive check that the braking power does not exceed the allowed braking
power. See Calculation of the allowed braking power below.
2. For the common DC-system check whether it needs to be equipped with an
additional brake chopper and resistor. This is the case if the total power of the
common DC-system is negative at any point of the duty cycle [i.e. braking motor(s)
regenerate more power to DC-link that can be consumed by other motors]. See the
figure below which shows the duty cycles of three drives and the sum, the common
DC duty cycle. A brake chopper and a resistor is needed to dissipate the surplus
braking energy (the shaded areas).

P
Drive A
duty cycle

P
Drive B
duty cycle

P
Drive C
duty cycle

P
Common DC
duty cycle
t

Design
10

Calculation of the allowed braking power

If drive is not connected to the main supply, ensure that the braking power meets
condition 1 below.
If drive is connected to the main supply, ensure the braking power meets condition 1
AND condition 2 below.
Condition 1
The drive braking power may not exceed the drive power rating.

P br P cont.max

Pbr = braking power

Pcont.max = drive power rating

Condition 2
The power flowing through the converter's DC-bus terminals to the other drives may
not exceed the drive power rating. This might happen when drive brakes and takes
power from the main supply at the same time. The power rating of the terminals is
not exceeded when the following condition is valid, i.e. the sum of the drive input
power and the drive braking power has to be equal or smaller than the drive power
rating.
P 1 P br + P 2
-------------------------------- P cont.max + P br P cont.max
P out.tot

Pbr = braking power

Pcont.max = drive power rating
Pout.tot = power limit of the common DC system
P1 = simultaneous load of the other converter
P2 = simultaneous load of the other converter

Design
 11

Example 3
The DC-buses of three converters ACS800-0140-5, 110 kW, R6; ACS800-0140-5,
110 kW, R6, and ACS800-0070-5, 55 kW, R5 are connected together. Only one
110 kW converter is connected to the main supply. The duty cycle is shown in the
table below.
Phase Converter powers (kW) Common DC
duty cycle (kW)
R6 (AC supplied) R6 R5

0t1 110 -30 30 110

t1t2 60 0 30 90

t2t3 -70 70 30 30

t3...t4 -50 70 -30 -10

t4t5 0 -30 30 0

Allowed braking powers

R6 connected to main supply:
Condition 1: 70 kW < 110 kW OK
Condition 2:

70kW 70kW + 30kW

------------------------------------------------------- 110kW + 70kW = 100kW 110kW ,t2...t3 OK
110kW

70kW 50kW + ( 30 )kW

--------------------------------------------------------------- 110kW + 50kW = 40kW 110kW ,t3...t4 OK
110kW

Pout.tot of the system is 110 kW.

R6 not connected to main supply:

Condition 1: 30 kW < 110 kW OK

R5 not connected to main supply:

Condition 1: 30 kW < 55 kW OK

Need for a brake resistor

The total power of the common DC-system is negative during phase interval t3...t4,
therefore a brake chopper and a brake resistor is needed.

Design
12

Internal brake chopper

Only one internal brake chopper is allowed to be active.
If an internal chopper is used, it must be in the biggest converter.
The maximum braking power of the brake chopper or the inverter must not be
exceeded.
A contactor must be used in the resistor circuit for protection against brake
chopper faults and against the overtemperature of the resistor.

External brake chopper

An external brake chopper can be used but not at the same time with an internal
brake chopper.
The external chopper must be installed close ,< 5 m, to the biggest braking
converter.
The external chopper can be selected according to the braking power demand.
For more information, see the appropriate drive Hardware Manual.
A contactor must be used for protection against brake chopper faults.

Contactors, DC-bus and brake circuit

If converters with different charging circuits are connected directly to the main
supply, the DC-links must be connected together via contactors.
With an external or an internal brake chopper a contactor must be used for
protection against brake chopper faults.
Contactors must be capable of cutting off the DC-current. The maximum
operational voltage over the contactor is the DC-voltage during the braking, i.e.
1.211.35 U1.
DC-current rating for the DC-contactor can be calculated by using equation 4.
P DC
I DC = -----------
U DC

P DC P cont.max (equation 4)

U DC = 1.35 U 1

Pcont.max is the drive power rating of the biggest converter and U1 is the supply
voltage of the converter.

Design
 13

Peak current through the contactor in brake resistor circuit can be calculated with
equation 5.

1.21 U DC
I = ------------------------- (equation 5)
R brake

The rms current during the braking can be calculated with equation 6.

P br
I rms = ------------- (equation 6)
R brake

Rbrake is the brake resistors resistance. Pbr is the applied braking power.

Design
14

Wiring

Supply
Use the same supply connection point. All converters must be fed from the same
transformer. The supply impedance is an important parameter, which influences the
current distribution. All converters must have equal supply impedance.

Powering the AC-fans in R7 and R8

See Appendix B Powering the AC-fans of R7 and R8 for more information.

Brake resistor circuit

Figure 3 presents an example of a three converter system. Both internal and
external brake choppers are shown.
Only one brake chopper is allowed to be used.
When an internal chopper is used, contactor K1 disconnects both poles of the brake
resistor when a fault is detected. An auxiliary contactor of the contactor K1 is used to
trip the drive on a START INHIBIT fault when the brake resistor overheats.
When an external chopper is used, contactor K3 disconnects both poles of the brake
resistor when a fault is detected. When the brake resistor is disconnected the whole
system will trip on a OVERVOLTAGE fault.

Connecting the contactor of the resistor circuit

Wire an output relay of the RMIO board to control the contactor. The default value
is that the contactor is closed during normal operation and when the power is off.
Set the output relay to open when drive trips on a FAULT or BC SHORT CIRCUIT.
See appropriate drive parameter from parameter group 14.

Warning! Application macro change resets the settings. Restore the settings to
correct values after the macro change.

Wiring
 15

F8 F7 F4

R8 R7 R4

+ - + - + -
- +
IC - + -

EC
M M M
3~ 3~ 3~

K2

IC K1 EC

ACS 800 X27 K3

2+
R 21
RO3 22 230 V~
23
2
R-

X22 +
+24V 28
-
29
2
10
DIIL 2
11
X27
21
RO3 22 230 V~
23

Figure 3. Common DC-connection with brake choppers. IC = internal chopper, EC =

external chopper, K2 = DC-contactors based on table 1. Note! Only one chopper
may be used at a time.

Wiring
16

Phase loss guard

It is recommended to use phase loss guard in the input supplies of all of the
converters. If phase loss guard is not used and the fuse of one of the input supply
phases blows, the semiconductors of the converters may be overloaded and
damaged.

Wiring
 17

Start-up

It is recommended to adjust parameters 20.11 P MOTORING LIM and

20.12 P GENERATING LIM to limit the maximum power. The braking power given
by equation 3 can also be used as the parameter value of 20.12 P GENERATING
LIM.
Parameter 99.04 MOTOR CTRL MODE must be set to DTC.
When brake chopper is used, set parameter 27.08 BC CTRL MODE to COMMON
DC. This activates the chopper when the DC-voltage is high. Also the parameter
20.05 OVERVOLTAGE CONTROL must be disabled from all of the converters
separately.
Switch on the possible DC-contactors based on Table 1 after all of the DC-links
are charged and the converters are in the READY state, i.e. when the power is on
and no faults appear.
All converters must be in the READY state before starting.

Note: The parameter settings apply to ACS800 Standard Application Program.

Start-up
18

Appendix A When one charging circuit is enough

Table 3 lists all the allowed combinations with two and three rectifiers when only the
biggest converter, drive a, is connected to the main supply.
When all of the converters are identical and two of them are directly connected to the
main supply, the system is always capable of charging the DC-bus. With frame sizes
R2-R4 only one direct main supply connection is enough.
Table 3. Allowed drive combinations when only the biggest drive is connected to the
main supply.
UN Drive a Drive b Drive c

415V R5 R2-R4 R2-R4

R6 ** R2-R6 ** R2-R5 **

R7 R2-R7 R2-R7

R8 ** R2-R8 ** R2-R7 **

500V R5 R2-R4 R2-R4

R6 ** R2-R5 ** R2-R4 **

R7 R2-R7 R2-R7

R8 ** R2-R7 ** R2-R6 **

690V R5 R2-R4 R2-R4

R6

R7 R2-R6 R2-R6

R7 ** R2-R7 **

R8 ** R2-R7 ** R2-R7 **

**The DC-links are allowed to be energized once during three minutes. The nominal
cycle is five chargings during ten minutes.

Appendix A When one charging circuit is enough

 19

Appendix B Powering the AC-fans of R7 and R8

If the supply of frame size R7 or R8 is not connected to the main supply, the AC-fan
must be powered separately.
Feed the primary of the fan circuit transformer with the converters nominal main
supply voltage, V- and W-phases, via the built-in fan circuit. The original cables
between the busbars and the fuses have to be removed. The feeding cable must be
protected against short circuits despite of the used built-in fuses.
The fuse locations are shown in the following picture.
500 V 690 V

R7

R8

Appendix B Powering the AC-fans of R7 and R8

20

Appendix B Powering the AC-fans of R7 and R8

 3AFE 64786555 REV C EN
EFFECTIVE: 12.09.2003

ABB Oy ABB Inc.

AC Drives Automation Technologies
P.O. Box 184 Drives & Motors
FIN-00381 HELSINKI 16250 West Glendale Drive
FINLAND New Berlin, WI 53151
Telephone +358 10 22 11 USA
Telefax +358 10 22 22681 Telephone 262 785-3200
Internet http://www.abb.com 800-HELP-365
Telefax 262 780-5135