ABB ACS480 - User Manual

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Summary

Introduction

Applicability

This manual applies to converter modules which have electrolytic DC capacitors in the DC link.

ABB Low Voltage AC Drives

Applies to drive, inverter, IGBT supply and three-phase brake modules in specific product series.

ABB Wind Turbine Converters

Applies to line-side and generator-side converter modules in specific product series.

ABB Solar Inverters

Applies to solar inverter modules in specific product series.

Target Audience and Manual Purpose

Outlines the intended reader's knowledge and the manual's objective for capacitor reforming.

Safety Instructions

Details essential safety precautions to prevent injury, death, or equipment damage during operation.

Reforming the Capacitors

Overview of Reforming and Reforming Time

Explains the need for capacitor re-aging and required time based on non-operational duration.

Checking the Converter Age

Explains how to determine the converter's manufacturing date from its serial number.

Reforming with Power On for 30 Minutes

Describes a method for capacitor reforming using 30 minutes of power-on time.

Reforming with External DC Power Supply

Details capacitor reforming using an external DC power supply for extended non-operational periods.

Reforming with External Diode Bridge

Outlines capacitor reforming using an external diode bridge for long non-operational periods.

Further Information

Product and Service Inquiries

Provides contact information for product inquiries and support.

Product Training

Information on ABB product training availability and navigation.

Providing Feedback on ABB Drives Manuals

Instructions on how to provide feedback for ABB Drives manuals.

Document Library on the Internet

Guidance on accessing ABB manuals and documents online in PDF format.

Summary

Introduction

Applicability

This manual applies to converter modules which have electrolytic DC capacitors in the DC link.

ABB Low Voltage AC Drives

Applies to drive, inverter, IGBT supply and three-phase brake modules in specific product series.

ABB Wind Turbine Converters

Applies to line-side and generator-side converter modules in specific product series.

ABB Solar Inverters

Applies to solar inverter modules in specific product series.

Target Audience and Manual Purpose

Outlines the intended reader's knowledge and the manual's objective for capacitor reforming.

Safety Instructions

Details essential safety precautions to prevent injury, death, or equipment damage during operation.

Reforming the Capacitors

Overview of Reforming and Reforming Time

Explains the need for capacitor re-aging and required time based on non-operational duration.

Checking the Converter Age

Explains how to determine the converter's manufacturing date from its serial number.

Reforming with Power On for 30 Minutes

Describes a method for capacitor reforming using 30 minutes of power-on time.

Reforming with External DC Power Supply

Details capacitor reforming using an external DC power supply for extended non-operational periods.

Reforming with External Diode Bridge

Outlines capacitor reforming using an external diode bridge for long non-operational periods.

Further Information

Product and Service Inquiries

Provides contact information for product inquiries and support.

Product Training

Information on ABB product training availability and navigation.

Providing Feedback on ABB Drives Manuals

Instructions on how to provide feedback for ABB Drives manuals.

Document Library on the Internet

Guidance on accessing ABB manuals and documents online in PDF format.

This manual provides instructions for reforming electrolytic DC capacitors in ABB converter modules, including low voltage AC drives, wind turbine converters, and solar inverters. The primary function of these instructions is to ensure the proper operation and longevity of converter modules that have been non-operational for extended periods.

Function Description

The core function described in this manual is the "reforming" or "re-aging" of electrolytic DC capacitors. Electrolytic capacitors, particularly those in the DC link of converter modules, can degrade over time if they remain unpowered for a year or more. This degradation can lead to damage when the converter is eventually powered on. Reforming is a process that gradually re-establishes the dielectric layer within the capacitor, restoring its intended electrical properties and preventing potential failure upon startup. The manual outlines three alternative methods for achieving this:

Reforming with power on for 30 minutes: This method is suitable for converters that have been non-operational for shorter durations (one to two years for some product series, and one to three years for others). It involves simply switching on the converter's power for a specified time without any load. The converter's internal circuitry handles the reforming process automatically.
Reforming with external DC power supply: This method is used for converters that have been non-operational for longer periods (two years or more for some series, and three years or more for others). It requires connecting an external DC power supply to the converter's DC terminals. The power supply's voltage is gradually increased, and the current is limited to a specified maximum, allowing for controlled reforming of the capacitors.
Reforming with external diode bridge: Similar to the external DC power supply method, this approach is for converters with extended non-operational times. It involves constructing a specific reforming circuit using an external diode bridge, a resistor, and a capacitor, which is then connected to the converter's DC terminals. The AC power supply for this circuit is switched on for the required reforming time.

The manual emphasizes the importance of checking the converter's age based on its serial number to determine the non-operational time and select the appropriate reforming method.

Usage Features

The manual is designed for electrical professionals and offers clear, step-by-step instructions for each reforming method. Key usage features include:

Applicability: A detailed list of ABB low voltage AC drives, wind turbine converters, and solar inverters that require capacitor reforming, along with specific module types and product series. This helps users quickly identify if their device is covered by the manual.
Target Audience: Explicitly states that the manual is intended for individuals familiar with standard electrical wiring practices, electronic components, and electrical schematic symbols, ensuring that users have the necessary background knowledge.
Safety Instructions: A prominent section on safety, including warnings about working with energized equipment, discharge times for intermediate circuit capacitors, and the need to measure for de-energization before starting work. It also provides guidance on using a multimeter and ensuring proper grounding.
Reforming Time Diagram: A graphical representation that helps users determine the required reforming time based on the non-operational duration of the converter and its product series. This visual aid simplifies the decision-making process.
Detailed Connection Diagrams: For the external DC power supply and external diode bridge methods, clear schematic diagrams illustrate how to connect the reforming circuits to the converter module, including component values for the external diode bridge method based on the nominal AC voltage.
Gradual Voltage Increase: For the external DC power supply method, instructions advise increasing the voltage gradually if the power supply lacks an adjustable current limiter, preventing sudden stress on the capacitors.
Post-Reforming Checks: After each reforming method, instructions include waiting for discharge, measuring DC terminal voltage to confirm de-energization, and disconnecting the reforming circuit.

Maintenance Features

The manual itself serves as a crucial maintenance tool, enabling users to perform preventative maintenance on their converter modules.

Preventative Maintenance: By providing instructions for reforming capacitors, the manual helps prevent potential damage and premature failure of converter modules that have been stored or non-operational for extended periods. This extends the lifespan of the equipment and reduces the need for costly repairs or replacements.
Troubleshooting Prevention: Proper capacitor reforming ensures that the converter starts up reliably, avoiding issues that could arise from degraded capacitors, such as fault codes or immediate component failure.
Guidance on External Equipment: The manual specifies the types of external equipment needed for reforming (e.g., DC power supply, multimeter, diode bridge components) and provides guidelines for their use, facilitating the acquisition and setup of necessary tools.
Information on Ready-Made Devices: It mentions that ABB can supply ready-made reforming devices, offering an alternative for users who prefer not to construct their own circuits.
Clear Identification of Converter Age: Instructions on how to interpret converter serial numbers to determine manufacturing week and year are provided, which is essential for calculating the non-operational time and selecting the correct reforming procedure.

Overall, this manual is a comprehensive guide for maintaining the health of electrolytic DC capacitors in ABB converter modules, ensuring their reliable operation after periods of inactivity.

ABB ACS480 Specifications

General

Output Voltage	0 to Input Voltage
Frame Sizes	R1 to R4
Control Method	Scalar control
Communication	Modbus RTU
Optional Communication	PROFINET, EtherNet/IP
STO	Safe torque off (STO) as standard
Built-in Features	EMC filter
Protection Features	Overvoltage, undervoltage, overcurrent, overload, short circuit, overtemperature