PM1381-D2G1008802-FDD-001 - Rev 01 - Part 2

Ideal Rig 135
User Manual
Customer References:
Customer: Pemex Exploracion y Produccion
Rig / Hull: Pemex 1381 / Ideal 135
Tag Number: N/A
National Oilwell Varco References:

SO Number / Project Number: 192941 / TX8912
Document Number: D2G1008802-FDD-001
Revision: 01
Volume: 2 of 2
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Document number D2G1008802-FDD-001
Revision 01
Page ii
REVISION HISTORY
01 01/31/2014 For Information JP AB AB

Rev Date (mm/dd/yyyy) Reason for issue Prepared Checked Approved
CHANGE DESCRIPTION
Revision Change Description

01 Initial Release
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Final Documentation Package SO Number: 192941
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Table of Contents
This manual may consist of several volumes, chapters and sections and is housed in a number of
different binders as necessary to adequately document the equipment presented. Each binder or
volume is provided with a “Table of Contents” and the rest of the Front Matter for the entire manual.
FINAL DOCUMENTATION PACKAGE

Pemex Exploracion y Produccion – Ideal 135
Description Chapter - Section
INTRODUCTION Title Page ........................................................ Front Matter

Table of Contents .............................................................. ii
Introduction ............................................................iii thru iv
Manual Organization ......................................................... v
Safety Summary ....................................................vi thru xii
Maintenance Issues ........................................ xiii thru xxxv
Overall Rig Drawings and Procedures ........................................................................... 1.0

Rig Layout .......................................................................................................................... 1.1
Equipment List.................................................................................................................... 1.2
Rig Electrical Single Line Diagram...................................................................................... 1.3
Rig Hydraulic Schematic .................................................................................................... 1.4
Rig Pneumatic Schematic .................................................................................................. 1.5
Rig Load List ...................................................................................................................... 1.6
Rig Up Procedure ............................................................................................................... 1.7
Drilling Module ................................................................................................................. 2.0

Hydraulic Catworks ............................................................................................................ 2.1
Deadline Anchor ................................................................................................................. 2.2
Drawworks ......................................................................................................................... 2.3
Drill Line Spooler ................................................................................................................ 2.4
Hydraulic Power Unit .......................................................................................................... 2.5
Mast ................................................................................................................................... 2.6
Raising Cylinders ............................................................................................................... 2.7
Rotary Table ....................................................................................................................... 2.8
Substructure ....................................................................................................................... 2.9
Top Drive...........................................................................................................................2.10
Travelling Block .................................................................................................................2.11
Winches ............................................................................................................................2.12
Wireline Unit ......................................................................................................................2.13
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Table of Contents (Continued)

Tubular Handling System ................................................................................................ 3.0
BX Elevator ........................................................................................................................ 3.1
Handling Tools ................................................................................................................... 3.2
Iron Roughneck .................................................................................................................. 3.3
Pipecat ............................................................................................................................... 3.4
Power Slips ........................................................................................................................ 3.5
Low Pressure Mud System.............................................................................................. 4.0

Mud Tank System - Equipment .......................................................................................... 4.1
Mud Tank System - Tanks .................................................................................................. 4.2
Trip Tank & Poorboy Degasser .......................................................................................... 4.3
Trip Tank & Water Transfer Pumps .................................................................................... 4.4
High Pressure Mud System ............................................................................................. 5.0

Choke and Kill Manifold ...................................................................................................... 5.1
High Pressure Piping .......................................................................................................... 5.2
Mud Pump .......................................................................................................................... 5.3
Mud Standpipe Manifold ..................................................................................................... 5.4
Power System .................................................................................................................. 6.0

Electrical Accessories......................................................................................................... 6.1
Generator House Assembly................................................................................................ 6.2
Generator Set ..................................................................................................................... 6.3
VFD/AC Drive ..................................................................................................................... 6.4
Controls & Instrumentation ............................................................................................. 7.0

Amphion ............................................................................................................................. 7.1
CCTV ................................................................................................................................. 7.2
Driller’s Cabin ..................................................................................................................... 7.3
BOP Control System ........................................................................................................ 8.0

BOP Control Unit ................................................................................................................ 8.1
BOP Stack.......................................................................................................................... 8.2
BOP Test Stump ................................................................................................................ 8.3
BOP Transport System....................................................................................................... 8.4
Air System ........................................................................................................................ 9.0

Air Compressor .................................................................................................................. 9.1
Air Compressor – Cold Start ............................................................................................... 9.2
Air Dryers ........................................................................................................................... 9.3
Air Receivers ...................................................................................................................... 9.4
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Table of Contents (Continued)
Utility System ................................................................................................................. 10.0

Fuel Filtration System ........................................................................................................10.1
Fuel Tank ..........................................................................................................................10.2
Water Tank ........................................................................................................................10.3
Workshop ..........................................................................................................................10.4
Safety System ................................................................................................................ 11.0

Safety Climbing Device .....................................................................................................11.1
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Copyrighted as an unpublished work.
All RIGHTS RESERVED

© COPYRIGHT 2014 by National Oilwell Varco
This work contains the CONFIDENTIAL AND PROPRIETARY INFORMATION of National Oilwell
Varco. Neither this document nor any information disclosed herein, shall be reproduced in any form,
used or disclosed to others for any purpose including manufacturing without express written permission
from National Oilwell Varco.
Introduction
This manual contains information and instructions pertaining to the preparation, operation and
preventive maintenance for the Pemex Ideal Rig 135 as related to the Mast, Substructure and
Accessories Package and assemblies as prepared by National Oilwell Varco. If properly operated and
maintained, this equipment is dependable and long lasting. Therefore, it is important that all operating
and maintenance personnel study carefully all sections of this manual that pertain to any tasks they
may need to perform.
Scope of Material
The scope of material included in this manual is limited to operations and recommended procedures
considered to be routine or frequent operations. The equipment in the scope of this manual is intended
to perform a variety of tasks and withstand a broad range of operating conditions. This includes
environmental, as well as operational requirements. Therefore, the information contained in this manual
is intended as a guideline only.
This manual is not intended as a textbook on mechanics, electronics or hydraulics. Sufficient

descriptive material and illustrations are included to enable the operator to understand the basic
construction, theory of operation and maintenance of this equipment. This is its primary objective. The
intent of this manual is to guide the operators and maintenance personnel in the proper use of the
equipment.
Each operator must prepare specific operating procedures that have been modified to account for
specific operating goals and conditions. These should include selecting suitable lubricants and other
fluids for the range of operating and temperature conditions. The procedure should consider the desired
method in addition to choosing a maintenance schedule that allows for optimum performance, minimum
equipment wear, failures and downtime. Reference “Maintenance Issues” in this front matter section foe
details.
Different operators can and do have very different operating procedures because of the wide variety of
methods and functions this equipment can perform. It is not possible to detail all facets of these
subjects; therefore, when situations are encountered that are outside the scope of routine operations or
abnormal conditions, please contact the National Oilwell Varco technical services department for Rig
Package Group. National Oilwell Varco will, on request and contract, provide trained personnel to assist
in maintenance and servicing of this equipment.
Personnel responsible for operation and maintenance should study the sections of the manual
pertaining to their particular duties. Similarly, before beginning a repair or overhaul job, the service
technician should read the manual carefully to become familiar with the components, parts or
subassemblies of the equipment.
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Warranty
1. All National Oilwell Varco equipment built in our plant is guaranteed to be free from defects in
workmanship for a period of twelve (12) months from the date of delivery to the original customer.
2. In the event of any failure on which a warranty claim may be represented, the owner must notify
National Oilwell Varco and follow instructions relative to the inspection of disposition of the defective
part or parts and to the repairing and/or replacement thereof.
3. The forgoing warranty is contingent on the proper application of equipment and products by the
owner in accordance with the recommendations of the manufacturer, National Oilwell Varco. The
warranty shall not apply to any products that have been repaired or altered in any way so as, in the
judgment of National Oilwell Varco, to adversely affect their performance and reliability, nor that
have been subject to misuse, negligence or accident, or equipment that has been repaired to any
other than National Oilwell Varco specifications.
4. National Oilwell Varco obligations under this warranty are limited to supplying parts and labor to
correct defective workmanship to an amount not exceeding the charges for the original repair and
shall not include transportation charges, loss of revenue, or any direct or indirect consequential
damages.
5. Travel time and travel expenses will be charged to customer’s account at cost.
6. All warranty work will be done on a straight time basis and the customer will be charged for the
difference between straight time and overtime.
7. The warranty does not cover any hoisting, trucking or transportation charges.
8. Products furnished by National Oilwell Varco but not manufactured by National Oilwell Varco will
carry only the warranty of the manufacturer of such products.
9. The entire liability and obligation of National Oilwell Varco with respect to workmanship is defined
by this warranty and is given in lieu of any and all other warranties, expressed or implied. No oral or
written statements or representations with respect to the subject matter hereof, shall be binding.
Upon the expiration of this warranty, all liability on the part of National Oilwell Varco in connection
herewith shall terminate in any event.
Warranty Limitations
This manual is prepared as a guide for normal installation, care and operations of your unit. Because of
the varying methods and requirements for these functions, it is not possible to detail all facets of these
subjects. It is requested that when situations encountered are outside the scope of this publication,
please refer to the manufacturer’s technical services department. The manufacturer will, on request and
contract, provide trained personnel to assist you in servicing of this equipment.
Improvements in design, engineering, materials, production methods, etc., may necessitate changes in
this product over time. We reserve the right to make these design changes without incurring any
obligation for equipment previously delivered.
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Manual Organization
This manual may be divided into several volumes, chapters, sections and pages. Each of these
divisions starts with page 1. Each page is numbered with the chapter, section and page, as required, in
the upper right corner of the page. In addition, the presentation sequence will appear in the Table of
Contents as “Chapter - Section” referring to the Chapter, Section and sub-section; if necessary.
The number of volumes or binders tends to be dictated by the total quantity of information required.
These are identified as Volume 1 of 3, 2 of 3, 3 of 3, etc., as required. Each binder or volume is
provided with a duplicate “Front Matter” chapter, including “Table of Contents” and all other front matter
basic information. These are identical in every volume and will reference material in the entire manual.
The reader will find it a useful reference tool for finding information and/or the availability of information,
especially in the event all volumes of a manual are not present.
To keep this document as simple as possible, the general organization of the manual is divided into
eleven (11) major chapters. These are referenced as:
Introduction (Front Matter)

The introduction is the first or front matter of the manual. This chapter contains information and
reference material that is general in nature and is pertinent to the basic use of the manual. Due to its
basic nature, this chapter is duplicated in every volume or binder and includes:
• Title Page (Includes volume, chapter and section, as required.)
• Table of Contents (The manual has only one table of contents. It is duplicated in the
front of every volume to maintain reader orientation.)
• Introduction (Includes scope of material, warranty and warranty limitations)
• Manual Organization (An overview and description manual organization.)
• Safety Summary (Discusses general safety issues and provides basic safeguards
for typical hazards.)
• Maintenance Issues (Discusses general maintenance issues and provides basic
guidelines for preparing detailed maintenance procedures.)
Chapter 1.0 thru 11.0 Major Components Detailed

These chapters contain general overview type information that is specific to all of the equipment and
systems discussed as complete equipment systems
Some chapters may include detailed component information provided by the original equipment
manufacturer*. This may be everything from small motors or replacement filters to major components
provided by another manufacturer that is specific to this rig’s major equipment and systems.
* Some item information is limited to include only those segments of information needed to provide adequate operation and maintenance
information. Some information may be omitted if it is not available from the manufacturer as of the release of these documents.
Content and Accuracy of Information

Every effort has been made to provide all critical operation and maintenance information in a timely
manner. All of the information in this manual is based on the latest production information available at the
time of publication release. The release date should always be prominent on the title page. This manual’s
content and the accuracy of the information it contains have been checked and approved for release
within the confines of human error. If for any reason, its contents or the accuracy of its information is in
question, please do not hesitate to contact National Oilwell Varco Energy Services or your nearest
National Oilwell Varco representative. Do not make the mistake of assuming we are aware of the problem.
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Safety Summary
Safety is Very Important

Read the entire Safety Summary located in this manual
prior to performing any operations or maintenance to this equipment.
General
Safety is everyone’s business and must be of primary concern at all times during any operations or
maintenance. Knowing the guidelines covered in this manual will help to provide for the safety of the
individual, for the group and for the proper operation of the equipment.
Only qualified personnel who are well versed in safety procedures should ever be allowed to operate
and/or maintain this equipment. No exception minimizes problems.
Safety summaries and safety procedures can never replace good common sense. As detailed as some
of these documents may be, some situations will require good common sense.
Recognize all standard safety symbols. Know generally their importance, read them carefully and make
sure you understand what they mean. If it is unclear, ask. Do not take chances with your life and others.
Safety Symbols
Look for these standard safety terms and conventions that point out items of importance to the safety of
the individual as well as other workers that may be in the area.
WARNING
WARNING safety notes MUST be followed carefully. Failure

to do so may result in catastrophic equipment failure
resulting in SERIOUS INJURY or DEATH.
CAUTION
CAUTION safety notes are also very important and should

be followed carefully. Failure to do so may result in
EQUIPMENT DAMAGE and/or PERSONAL INJURY.
NOTE
NOTE is used to notify personnel of information that is
IMPORTANT but NOT HAZARD RELATED.
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Basic Safety Precautions

As mentioned earlier, all personnel performing operations or maintenance tasks of any kind should be
trained in both general safety and hazard recognition around a drilling rig or equipment, as well as
specific instruction pertaining to the particular rig they are working. All operators and maintenance
personnel should be versed in specifics regarding performance characteristics and limitations of all rig
and equipment.
Any personnel who intend to operate the unit need to be both qualified and trained on the rig or
equipment’s operating controls, and have a through understanding of the limitations and function of
each piece of equipment or rig.
All personnel should be protected from exposed mechanical dangers such as guards fabricated from
expanded metal and other similar hazards. Safeguards, such as keeping hands, hair, clothing, jewelry,
rags, tools, etc. away from all moving parts, should be familiar and a part of all activities.
Do not attempt equipment operation with inadequate visibility. This can be aggravated by poor lighting,
bad weather conditions or other reasons. If you cannot see what you are doing, don’t do it!
Operating and maintenance personnel should wear suitable protective clothing in addition to any other
personal safety devices that conditions may dictate.
Equipment used in lifting and moving the unit and accessories during operations must be sufficiently
rated to handle the weights involved.
Before performing maintenance on or disconnecting any high pressure flanges, piping, hoses or
vessels, ensure the unit or system has been bleed to “Zero” pressure. Shut down, isolate and tag the
system controls as “Out of Service,” so that others cannot pressurize the system during maintenance or
repairs. Observe similar procedures for electrical connections, ensuring the system is locked out before
attempting any maintenance.
Promote good safety measures at all times around the equipment and throughout all phases of
operations. It is the equipment owners’/operators’ responsibility to establish good safety measures,
including personnel training and enforcement of safety practices. However, the fellow in the field is
usually the first to be hurt by poor safety practices.
WARNING
Operating instructions tend to be general in nature to make

them clear and easy to understand, they give minimal details
on individual component operation. If the operator is not
thoroughly familiar with all control functions, equipment limits
and safety procedures, DO NOT OPERATE THIS EQUIPMENT.
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Major Hazards
AREA HAZARD SAFEGUARDS

Securing Equipment Equipment chassis assemblies and All truck, trailer or skid mounted
subassemblies should always be pieces of equipment should be
inspected prior to each operation. secured with blocks and/or
Undesirable movement and/or moorings prior to operation. All
malfunctioning equipment can equipment should receive a
cause serious injury or death. thorough inspection before any
operation.
Equipment Handling Equipment that falls or swings while Keep all people from under and
being hoisted or lifted can crush around the machine or item
body parts or bodies between itself during hoisting or lifting
and immovable objects, causing operations.
serious injury or death.
Drive Systems Drive systems can cut off fingers Keep guards in place and in
and hands. If clothing is caught by good condition. Keep hands
a moving part, it can drag the entire and clothing clear of the drive
arm or body into the main drive system cavity at all times when
system, causing serious damage or the drive is in motion.
death.
Hydraulic/Pneumatic Hydraulic or pneumatic system Avoid striking or puncture of

Systems parts and connection lines can any of the component parts or
contain high pressure that can connections. When working in
cause serious injury or even death the area, slowly bleed
in certain circumstances. pressure, disconnect and tag,
prior to any work on the
system.
Electrical Systems Some electrical system parts and Ensure all electrical power is
connection lines can contain high turned off prior to any electrical
voltage that may cause serious work. Avoid striking or
injury or death when grounded by puncturing any component
you, most metal objects, water or parts or electrical connections.
any other electrical conductor.
Lubrication/Filtration Failure to adequately maintain Institute a complete lubrication

Systems lubrication and/or filtration systems program at regular intervals
can result in various types of and thoroughly inspect all
catastrophic equipment failure that systems before each operation.
can cause serious injury or death.
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Typical Safety Warnings and Precautions

The safety warnings and cautions contained herein are typical and not specific to this equipment. In
addition, these are not the only types of general precautions that should always be observed during all
phases of operation and maintenance. Specific precautions are outlined with operating procedures.
Primary safety responsibility must always rest with the individual and/or group of individuals that are on
location performing the many tasks at hand and dealing with all of the contributing factors that create a
safe or an unsafe situation. Any unusual circumstances or sequence of events should always dictate a
common sense response that will overcome hazardous situations.
Be Reminded
If a WARNING is designated a warning, failure to comply could cause serious injury or death. This is
always the case whether it is implicitly stated in the text or not. In the case of a CAUTION, personal
injury and/or equipment damage is always at stake.
WARNING
Always use caution when inspecting equipment. Begin only

when equipment is shut down, isolated and tagged “OUT OF
SERVICE”. Any accidental or poorly timed operation can
cause serious injury or death to personnel and/or damage to
the equipment.
WARNING
All equipment should be shut down, isolated and tagged

“OUT OF SERVICE” before any maintenance procedure is
performed. Any unexpected startup of equipment during
procedure can cause serious injury or death to personnel
and/or damage to the equipment.
WARNING
Do not wear loose clothing, unbuttoned shirts, shirt sleeves,

or neckties while working moving assemblies. Moving parts
can cause serious injury or death to personnel and/or
damage to the equipment.
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Typical Safety Warnings and Precautions (Continued)
WARNING
DO NOT LEAVE ZERK FITTINGS INSTALLED ON THIS HIGH

PRESSURE EQUIPMENT. Extreme pressure in this assembly
exceeds 10.000 psi and can cause the Zerk check ball to
blow out.
WARNING
Always use lifting equipment, supports and chains with a

minimum capacity of one and a half times that of the object
being lifted or supported. Serious injury or death can result
from falling or swinging equipment.
WARNING
Exercise extreme caution when performing maintenance on

the hydraulic system. Fluid escaping under pressure can
easily cause serious injury or death to personnel and/or
WARNING
Prior to hoisting equipment, ensure that no loose bars, tools

parts and the like are lying in or on part of the unit, as they
could cause serious injury or death to personnel and/or
WARNING
For your own protection, DO NOT USE SUBSTITUTE PARTS

without the approval of National Oilwell Varco.
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WARNING
Leaking joints, fittings and connections should only be

tightened when the pressure source is isolated, cut off and
the system depressurized.
CAUTION
When cleaning, use only approved solvents to prevent

damage and/or deterioration of the equipment.
CAUTION
When using Teflon tape, always start the wrap about two (2)
threads away from the opening. This will prevent Teflon
contamination of the hydraulic system.
CAUTION
The hydraulic tank RETURN connector MUST be connected

before any system is operated; failure to do so could cause
reservoir drain, fluid starvation and equipment damage.
CAUTION
Use only specified fluid types. Use only fresh fluids that are
free of contamination. Do NOT mix fluids.
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CAUTION
Ensure the battery connection is made up to the positive or

plus (+) terminal ONLY. Failure to do so may result in
EQUIPMENT DAMAGE and/or PERSONAL INJURY
CAUTION
DO NOT grip polished area with tongs or any other gripping

device. This could cause equipment failure.
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Maintenance Issues
This section reviews general maintenance issues and provides basic guidelines for consideration in
preparing maintenance procedures. These are only guidelines, however, and all items may not apply
to every rig.
The National-Oilwell equipment provided on this rig is designed and constructed to provide many years
of reliable and cost effective service. The only way this can be achieved is to maintain the equipment at
optimum performance levels. Bottom line; better maintenance equals better performance, equals better
productivity, equals longer equipment life, and in some cases, personnel lives as well.
The mechanical components used to create the operating systems on this rig have been selected to
provide the most reliable yet cost-effective operation. Correct preventive maintenance should be
considered an investment in smooth field operations with minimum downtime. Another consideration
should be when equipment is in the yard or shop for repairs or strip-down, new parts may be installed
at far less expense than when the equipment is at a field location. In fact, if equipment is on location
and the entire operation of the platform is shut down for emergency repairs, the cost of that repair can
be many times that of a regular overhaul time repair.
Application of Preventive Maintenance

Preventive maintenance may be carried out by regular operating personnel. Other, more complex types
of maintenance should be performed by specialists. The disassembly, mechanical inspection and repair
during equipment strip-down should be performed by a qualified and experienced mechanic, who is
familiar with the equipment and the proper use of appropriate tools to complete each task.
To minimize chances of personnel injury and equipment damage when working on equipment, provide
a safe working area and ensure that all items being worked on are adequately and correctly supported
and/or blocked. All systems need to be isolated, shut down and tagged as “OUT OF SERVICE” before
any procedures are done. When other than routine servicing is necessary, it is suggested that, if
possible, the unit or major component be removed to an area where ample workspace, tools and
handling accessories are accessible.
Preparing Schedules
All maintenance should be performed from a routine maintenance schedule that provides both a
checklist of items and/or procedures to be followed, and details a timeframe or frequency interval that
these tasks are to be performed in. Some operators like to prepare a series of simple checklists to be
used by maintenance personnel, one for everyday or prior to each use, and a weekly, monthly and
annual overhaul or strip-down checklist.
Time frames may be very different for a rig or equipment operating in blowing sand, or offshore, or in an
arctic setting. Other considerations include actual run time, how hard the rig is actually being worked
and any other factors that would require more frequent maintenance. Careful consideration and a
tendency to do a little more than absolutely necessary maintenance are the keys to reaping the benefits
of a regular maintenance program.
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Major Maintenance Types

Typical maintenance must include several different types of operations that may be performed in any
number of sequences depending on well conditions, operating environment, or a variety of other
contributing factors. These are only guidelines, however, and all items may not apply to every rig.
Procedures outline typical maintenance events that can be modified as required to meet the operator’s
preferences, the objectives of the drilling crew, as well as the specific well and rig conditions.
Maintenance Personnel
A reminder about maintenance personnel: These employees must have training, in some cases more
training than the regular rig operator(s). The specialized number of required tasks to keep all
equipment at peak or even acceptable operational performance levels is enormous, and without
good training cannot be performed properly.
Equipment disassembly, mechanical inspection and repair during a general rig strip-down should be
performed by a qualified and experienced mechanic, who is familiar with the equipment and the proper
use of appropriate tools to complete each task. Preventive maintenance may be carried out by regular
operating personnel. Other, more complex types of maintenance should be performed by specialists.
Major Maintenance Procedure Types
• Maintaining the Rig for Daily Operations:

This procedure in many ways is the simplest of all maintenance. It includes all of the
routine items that allow for a full 24 hours of operation, under whatever optimum
conditions the rig is expected to operate. Typical items to include are:
- Inspect all moorings, outriggers, etc. for rig stability.
- Inspect all areas with moving parts to be free and clear of debris.
- Inspect all work areas, catwalks, etc. (free and passable).
- Check all fluid levels. (day tanks, hydraulic reservoir, etc.)
- Check all batteries for connection corrosion and adequate charge.
- Ensure all controls and instrumentation are in good working order.
- Check and grease fittings and bearings (drawworks, winches, crown

block assembly, winches, sheaves, etc.)
- Check all safety equipment to be present and functional.
This list can and in some cases should contain more items and more detailed
instruction, but basically it should include all day-to-day checks to ensure safe and
reliable operation.
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Major Maintenance Types (Continued)
Periodic Rig or Equipment Maintenance:
These typical procedures are usually broken up to define a weekly or so many hours
of operation, monthly, between jobs, and/or annual maintenance. Actual quantity and
depth of the maintenance at any given interval will vary greatly, depending on what
average operating conditions the rig is expected to operate.
Typical items to include relate to usually two (2) or three (3) levels of maintenance.
• Level One (1) or Weekly -This typical procedure should include, but not necessarily
be limited to:
- Check all batteries for connections, charge and fluid level.
- Ensure all controls and instrumentation are in good working order.
- Check all safety equipment to be present and run functionality tests

as necessary.
- Inspect all hydraulic lines and connections for any indications of

damage and/or leaking, and repair as necessary.
- Inspect and replace, as necessary, all hydraulic and air filters.
- Clean all inline traps and screens of debris.
- Inspect all diesel engines, filters, oil & coolant levels, batteries, etc.
replace as required.
- Check and grease fittings and bearings (drawworks, winches, crown

block assembly, winches, sheaves, etc.).
- Check and replenish oil baths, oiling or retarder systems.
- Check and test all major systems for functionality.
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Periodic Rig or Equipment Maintenance (Continued):
• Level Two (2), Monthly or Between Jobs -This typical procedure should include,
but not necessarily be limited to:
- Check all batteries for connection corrosion, charge and fluid level.
- Check all safety equipment to be present and run functionality tests

as necessary.
- Inspect all hydraulic lines and connections for any indications of

damage and/or leaking, and repair as necessary.
- Inspect and replace, as necessary, all hydraulic and air filters.
- Clean all inline traps and screens of debris.
- Pressure test all hydraulic and pneumatic systems to required working

pressures, and inspect for leaks.
- Inspect all hydraulic and pneumatic motors for worn parts and/or
pressure seals; inspect for leaks and repair as necessary.
- Tune up and inspect all diesel engines, filters, oil and coolant levels,
batteries, belts, rubber products, etc. Replace as required.
- Check and replenish oil baths, oiling or retarder systems.
- Check and test all major systems for functionality.
- Test and inspect all safety equipment for functionality, as needed.
- Check and grease fittings and bearings on drawworks, winches, crown

block assembly, sheaves, etc.
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Periodic Rig or Equipment Maintenance (Continued):
• Level Two (2), Monthly or Between Jobs (Continued)
- Inspect all chains, belts and cables for indications of wear or damage.
- Test all hydraulic reservoirs for contaminants, and replace as necessary.
- Inspect all structural members for damage or wear, and repair as necessary.
- Test all electrical circuits. Inspect all connections and wiring for damage.
- Check calibration of all system controls and instrumentation; adjust and

re-calibrate as necessary.
• Level Three (3), Annual or Major Overhaul - This typical procedure should be a
complete drilling rig review of all mechanical, hydraulic, pneumatic and structural
systems and accessories.
The overhaul should thoroughly inspect and test to acceptable levels that all systems
are in optimum working order.
This is also the time to do preventive maintenance in the form of:
- Replacement of any marginal equipment, motors, etc.
- Complete rig cleaning, priming and painting.
- Replacement of all rubber and any other perishable items.
- This is also a good time to do any equipment, systems and/or general

rig upgrades that may be desired.
Periodic Rig/Equipment Maintenance Summary

As these maintenance procedures suggest, the depth and thoroughness of each successive level of
maintenance is necessarily more intense than the level preceding it. This insures reliable and safe
operation. In addition, active operators involved in year-round operations usually schedule a major rig
evaluation and maintenance procedure annually. If the rig or equipment has been in prolonged storage
or a significant out-of-service period has been incurred, regardless of the storage conditions, the rig or
equipment should undergo a major evaluation and maintenance procedure. It is most important for the
operator and the men working with the equipment to know exactly what they are dealing with.
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General Preventive Maintenance

The preventative maintenance time intervals, instruction and procedures presented are general in
nature and would apply to any type of oil field drilling or servicing rig. These are guidelines only,
however, and all items may not apply to every rig. These guidelines cannot take into account any
specific location or weather conditions. Any field application of this material must take actual rig
operating conditions into consideration for any applied field maintenance procedures.
Reference all applicable sections for additional detailed maintenance information on individual rig
component parts and assemblies. Check the Table of Contents in the front on every volume of this
manual for a complete listing of all component sections.
Preventative Maintenance Frequency Intervals

Equipment Maintenance Procedure Daily Wk. Mo. 6-Mo. Year
Rig Check fluid(s) and lubricant levels including
engine(s) oil (dipstick), coolant, transmission
(dipstick), hydraulic pump, gearbox (dipstick),     
hydraulic reservoir(s) and drawworks chain case
(sight glass).
Inspect equipment during operation, note any
abnormal sounds or vibrations. Investigate any fluid     
leaks and take remedial action as necessary.
Disassemble and clean all air valves using clean
water DO NOT use gasoline or solvents for cleaning
diaphragms or composition valve seats. Lubricate  
with silicone grease, assemble and ensure all parts
are tightened and secure.
Flush drawworks brake coolant system. Inspect and
test all controls and linkage. Clean all connections 
and reservoir. Renew system with fresh coolant.
Check and re-calibrate all rig instrumentation. 
Drive Apply grease to all fittings at each joint in the drive
Line line(s) with the transmission in neutral gear and the    
engine(s) stopped. Check for any loose linkage.
Brakes check (Drawworks service & parking brakes).    
Functional Test - Operate all drive lines, preferably
under load, inspect binding, unbalance, bent shafts,   
misalignment, wear, looseness or unusual noise.
Gear Check oil (dip stick). Add as necessary.
    
Box
Drain, clean, check gear backlash, renew lubricant.  
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General Preventive Maintenance (Continued)

Draw- Check lubricant levels for drawworks input and brake
works chain case (sight glass). Correct level is between the     
middle to top of sight glass. Replenish as necessary.
Inspect coolant in the brake coolant tank. Replenish
as necessary. Above Freezing - Add corrosion
inhibitor and water mixture to prevent deterioration.     
Below Freezing - Add glycol and water mixture.
Adjust as necessary.
Apply grease to all (Zerk) fitting(s) at drum. This is
particularly important each day, due to the extreme     
loads on this equipment.
Inspect and verify that the air clutch(s) engage and
disengage properly. Operation should be smooth
   
and without slippage under load to minimize
overheating.
Brakes check. (Drawworks service and parking
brakes) Adjust bands and tension, and replace
   
blocks as necessary. Inspect pads and disc repair as
necessary.
Check and tension chains. Visually check for true
and alignment of chain, sprockets and shafts.
Drawworks shafts are fixed position. Tighten chains
by removing one (1) link at a time and adding half-
links as necessary.
  
CAUTION
DO NOT over tighten chains. This will severely
shorten life of the equipment and can cause
equipment failure.
Flush drawworks brake coolant system. Check and
replace all worn parts. Check and re-calibrate entire

system. Clean all connections and reservoir. Renew
system with fresh coolant.
Slip and cut wireline. Inspect for wear. Ensure that
fastline pigtail ferrule is pulled tightly against the
drum to avoid loosening. Prevent the pigtail from

being exposed. Keep it short and restrained against
the drum to avoid damage to the piping in the
housing.
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Brake Check and lubricate all linkage points. Lubricate with
Linkage silicone grease, assemble and ensure that all parts    
are tightened and secure.
Check, inspect and repair all linkage pivot points as
indications of wear are identified. Replace and   
readjust as necessary.
Crown Perform a simple functionality test of the system by
Saver actually tripping the topmast toggle. Adjust as    
necessary and reset the system.
Run a complete functional test. Inspect all system
components for wear. Re-calibrate toggle setting and   
adjust as necessary. Reset the system.
Diesel Before Starting Walk-around inspection. Check all
Engine(s) day fuel tanks and other fluid levels to be full or at
specified levels. Check all belts and battery cable     
connections. Check all gauges, controls, loose or
broken fittings, guards, etc. Repair as necessary.
After Starting Walk-around inspection. Check oil
pressure, rpm, water temperature and generated
    
voltage. Set and/or repair as required. Check for any
leaks and/or unusual noise. Fix as necessary.
Replace crankcase oil and filters. Clean or replace
air filters and breathers. Check all linkages and
adjust as necessary. Inspect radiator and fuel tank
for any contamination, clean and renew as needed.   
Inspect batteries and replace as required. Test and
inspect any alarms or shutdown devices. General
wipe down and cleaning of entire engine assembly.
Complete drain, flush and cleaning of oil, fuel and air
systems. Inspect and test old oil and coolant for any
indication of unusual or abnormal wear and tear on
internal parts. Carefully inspect all external moving
 
parts; clean, adjust and repair as necessary. Inspect,
test and replace, as necessary, all belts, hoses and
any other rubber products. Inspect, test and replace,
as necessary, all gauges and controls.
 Diesel Engine Maintenance; these are just a few common sense maintenance items for a drilling rig diesel application. Reference
complete diesel manufacturer’s maintenance information.
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Diesel Complete engine tune-up. Replace all batteries,
Engine(s) hoses, belts and any other rubber products. Remove
and replace all fluids and filters. General cleaning of
all parts and assemblies. Inspect and replace worn 
or damaged parts. Replace all seals and gaskets.
Clean and adjust all linkage and cables. Inspect, test
and replace, as necessary, all gauges and controls.
Check transmission fluid. Observe equipment
during operation, note any abnormal sounds or     
vibrations. Adjust if necessary.
Inspect and test, if necessary, for any transmission
fluid contamination. Investigate any fluid leaks and    
take remedial action as necessary.
Change transmission fluid and external filters.
Inspect and test, if necessary, for any transmission
fluid contamination, every 6 months or 1,000 hours
 
of operation. Also check for any unusual signs of
wear. Clean breather above the transmission
housing.
Pneumatic Monitor gauges for WP. Check all filters and dryers.
Systems Remove all water. Listen and check all lines and     
connections for any leaks, repair as necessary.
Observe equipment during operation; note any
abnormal sounds or vibrations. Adjust, if necessary. .
  
Clean or replace air filters and breathers. Inspect
and clean all connections and lines.
Check, re-calibrate and pressure test all system lines
and instrumentation. Clean, adjust, and replace any  
components necessary. Lubricate all parts.
 Diesel Engine Maintenance, these are just a few common sense maintenance items for a drilling rig diesel application. Reference
complete diesel manufacturer’s maintenance information.
 Transmission Maintenance, these are just a few common sense maintenance items for a drilling rig application. Reference
complete transmission manufacturer’s maintenance information.
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Electrical Check all batteries, cables and connections. Observe
Systems generated voltage and listen for any indication of     
equipment or system(s) miss or short-out.
Inspect and replenish battery electrolytes. Inspect for
any frayed wiring or connections. As necessary,    
perform any functional test or circuit continuity test.
Check, re-calibrate and circuit test all system lines
and instrumentation. Clean, adjust, and replace any  
components necessary.
Hydraulic Monitor gauges for WP. Check all filters and/or
Systems screens. Remove all water and/or foreign material;
    
replace fluid as needed. Check all lines and
connections for any leaks; repair as necessary.
Observe equipment during operation; note any
abnormal sounds or vibrations. Adjust, if necessary.
Inspect main hydraulic reservoir for any indication of
   
contamination; clean or renew as needed. Clean and
flush all system filters, screens and traps. Inspect
and clean all connections and lines.
Inspect main hydraulic reservoir for any indication of
contamination. Clean and flush all system filters,
screens and traps. Inspect and clean all connections
and lines. Replace system hydraulic fluid. Check, re- 
calibrate and pressure test all system lines and
instrumentation. Clean, adjust, and replace any
components necessary.
CAUTION
These are general maintenance issues and ALL ITEMS MAY NOT
APPLY TO EVERY RIG. There is an assortment of additional
maintenance that will be required to keep this rig at optimum
performance levels. Reference all Chapter 2 sections for
procedures on “Major Component Parts Detailed”.
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Fluids and Lubricants Table
Service Period Lubricant Quantity Lubricant Type Component/Part(s)
600 hours - Filters Fill as Required Transmission Fluid or SAE

Top of Sight Gauge 10W-30 meeting Allison spec Transmissions
1,200 hours - Fluid (if equipped) C-3 or C-4
Fill as Coolant / Antifreeze, Brake

Weekly
Required (Ethylene Glycol based) Cooling System
Fill as Lithium-based Drawworks Drum

Daily
Required Number 2 EP Grease Shaft Grease Fittings
Fill as Lithium-based Universal Joints

Weekly
Required Number 2 EP Grease Grease Fittings
Monthly Fill as Lithium-based All other

or as Required Required Number 2 EP Grease Grease Fittings
~ 15 liters Gear Oil Right-Angle

Yearly
Check Dipstick SAE 75W-80W Gearbox
Fill as Required SAE 10W30 Drawworks

Yearly
Top of Sight Gauge or Chain Oil Chain Case(s)
Fill as Coolant Brake Coolant

Yearly
Required Antifreeze Solution Circuit
 As  As Air Components and

SAE
Required Required Air Operated Controls
 Reference component maintenance instructions for specific lubrication information.
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Hydraulic Fluids
• The hydraulic oil should have a viscosity index of no lower than 90 and a viscosity
SUS 110-150 at 100 degrees F. The aniline point should be 165 or higher.
• Oil should have anti-foam and anti-oxidation additives.
• Do not use low viscosity naphtha based oils, aircraft hydraulic fluid or hydraulic brake
fluid.
• Oil with a low pour point should be used when operation is to be in cold, low
temperature climates.
• Oil operating temperature should not exceed 180 degrees F.
• When hydraulic fluid reaches a temperature in access of 180 degrees, it should be
considered "burned," and is no longer fit for use. "Burned" fluid exhibits a "burned"
odor and will generally have a darker amber color than when new. Drain the
reservoir and hoses of burned fluid.
• Fluid that becomes and remains "cloudy" must be considered contaminated.
Aeration may temporarily "cloud" the hydraulic fluid in the sight glass on the
reservoir, but such "cloudiness" generally disappears rather quickly. If fluid remains
cloudy after the unit has been sitting, non-operational, for a few hours, it is
contaminated! Always drain contaminated fluid from the reservoir and hoses.
WARNING
Operating this unit with BURNED OR CONTAMINATED fluid

can cause catastrophic failure of the hydraulic pumps or the
motors they are driving.
NOTE
Don't take chances with marginal hydraulic fluid. When the
reservoir is drained, pull the cover and clean both the
reservoir and the screen suction filters. Always replace the
return line filter elements prior to refilling the reservoir with
new fluid.
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Hydraulic Hose Fittings and Tubing Inspection
All hydraulic hoses, and particularly those which flex in normal operation of the equipment function,
should be visually inspected once every working day. A thorough inspection of all hoses, fittings and
rigid tube lines should be made at least once a month.
CAUTION
Daily hydraulic line inspection should be a routine part of all

active, in-service hydraulic systems.
Any hose, fitting and/or rigid tube line deterioration should be carefully examined as to whether further
use of the component would constitute a safety hazard. Conditions such as the following should be
sufficient reason for consideration of replacement:
a) Any evidence of hydraulic oil leakage at the surface of a flexible hose of its junction with the
metal end couplings.
b) Any blistering or abnormal deformation of the outer covering of a hydraulic hose.
c) Hydraulic oil leakage at any threaded or clamped joint that cannot be eliminated by normal
tightening or recommended procedures.
d) Evidence of excessive abrasion or scrubbing on the outer surface of a hose, rigid tube or
hydraulic fitting. Means shall be taken immediately to eliminate the interference of the
elements in contact or otherwise protect the components.
Wire Rope Inspections

CAUTION
Daily wire rope inspection should be a routine part of all

active, in-service equipment utilizing wire ropes. Serious
hazards can be avoided at the wire ropes.
One of the most critical inspections should be the wire ropes. All wire ropes in active service should be
visually inspected once every working day. A thorough inspection of such ropes should be made at
least once a month and dated records kept as to rope condition.
Any deterioration resulting in appreciable loss of original strength should be carefully examined, and
determination made as to whether further use of the rope would constitute a safety hazard.
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Wire Rope Inspections (Continued)
Conditions such as the following should be sufficient reason for questioning rope safety and for
consideration of replacement:
a) Corrosion or any indication of corrosion beginning needs to be monitored carefully.
b) More than one broken wire in any one strand. Breaks occurring on crowns of outside wires
indicate normal deterioration. Breaks in valleys between strands indicate an abnormal
condition, possibly fatigue or breakage of other wires not readily visible.
c) More than one broken wire near attached fittings.
d) Heavy wear and/or broken wires in rope sections under sheaves where rope travel is limited
or at points of contact with saddles.
e) Evidence of appreciable reduction in original rope diameter after allowance for normal
stretch and diameter reduction of newly installed rope.
f) Extensive abrasion, scrubbing and penning of outside wires, pitting, kink damage or other
mechanical abuse causing distortion of rope structure.
g) Sheaves, guards, drums, flanges, and other surfaces contacted by the rope during operation
should be inspected for conditions harmful to the rope.
Wire Rope Replacement

A fully comprehensive and precise set of rules cannot be given for determination of exact time for rope
replacement, since many variable factors are involved.
Safety in this respect depends largely on the use of good judgment by competent maintenance
personnel in evaluating remaining rope strength in a used rope. However, wire rope should be taken
out of service when any of the following conditions exist:
a) In running ropes, six randomly distributed broken wires in one rope lay, or three broken
wires in one strand in one rope lay.
NOTE
A rope lay is the length along the rope in which one strand
makes a complete revolution around the rope.
b) In independent or standing ropes, more than two broken wires in one lay in sections beyond
end connections or more than one broken wire at an end connection.
c) Abrasion, scrubbing, or pining, causing wear of more than 1/3 of the original diameter of the
outside wires.
d) Evidence of severe corrosion.
e) Evidence of any heat damage from any cause.
f) Marked reductions in diameter of wire rope indicate deterioration of the rope core, resulting
in lack of support for the load carrying strands.
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Wire Rope Replacement (Continued):
The following is a guide to determine reductions from nominal diameters of Wire Rope.
Reduction from Nominal Diameter Wire Rope Nominal Diameter
1/64" inch or more Diameters up to and including 5/16 inch
1/32" inch or more Diameters 3/8 inch, up to and including 1/2 inch
3/64" inch or more Diameters 9/16 inch, up to and including 3/4 inch
1/16" inch or more Diameters 7/8 inch, up to and including 1 1/8 inch
3/32" inch or more Diameters 1-1/4 inch, up to and including 1-1/2 inch
Excessive rope stretch or elongation may also be an indication of internal deterioration.
a) Kinking, crushing, bird caging or any other damage resulting in distortion of the rope
structure.
b) Noticeable rusting or development of broken wires in the vicinity of attachments.

NOTE
If this condition is localized in an operating rope, and the
section in question can be eliminated by making a new
attachment, this may be preferable to replacing the entire
rope.
c) Boom hoist ropes should be inspected near dead end for breaks in heart of rope not visible
from outside caused by vibrations.
d) When replacing ropes, do not weld ends to seize them as this can cause premature failure.
This is especially critical on the boom hoist dead end.
e) All rope should be of proper size, grade and construction, as recommended by the original
equipment manufacturer.
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Critical Connections
This assembly utilizes an assortment of bolts in its design. These key fasteners for critical connections
provide the assembly with overall structural integrity, and it is essential that they are installed and with
enough tension to secure and maintain assembly components. Over-tensioning of bolts can be just as
dangerous and subject to failure as bolts that are missing from an assembly.
WARNING
Operating equipment with bolts and nuts that are TOO

TIGHT OR MISSING ALL TOGETHER can cause catastrophic
equipment failure resulting in serious injury or death.
An important part of any maintenance program must include periodic inspection of all assembly bolts
and nuts. Inspect all assembly components for structural integrity and ensure that all bolts and nuts are
in place and are made-up to appropriate minimum tension requirements for all fasteners of slip critical
or direct tension connections. A connection that is plus or minus five (5) percent of these tension
requirements is the primary critical requirement indicating a secure connection. Reference these
minimum requirements in these AISC specifications.
Minimum Bolt Tension*

Minimum Tension* in 1000”s of pounds (kips)
Nominal Bolt Size (inches)
A325 A490
1/2 12 15
5/8 19 24
3/4 28 35
7/8 39 49
1 51 64
1-1/8 56 80
1-1/4 71 102
1-3.8 85 121
1-1/2 103 148
* AISC Spec 2(a), 2(e), 8(d)(4); Equal to 70% of specified minimum tensile strength of bolts (as specified in ASTM Spec for test of full
size A325 & A490 bolts w/UNC threads loaded in axial tension) rounded to the nearest kip.
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Tensioning Bolts
Field operations generally use two basic methods to apply tension to bolts; either by the “Turn of Nut”
tightening method, or by measuring applied torque with the “Calibrated Wrench” method. It is important
to understand that both methods have demonstrated inconsistent results if not properly implemented.
There simply is no easy, shortcut way to consistently tension bolts. Implemented properly, the best
method of producing consistent results is the “Turn of Nut” method, when care is taken to apply it
carefully.
With any tensioning method of making connections, it important to install bolts in all holes of the
connection and bring them to a snug-tight condition to compact the joint. Tightening should begin at the
most rigidly fixed or stiffest point and progress toward the free edges, both in the internal snugging-up
and in the final tightening.
Turn-of-Nut-Tightening*
Properly implemented, “Turn-of-Nut” method provides more uniform tension in bolts than does torque
controlled tensioning methods, because it is primarily dependent upon bolt elongation for tension.
Consistency and reliability are dependent upon assuring that the joint is well compacted and all bolts at a
joint are at a snug tight condition, prior to application of the final required partial turn. Reliability is also
dependent upon assuring that the final turn applied is relative between the bolt and the nut; thus, it is critical
that the element not turned in tightening must be prevented from rotating while the required degree of turn is
applied to the turned element. *Reference RCSC specification AISC (8) c), for more details.
Nut-Rotation from Snug Tight Condition a b

Disposition of Outer Face of Bolted Parts
One face normal to bolt Both faces sloped not
Bolt Length (under
Both faces normal axis and other sloped not more than 1:20 from
side of head to end
to bolt axis more than 1:20 (beveled normal to the bolt axis
of bolt)
washer not used) (beveled washer not used)
Up to and including
4 diameters 1/3 turn 1/2 turn 2/3 turn
Over 4 diameters
but not exceeding 1/2 turn 2/3 turn 5/6 turn
8 diameters
Over 8 diameters
but not exceeding 2/3 turn 5/6 turn 1 turn
12c diameters
a Nut rotation is relative to bolt regardless of the element (nut or bolt) being turned. Bolts installed by 1/2 turn and less, tolerance is
± 30°; bolts installed by 2/3 turn and more, tolerance is ± 45°.
b Applicable only on connection in which all material within the grip of the bolt are steel.
c No research has been performed by AISC to establish the turn-of-nut values for bolt lengths exceeding 12 diameters. Therefore,
the required rotation must established by actual test in a suitable tension measuring devise which simulates conditions of solidly
fitted steel.
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Other Methods of Tensioning Bolts

Generally speaking, other methods of tensioning bolts are not recommended, including the “Calibrated
Wrench” method, because of the detailed and cumbersome requirements necessary to use these other
methods with any acceptable degree of consistency.
For further details regarding the application of other bolt tensioning methods, reference current AISC
specifications and recommendations.
CAUTION
Calibrated Wrench Tightening and the use of Torque Values are NOT
RECOMMENDED as the best method of tensioning bolts for critical
connections. If it is used, the torque values presented only apply
when all provisions of “AISC - CALIBRATED WRENCH TIGHTENING”
specifications are applied to ensure reliable results.
Calibrated Wrench Tightening

Research has demonstrated that inconsistent tension values are to be expected when using torque as
an indirect indicator of tension. Numerous variables not related to tension affect torque and induced
tension. It is recognized, however, that if the calibrated wrench method is implemented without short-
cuts to RCSC specification; AISC (8) (d,1, 2, 3 & 4), there will be a 90% assurance that the minimum
bolt tension will be within acceptable tolerances.
These requirements contain key specifications for daily tool calibration; hardened washers must be
used and bolts must be protected from dirt and moisture at the job site. Additionally, to achieve reliable
results, attention should be given, insofar as practical, to those controllable factors that contribute to
variability. These include such factors as the make and manufacturer of nuts and bolts, uniformity of
lubrication, any presence of dirt, moisture, etc.
Reference RCSC specification; AISC (8) (d,1, 2, 3 & 4) for more detailed information.
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Recommended Torque*
CAUTION
Calibrated Wrenches and the use of Torque Values are NOT

RECOMMENDED as the best method of tensioning bolts for critical
connections. If it is used, the torque values presented only apply
when all provisions of “AISC - CALIBRATED WRENCH TIGHTENING”
specifications are applied to ensure reliable results.
All values do not exceed recommended AISC and IFI certification guidelines. Preload is 80% of yield.
Torque (ft-lb.) = k x Bolt diameter (in) x Preload (kips) x 1000/12
A325 Bolts (SAE** GR 5)

Bolt size Threads/inch Tensile Area Yield FY Yield Force Preload Torque (ft-lb.)*
(in) /series Sq. in (ksi) (kips) (Kips) Dry k=0.2 Grease k=.15
0.875 9 -- UNC 0.462 92 42.5 34.0 496 372
1.000 8 -- UNC 0.606 92 55.8 44.6 743 558
1.125 7 -- UNC 0.763 81 61.8 49.4 927 695
1.250 7 -- UNC 0.969 81 78.5 62.8 1308 981
1.375 6 -- UNC 1.155 81 93.6 74.8 1715 1286
1.500 6 -- UNC 1.405 81 113.8 91.0 2276 1707
1.625 6 -- UNC 1.680 81 136.1 108.9 2948 2211
1.750 5 -- UNC 1.900 81 153.9 123.1 3591 2693
1.875 6 -- UN 2.300 81 186.3 149.0 4658 3493
2.000 4.5 -- UNC 2.500 81 202.5 162.0 5400 4050
2.125 6 -- UN 3.030 81 245.4 196.3 6954 5215
2.250 4.5 -- UNC 3.250 81 263.3 210.6 7898 5923
2.375 6 -- UN 3.850 81 311.9 249.5 9875 7406
2.500 4.0 -- UNC 4.000 81 324.0 259.2 10800 8100
* Values do not exceed recommended AISC and IFI guidelines
** SAE grade specification for fasteners
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A320 Bolts (SAE** GR L7)
0.875 9 -- UNC 0.462 105 48.5 38.8 566 424
1.000 8 -- UNC 0.606 105 63.6 50.9 848 636
1.125 7 -- UNC 0.763 105 80.1 64.1 1,202 901
1.250 7 -- UNC 0.969 105 101.7 81.4 1,696 1,272
1.375 6 -- UNC 1.155 105 121.3 97.0 2,223 1,668
1.500 6 -- UNC 1.405 105 147.5 118.0 2,951 2,213
1.625 6 -- UNC 1.680 105 176.4 141.1 3,822 2,867
1.750 5 -- UNC 1.900 105 199.5 159.6 4,655 3,491
1.875 6 -- UN 2.300 105 241.5 193.2 6,038 4,528
2.000 4.5 -- UNC 2.500 105 262.5 210.0 7,000 5,250
2.125 6 -- UN 3.030 105 318.2 254.5 9,014 6,761
2.250 4.5 -- UNC 3.250 105 341.3 273.0 10,238 7,678
2.375 6 -- UN 3.850 105 404.3 323.4 12,801 9,601
2.500 4.0 -- UNC 4.000 105 420.0 336.0 14,000 10,500
A490 Bolts (SAE** GR 8)

0.875 9 -- UNC 0.462 130 60.1 48.0 701 526
1.000 8 -- UNC 0.606 130 78.8 63.0 1,050 788
1.125 7 -- UNC 0.763 130 99.2 79.4 1,488 1,116
1.250 7 -- UNC 0.969 130 126.0 100.8 2,100 1,575
1.375 6 -- UNC 1.155 130 150.2 120.1 2,753 2,065
1.500 6 -- UNC 1.405 130 182.7 146.1 3,653 2,740
1.625 6 -- UNC 1.680 130 218.4 174.7 4,732 3,549
1.750 5 -- UNC 1.900 130 247.0 197.6 5,763 4,323
1.875 6 -- UN 2.300 130 299.0 239.2 7,475 5,606
2.000 4.5 -- UNC 2.500 130 325.0 260.0 8,667 6,500
2.125 6 -- UN 3.030 130 393.9 315.1 11,161 8,370
2.250 4.5 -- UNC 3.250 130 422.5 338.0 12,675 9,506
2.375 6 -- UN 3.850 130 500.5 400.4 15,849 11,887
2.500 4.0 -- UNC 4.000 130 520.0 416.0 17,333 13,000
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Pemex Exploracion y Produccion – Ideal 135 Page: xxxvi of xxxvi

Preservation Procedure
From time to time it may be necessary to remove equipment from service for extended periods. It is
highly desirable to perform some basic pickling or preserving procedures to maximize the storage life of
the equipment and minimize the expense of activating the equipment after storage.
Galvanized or Painted Derrick Long Term Storage

Galvanized equipment that has its protective coating intact with no breaks in the surface going down to
the raw metal requires only minimum preparation for long term storage.
Unassembled Storage
Inspect all surface areas of the primary structural members for coating damage to the protective
galvanized coating. Repair surface as necessary to prevent air and moisture contact with raw metal.
When the integrity of the surface has been determined, all members should be placed on wooden
blocks, off the ground, and with minimum contact with each other. Use wood spacers to stack layers.
NOTE
Primary objective is to eliminate all contact with the ground,
vegetation or anything else that would allow the metal
prolonged contact with water and without the ability to dry out.
Standing water and particularly submerged metal in standing
water, for prolonged periods of time, must be avoided.
Assembly bolts, pins, etc., assuming these have only partial or no galvanized surfaces, should be
stored in shipping containers or coated in light oil. Pack or bag in airtight and watertight containers and
store to avoid standing water. Inspect containers periodically, particularly after being submerged, for
water contamination and container integrity.
Crown and other assemblies with sheaves and roller bearings have special requirements:
If stored outside, with exposure to rain, etc., all bearings must be fully packed with a Lithium-based
number 2 EP grease before prolonged storage. In addition, crown and other sheaves and/or bearings
must be rotated at least ten (10) full revolutions every two (2) weeks.
If stored inside, in a building, sheave bearing rotation is necessary only every two (2) months.
Assembled Storage
The Derrick itself is galvanized and needs no additional preparation for storage except an inspection to
ensure that all surface areas of the primary structural members are not damaged and the integrity of
the galvanized coating is intact.
Assembly bolts, pins, etc., assuming these have only partial or no galvanized surfaces, need to be
inspected periodically (every 2 months) for corrosion or rust. If detected, these should be sprayed with
a cold galvanizing compound.
Crown and other assemblies with sheaves and roller bearings need to be fully packed with a Lithium-
based number 2 EP grease and must be rotated at least ten (10) full revolutions every two (2) weeks.
This prevents moisture migration that causes corrosion and rust of the rollers and braces and leads to
premature if not immediate bearing failure, depending on the amount of corrosion and rust.
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FINAL DOCUMENTATION
Ideal Rig 135
Chapter 6.0
Power System
www.nov.com
FINAL DOCUMENTATION
Ideal Rig 135
Section 6.1
Electrical Accessories
www.nov.com
6200 SERIES
ALUMINUM OR
STAINLESS STEEL
FLUORESCENT
HAZARDOUS
CLASS I, DIV. 2
GROUPS A, B, C & D
LISTINGS:
• UL/CUL Listed (UL 844)
Class I, Div. 2
Groups A, B, C & D
• UL Listed (UL 1598A)
FEATURES & SPECIFICATIONS:
Marine/Outdoor use
Construction
• IP 66
• Heavy-duty formed and welded housing and door frame of copper-free
• ABS Approved
aluminum or 304 stainless steel alloys (316 stainless steel optional)
• Ballast is replaceable from inside the fixture without removing • *55°C Ambient
*T12HO, T5 & T5HO
from mounting
• All external hardware is stainless steel to resist corrosion
• Heavy-duty safety cable harness welded at both ends
• One-piece high temperature propylene gasket provides a water-tight APPLICATIONS:
seal between the door frame and housing • Drilling rigs
• Latching system allows for tool-free access to lamp chamber • Offshore platforms
(see inset below) • Chemical plants
• Lens can be easily replaced in existing door frame • Pharmaceutical plant
• 1⁄2” or 3⁄4” hub supplied on one end with option for hubs on both ends • Mining
for thru-wiring • Shipyard facilities
• Standard finish is natural aluminum or unfinished stainless steel • Coastal marine facilities
• Power generation plant
Optical System • Hazardous storage areas
• Impact resistant polycarbonate lens is standard, other lenses available • Marine shipping
• High reflectance die formed pre-coated aluminum reflector • Cold storage facilities
• Corrosive atmospheres
Electrical System
• Ballasts are UL listed (UL 935) and CSA certified, Class P, high
power factor, Type 1 Outdoor, Type HL OPTIONS:
• All electronic ballasts are universal voltage (120-277V, ≤10% THD) • 316 Stainless steel housing
operating at 50/60HZ standard & door frame
• Cold weather operation to -20°C (T8HO & T12HO) and 0°C (T8) • Emergency battery
• Cold weather operation to 0°C with optional battery pack (1 or 2 lamps, 350-575 lumens)
• Lamps are supplied standard on both 2’ & 4’ models • Fusing (Non-Marine)
• Hubs on both ends
SNELSON’S STAINLESS STEEL for thru wiring
TOOL-FREE LATCHING SYSTEM • 4’ Stainless steel safety cable
• Various mounting options
SHIPPING WEIGHT:
• 20 LBS Aluminum
• 29 LBS Stainless Steel
6200 SERIES FLUORESCENT
ORDERING INFORMATION
LAMP CURRENT
SERIES CONSTRUCTION & WATTAGE LENGTH VOLTAGE OPTIONS
62 A 800 4 A
SERIES CONSTRUCTION LENGTH OPTIONS

62 = 6200 SERIES A = ALUMINUM 2 = 2’ C = 1/2” HUB ONE END
SS = STAINLESS STEEL (304) 4 = 4’ D = 1/2” HUB EACH END
E = 3/4” HUB ONE END
LAMP CURRENT VOLTAGE EM = EMERGENCY
& WATTAGE A = MULTI-VOLT BATTERY
800 = 800MA 60/35 WATT (T12HO LAMPS) (120V-277V, 50HZ/60HZ) F = 3/4” HUB EACH END
430 = 430MA 34/20 WATT (T12 LAMPS) E = 12 VOLT DC 316 = 316 STAINLESS
265 = 265MA 32/17 WATT (T8 LAMPS) H = 347V/60HZ STEEL
14 = 14W T5 (2’) **Multi-volt ballast
24H = 24W T5HO (2’) (“A” option above)
28 = 28W T5 (4’) operates at 220V/50HZ
44H = 44W T8HO (4’)
54H = 54W T5HO (4’)
(HUB MATERIAL METALLIC UNLESS OTHERWISE NOTED)
MOUNTING OPTIONS
4315 5030 5032 5037 5040 ADJUSTABLE MOUNTING KIT

5022
RELATED PRODUCTS
5200 SERIES 7200 SERIES PLUGS AND RECEPTACLES

CSA LABEL OPTIONAL UL LISTED, CLASS I, DIV. 1 LEXAN (NON LISTED)
DIMENSIONS
SNELSON OILFIELD LIGHTING

817-926-0571 Phone
3619 ALICE STREET www.snelsonlights.com 817-926-0741 Fax
FORT WORTH, TX 76110
7200 SERIES
EXPLOSION PROOF
FLUORESCENT
CLASS I, DIV. 1
GROUPS C & D
LISTINGS:
• UL/CUL Listed (UL 844)
Class I, Div. 1
Groups C & D
• UL Listed (UL 1598A)
Marine/Outdoor use
INTENDED USE: • ABS Approved
Designed for use in hazardous locations where flammable gases, vapors
and combustible dusts are normally present
APPLICATIONS:
• Drilling rigs
FEATURES & SPECIFICATIONS: • Offshore platforms
Construction • Waste water treatment plants
• Housing and end caps are heavy-duty cast, copper-free aluminum • Paint booths
that is both durable and corrosion resistant • Shipyard facilities
• End caps are removable without the use of special tools • Coastal marine areas
• External hardware is 316 stainless steel • Chemical plants
• One-piece high temperature propylene gasket protects ballast • Pharmaceutical plants
housing and end caps from outside elements • Mining
• Spring-loaded sockets provide positive electrical • Cold storage facilities
contact and vibration resistance • Hazardous storage areas
• Threaded end caps allow relamping from either side of the fixture • Corrosive environments
Optical System
• Reflector is heavy-duty extruded aluminum with a white powder
coat finish providing high reflectance OPTIONS:
• Tempered borosilicate glass tubes • Emergency battery pack
(1100 lumens)
Electrical • Wire guard (4’ only)
• Ballasts are UL listed (UL 935) and CSA certified, Class P, high • Shock mount kit
power factor, Type 1 Outdoor, Type HL • 4’ Stainless steel safety cable
• All electronic ballasts are universal voltage (120V-277V)
operating at 50/60 HZ standard
• Lamps are supplied standard on 2’ and 4’ models
SHIPPING WEIGHT:
• 53 LBS (Standard Unit)
• 75 LBS (Emergency Unit)
7200 SERIES FLUORESCENT
ORDERING INFORMATION
LAMP CURRENT
SERIES CONSTRUCTION & WATTAGE LENGTH VOLTAGE OPTIONS
72 A 800 4 A
SERIES CONSTRUCTION LENGTH OPTIONS

72 = 7200 SERIES A = ALUMINUM 2 = 2’ EM = EMERGENCY
FLUORESCENT 4 = 4’ BATTERY
LAMP CURRENT WG = WIRE GUARD
& WATTAGE VOLTAGE (STAINLESS STEEL)
800 = 800MA 60/35 WATT (T12HO LAMPS) A = MULTI-VOLT 4’ ONLY
430 = 430MA 34/20 WATT (T12 LAMPS) (120V-277V, 50HZ/60HZ) TB = TERMINAL BLOCK
265 = 265MA 32/17 WATT (T8 LAMPS) E = 12 VOLT DC
44H = 44W T8HO (4’) H = 347V/60HZ
**Multi-volt ballast (“A” option above)
operates at 220V/50HZ
MOUNTING OPTIONS
4315 5037 5039 5040 7301

STAINLESS STEEL SHOCK MOUNT KIT
RELATED PRODUCTS
7400 SERIES
6200 SERIES 6500 SERIES ETL LISTED TO UL
UL LISTED, CLASS I, DIV. 2 UL LISTED, CLASS I, DIV. 2 STANDARDS, CLASS I, DIV. 2
DIMENSIONS
SNELSON OILFIELD LIGHTING

817-926-0571 Phone
3619 ALICE STREET www.snelsonlights.com 817-926-0741 Fax
FORT WORTH, TX 76110
Conductor
Tin-coated copper, Exane®-125
(various strandings) Oil Rig/Commercial
Marine
Single Conductor Power*
Unarmored
(XLPO)
600 & 2000 Volt
UL Marine Shipboard
(E83358)
Insulation IEEE 45, /IEEE 1580 Type P
Flame retardant UL 1309/CSA C22.2 No.245
crosslinked polyolefin
Spec. DAA1048B
Scope
Exane®-125 single conductor 600 and 2000 volt cable is and moisture. The material also has excellent flame
an extremely tough construction ideally suited for use retardance, acid gas, and electrical characteristics. Due
in rugged marine/oil rig applications. The insulation has to Exane’s 125°C temperature rating, ampacity levels
outstanding resistance to abrasion, cut-through, low are higher. This leads to important benefits regarding
and high temperatures, petrochemical fluids, sunlight, size, weight, tray fill, and ease of installation.
Features Performance Standards Construction

• Thermoset Insulation • IEEE-45, /IEEE 1580 Type P Conductor:
Annealed, Tinned copper per ASTM
• Superior mechanical properties • UL 1309 Marine Shipboard Cable B33, B8 and B172
(File E83358)
• Flexible construction Insulation:
• CSA C22.2 No. 245 Marine Shipboard Irradiated crosslinked polyolefin
• Flame retardant
• U.S. Coast Guard recognized Exane®125°C* (Colors – as required)
• Excellent fluid/oil resistance
• Canadian Coast Guard recognized
• Moisture and sunlight resistant
• Performance Requirements of IEC 92-3
• Type approved ABS, DNV, NVE and
Lloyds
• IEC 332-3 Category “A” Flame Test * Rockbestos Surprenant rated 125°C, UL 110°C
and IEEE-45 100°C
• Insulation ICEA Standard S-95-658
and NEC Type XHHW
• IEC 60092-353
• Meets requirements of 46 CFR Parts
110 and 111
Rockbestos-Surprenant Cable Corp. © 2001 • Clinton, MA • East Granby, CT • 800-444-3792 • 978-365-6331 • Fax: 978-365-4054 • http://www.r-scc.com R-1
Exane®-125
Oil Rig/Commercial Marine
Single Conductor Power*
Unarmored
(XLPO) 600 & 2000 Volt
UL/CSA Marine Shipboard Cable
IEEE 45/IEEE 1580 Type P
Spec. DAA1048B
600 Volt
Nominal
Number Insulation Overall Approx.
Product of AWG/ Thickness Diameter Net Weight
Number Conductors MCM mm2 Stranding Inches mm Inches mm Lbs/m’ kg/km
O1C18-600V 1 18 0.96 19/30 .030 .76 .107 2.72 11 16
O1C16-600V 1 16 1.22 19/29 .030 .76 .114 2.90 13 19
O1C14-600V 1 14 1.94 19/27 .030 .76 .127 3.23 18 27
O1C12-600V 1 12 3.08 19/25 .030 .76 .146 3.71 27 40
O1C10-600V 1 10 5.53 27/24 .030 .76 .183 4.65 45 68
O1C8-600V 1 8 7.58 37/24 .045 1.14 .231 5.87 65 97
O1C6-600V 1 6 12.50 61/24 .045 1.14 .280 7.11 101 152
O1C5-600V 1 5 18.60 91/24 .045 1.14 .330 8.38 149 222
O1C4-600V 1 4 21.50 105/24 .045 1.14 .350 8.89 165 248
O1C3-600V 1 3 25.00 125/24 .045 1.14 .375 9.53 195 290
O1C2-600V 1 2 30.70 150/24 .045 1.14 .410 10.41 233 358
O1C1-600V 1 1 46.00 225/24 .055 1.40 .495 12.57 343 515
O1C1/0-600V 1 1/0 56.30 275/24 .055 1.40 .545 13.84 408 612
O1C2/0-600V 1 2/0 66.50 325/24 .055 1.40 .590 14.99 481 722
O1C3/0-600V 1 3/0 92.10 450/24 .055 1.40 .660 16.76 653 980
O1C4/0-600V 1 4/0 112.60 550/24 .055 1.40 .720 18.29 790 1176
O1C262-600V 1 262 133.00 650/24 .065 1.65 .785 19.94 931 1385
O1C313-600V 1 313 158.60 775/24 .065 1.65 .850 21.59 1099 1635
O1C373-600V 1 373 189.30 925/24 .065 1.65 .900 22.86 1300 1934
O1C444-600V 1 444 225.10 1100/24 .065 1.65 .980 24.89 1551 2308
O1C535-600V 1 535 271.20 1325/24 .080 2.03 1.110 28.20 1930 2895
O1C646-600V 1 646 327.00 1600/24 .080 2.03 1.215 30.86 2250 3348
O1C777-600V 1 777 394.00 1925/24 .080 2.03 1.280 32.51 2670 3973
O1C1111-600V 1 1111 563.00 2750/24 .110 2.80 1.530 38.90 3780 5625
2000 Volt
Nominal
O1C18-2KV 1 18 0.97 19/30 .045 1.14 .137 3.47 15 23
O1C16-2KV 1 16 1.22 19/29 .045 1.14 .144 3.66 17 25
O1C14-2KV 1 14 1.94 19/27 .045 1.14 .157 3.99 23 35
O1C12-2KV 1 12 3.08 19/25 .045 1.14 .176 4.47 32 48
O1C10-2KV 1 10 5.53 27/24 .045 1.14 .213 5.41 50 75
O1C8-2KV 1 8 7.58 37/24 .055 1.40 .252 6.40 71 106
O1C6-2KV 1 6 12.50 61/24 .055 1.40 .305 7.75 105 157
O1C5-2KV 1 5 18.60 91/24 .055 1.40 .354 8.99 157 234
O1C4-2KV 1 4 21.50 105/24 .055 1.40 .374 9.50 176 264
O1C3-2KV 1 3 25.00 125/24 .055 1.40 .399 10.13 208 312
O1C2-2KV 1 2 30.70 150/24 .055 1.40 .434 11.02 240 358
O1C1-2KV 1 1 46.00 225/24 .065 1.65 .519 13.18 360 540
O1C1/0-2KV 1 1/0 56.30 275/24 .065 1.65 .565 14.35 435 653
O1C2/0-2KV 1 2/0 66.50 325/24 .065 1.65 .610 15.50 492 738
O1C3/0-2KV 1 3/0 92.10 450/24 .065 1.65 .679 17.25 685 1028
O1C4/0-2KV 1 4/0 112.60 550/24 .105 2.67 .820 20.83 852 1278
O1C262-2KV 1 262 133.10 650/24 .105 2.67 .862 21.89 981 1460
O1C313-2KV 1 313 158.70 775/24 .105 2.67 .930 23.62 1131 1670
O1C373-2KV 1 373 189.00 925/24 .105 2.67 .980 24.89 1354 2031
O1C444-2KV 1 444 225.20 1100/24 .105 2.67 1.060 25.92 1607 2410
O1C535-2KV 1 535 271.30 1325/24 .120 3.05 1.165 29.60 1994 2990
O1C646-2KV 1 646 327.00 1600/24 .120 3.05 1.295 32.89 2303 3455
O1C777-2KV 1 777 394.00 1925/24 .120 3.05 1.360 34.54 2734 4100
O1C1111-2KV 1 1111 563.00 2750/24 .120 3.05 1.580 40.13 3743 5615
R-2 Rockbestos-Surprenant Cable Corp. © 2001 • Clinton, MA • East Granby, CT • 800-444-3792 • 978-365-6331 • Fax: 978-365-4054 • http://www.r-scc.com
Conductor
Jacket
Tin-coated copper, Exane-125®
(various strandings) Oil Rig/Commercial
Neoprene
Marine
Multicondcutor Power Cable
Unarmored
(XLPO/NEO)
600 Volt
UL Marine Shipboard
E83358
Crosslinked polyolefin UL 1309/CSA C22.2 No.245
Spec. DAC1048C
Scope
Exane-125® multiconductor unarmored drill rig wide ambient temperature range. These cables also
power cable is ideally suited for use in rugged rig exceed current industry standards regarding tempera-
applications. These constructions provide a cable with ture rating and ampacity which provides important
outstanding resistance to mechanical abuse, moisture, benefits regarding size, weight, tray fill and ease of
flame, sunlight, and petrochemical fluids through a installation.

• Wide insulated conductor temperature • IEEE-45, /IEEE 1580 Type P Conductors:
range –55°C to 125°C Annealed, Tinned copper per ASTM
• UL 1309 Marine Shipboard Cable B33, B8 and B172
• Superior mechanical properties (File E83358)
Insulation:
• Flexible construction • CSA C22.2 No. 245 Marine Shipboard Irradiated Crosslinked polyolefin
• Flame retardant • U.S. Coast Guard recognized Exane® 125°C*
• Excellent fluid/oil resistance • Canadian Coast Guard recognized Color Code**:

IEEE 45-1998 Table 8-31
• Moisture and sunlight resistant • Performance Requirements of IEC 92-3
Fillers:
• Type approved ABS, DNV, NVE and When required, flame retardant and non-
Lloyds hygroscopic
• IEC 332-3 Category “A” Flame Test Binder Tape:
Non-hygroscopic and non-wicking
• Insulation ICEA S-95-658
Jacket:
• IEC 60092-353 Black arctic neoprene
• Meets requirements of 46 CFR Parts
110 and 111 * Rockbestos Surprenant rated 125°C, UL 110°C
and IEEE-45 100°C.
** Other color codes available upon request
Exane-125®
Multiconductor Power Cable
Unarmored
(XLPO/NEO) 600 Volt
Spec. DAC1048C
Nominal
O2C8 2 8 7.57 37/24 .045 1.14 .590 14.99 217 326
O2C6 2 6 12.50 61/24 .045 1.14 .700 17.78 316 474
O2C5 2 5 18.60 91/24 .045 1.14 .790 20.07 409 614
O2C4 2 4 21.50 105/24 .045 1.14 .870 22.10 506 759
O2C3 2 3 25.60 125/24 .045 1.14 .920 23.37 583 875
O2C2 2 2 30.70 150/24 .045 1.14 .990 25.15 682 1023
O2C1 2 1 46.00 225/24 .055 1.40 1.160 29.46 923 1385
O2C1/0 2 1/0 56.30 275/24 .055 1.40 1.260 32.00 1087 1630
O2C2/0 2 2/0 66.50 325/24 .055 1.40 1.350 34.29 1271 1907
O2C3/0 2 3/0 92.10 450/24 .055 1.40 1.530 38.86 1870 2805
O2C4/0 2 4/0 112.60 550/24 .055 1.40 1.670 42.42 2220 3330
O2C262 2 262 133.00 650/24 .065 1.65 1.830 46.48 2600 3900
O2C313 2 313 158.60 775/24 .065 1.65 1.960 49.78 3100 4650
O2C373 2 373 189.30 925/24 .065 1.65 2.060 61.21 3605 5408
O2C444 2 444 225.10 1100/24 .065 1.65 2.220 56.39 4135 6023
O2C535 2 535 271.20 1325/24 .080 2.03 2.495 63.37 4950 7425
O2C646 2 646 327.50 1600/24 .080 2.03 2.720 69.09 5860 8790
O2C777 2 777 393.80 1925/24 .080 2.03 2.850 72.39 7010 10515
O3C8 3 8 7.57 37/24 .045 1.14 .625 15.88 275 413

O3C6 3 6 12.50 61/24 .045 1.14 .735 18.67 403 605
O3C5 3 5 18.60 91/24 .045 1.14 .880 22.35 572 858
O3C4 3 4 21.50 105/24 .045 1.14 .925 23.50 666 999
O3C3 3 3 25.60 125/24 .045 1.14 .975 24.77 761 1142
O3C2 3 2 30.70 150/24 .045 1.14 1.050 26.67 891 1337
O3C1 3 1 46.00 225/24 .055 1.40 1.235 31.37 1270 1905
O3C1/0 3 1/0 56.30 275/24 .055 1.40 1.340 34.04 1479 2219
O3C2/0 3 2/0 66.50 325/24 .055 1.40 1.480 37.59 1795 2693
O3C3/0 3 3/0 92.10 450/24 .055 1.40 1.650 41.91 2385 3578
O3C4/0 3 4/0 112.60 550/24 .055 1.40 1.780 45.21 2901 4352
O3C262 3 262 133.00 650/24 .065 1.65 1.940 49.28 3393 5090
O3C313 3 313 158.60 775/24 .065 1.65 2.090 53.09 3968 5952
O3C373 3 373 189.30 925/24 .065 1.65 2.195 55.75 4633 6950
O3C444 3 444 225.10 1100/24 .065 1.65 2.395 60.83 5552 8328
O3C535 3 535 271.20 1325/24 .080 2.03 2.660 67.56 6824 10236
O3C646 3 646 327.50 1600/24 .080 2.03 2.905 73.79 8016 12024
O3C777 3 777 393.80 1925/24 .080 2.03 3.040 77.22 9382 14073
O4C8 4 8 7.57 37/24 .045 1.14 .690 17.53 356 534

O4C6 4 6 12.50 61/24 .045 1.14 .805 20.47 524 786
O4C5 4 5 18.60 91/24 .045 1.14 .965 24.51 748 1122
O4C4 4 4 21.50 105/24 .045 1.14 1.020 25.91 863 1295
O4C3 4 3 25.60 125/24 .045 1.14 1.080 27.43 982 1473
O4C2 4 2 30.70 150/24 .045 1.14 1.160 29.46 1153 1730
O4C1 4 1 46.00 225/24 .055 1.40 1.350 34.29 1650 2475
O4C1/0 4 1/0 56.30 275/24 .055 1.40 1.520 38.35 1950 2925
O4C2/0 4 2/0 66.50 325/24 .055 1.40 1.650 41.91 2372 3558
O4C3/0 4 3/0 92.10 450/24 .055 1.40 1.820 46.23 3216 4824
O4C4/0 4 4/0 112.60 550/24 .055 1.40 1.995 50.67 3815 5723
O4C262 4 262 133.00 650/24 .065 1.65 2.145 54.48 4435 6653
O4C313 4 313 158.60 775/24 .065 1.65 2.340 59.44 5292 7938
O4C373 4 373 189.30 925/24 .065 1.65 2.460 62.48 6276 9414
O4C444 4 444 225.10 1100/24 .065 1.65 2.650 67.31 7390 11085
O4C535 4 535 271.20 1325/24 .080 2.03 2.940 74.68 9159 13739
O4C646 4 646 327.50 1600/24 .080 2.03 3.220 81.79 10654 15980
O4C777 4 777 393.80 1925/24 .080 2.03 3.375 85.73 12730 19095
O5C8 5 8 7.57 37/24 .045 1.14 .760 19.30 410 615

O5C6 5 6 12.50 61/24 .045 1.14 .925 23.50 675 1013
O5C5 5 5 18.60 91/24 .045 1.14 1.060 26.92 960 1440
O5C4 5 4 21.50 105/24 .045 1.14 1.115 28.32 1055 1583
O5C3 5 3 25.60 125/24 .045 1.14 1.185 30.10 1270 1905
O5C2 5 2 30.70 150/24 .045 1.14 1.280 32.51 1412 2118
O5C1 5 1 46.00 225/24 .055 1.40 1.550 39.37 2168 3252
O5C1/0 5 1/0 56.30 275/24 .055 1.40 1.700 43.18 2514 3771
O5C2/0 5 2/0 66.50 325/24 .055 1.40 1.825 46.36 3005 4508
O5C3/0 5 3/0 92.10 450/24 .055 1.40 2.040 51.82 4046 6069
O5C4/0 5 4/0 112.60 550/24 .055 1.40 2.210 56.13 4682 7023
Inner Jacket Drain Wires
Outer Sheath Neoprene Tin-coated copper Conductor
Exane-125®
Neoprene Tin-coated copper, Oil Rig/Commercial
(various strandings) Marine
Signal Cable
Armored and Sheathed
(XLPO/NEO)
Multi-Shielded Pairs With
Overall Shield
600 Volt
Armor Shield Insulation UL Marine Shipboard (E83358)
Tape Crosslinked IEEE 45, /IEEE 1580 Type P
polyolefin UL 1309/CSA C22.2 No.245
Spec. DAC1048C
Scope
Exane-125® multiconductor signal cables are ideally abuse, moisture, flame, sunlight, and petrochemical
suited for use in signal applications including elec- fluids through a wide ambient temperature range.
tronic governor actuators, interconnect cable for driller These cables also provide important benefits regarding
consoles, and SCR systems located in a high electro- size, weight, tray fill, and ease of installation. These
static noise environment. These constructions provide cables may be supplied either with armor or with
a cable with outstanding resistance to mechanical armor and sheath.

• Wide insulated conductor temperature • IEEE-45, /IEEE 1580 Type P Conductors:
range –55°C to 125°C Annealed, Tinned copper per ASTM
• UL 1309 Marine Shipboard Cable B33, B8 and B172
• Thermoset Insulation (File E83358)
Insulation:
• Superior mechanical properties • CSA C22.2 No. 245 Marine Shipboard Irradiated Crosslinked polyolefin
• Flexible construction • U.S. Coast Guard recognized Exane® 125°C*
Pair Assembly*:
• Flame retardant • Canadian Coast Guard recognized
Two insulated conductors twisted with a
• Excellent fluid/oil resistance • Performance Requirements of IEC 92-3 tin-coated copper drain wire, a helically
applied aluminum/polyester laminated
• Moisture and sunlight resistant • Type approved ABS, DNV, NVE and tape shield, and an isolation tape
Lloyds
Cabling:
• IEC 332-3 Category “A” Flame Test Required number of pairs cabled together
• Insulation ICEA S-95-658 Overall Shield System**:
Helically applied aluminum/polyester
• IEC 60092-353 laminated tape shield in continuous con-
• Meets requirements of 46 CFR Parts tact with tin-coated copper drain wire
110 and 111 Color Code***:
IEEE 45-1998 Table 8-31
* Rockbestos Surprenant rated 125°C, UL 110°C Inner Jacket:

and IEEE-45 100°C. Arctic neoprene
** Tinned copper braid optional Armor:
*** Other color codes available upon request Bronze, aluminum tinned copper
Outer Jacket:
Black arctic Neoprene
Exane-125®
Signal Cable
Armored and Sheathed
(XLPO/NEO) 600 Volt
Multi-Shielded Pairs With Overall Shield
Spec. DAC1048C
Nominal
Number Pairs MCM mm2 Stranding Inches mm Inches mm Lbs/m’ kg/km
O1P22I/S-OSBN 1 22 0.38 19/34 .030 .76 .497 12.62 162 243
O2P22I/S-OSBN 2 22 0.38 19/34 .030 .76 .668 13.96 264 396
O3P22I/S-OSBN 3 22 0.38 19/34 .030 .76 .678 17.22 266 399
O4P22I/S-OSBN 4 22 0.38 19/34 .030 .76 .745 18.92 322 483
O5P22I/S-OSBN 5 22 0.38 19/34 .030 .76 .785 19.94 350 525
O6P22I/S-OSBN 6 22 0.38 19/34 .030 .76 .882 22.40 432 648
O7P22I/S-OSBN 7 22 0.38 19/34 .030 .76 .882 22.40 443 664
O8P22I/S-OSBN 8 22 0.38 19/34 .030 .76 .925 23.49 480 720
O10P22I/S-OSBN 10 22 0.38 19/34 .030 .76 1.027 26.08 568 852
O12P22I/S-OSBN 12 22 0.38 19/34 .030 .76 1.088 27.63 654 981
O16P22I/S-OSBN 16 22 0.38 19/34 .030 .76 1.190 30.22 770 1155
O17P22I/S-OSBN 17 22 0.38 19/34 .030 .76 1.237 31.42 814 1221
O19P22I/S-OSBN 19 22 0.38 19/34 .030 .76 1.256 31.90 850 1275
O20P22I/S-OSBN 20 22 0.38 19/34 .030 .76 1.280 32.51 885 1327
O24P22I/S-OSBN 24 22 0.38 19/34 .030 .76 1.450 36.83 1090 1635
O1P20I/S-OSBN 1 20 0.61 19/32 .030 .76 .511 12.98 165 247

O2P20I/S-OSBN 2 20 0.61 19/32 .030 .76 .725 18.41 298 447
O3P20I/S-OSBN 3 20 0.61 19/32 .030 .76 .738 18.74 325 487
O4P20I/S-OSBN 4 20 0.61 19/32 .030 .76 .782 19.86 363 544
O5P20I/S-OSBN 5 20 0.61 19/32 .030 .76 .888 22.55 438 657
O6P20I/S-OSBN 6 20 0.61 19/32 .030 .76 .925 23.49 482 723
O7P20I/S-OSBN 7 20 0.61 19/32 .030 .76 .925 23.49 500 750
O8P20I/S-OSBN 8 20 0.61 19/32 .030 .76 .978 24.84 545 817
O10P20I/S-OSBN 10 20 0.61 19/32 .030 .76 1.123 28.50 694 1041
O12P20I/S-OSBN 12 20 0.61 19/32 .030 .76 1.132 28.75 735 1080
O16P20I/S-OSBN 16 20 0.61 19/32 .030 .76 1.254 31.85 888 1103
O20P20I/S-OSBN 20 20 0.61 19/32 .030 .76 1.340 34.03 1052 1578
O24P20I/S-OSBN 24 20 0.61 19/32 .030 .76 1.540 39.11 1250 1875
O1P18I/S-OSBN 1 18 0.96 19/30 .030 .76 .530 13.46 270 405

O2P18I/S-OSBN 2 18 0.96 19/30 .030 .76 .795 20.19 376 564
O3P18I/S-OSBN 3 18 0.96 19/30 .030 .76 .864 21.94 454 681
O4P18I/S-OSBN 4 18 0.96 19/30 .030 .76 .917 23.29 508 762
O5P18I/S-OSBN 5 18 0.96 19/30 .030 .76 .928 23.57 525 787
O6P18I/S-OSBN 6 18 0.96 19/30 .030 .76 1.034 26.26 580 870
O7P18I/S-OSBN 7 18 0.96 19/30 .030 .76 1.034 26.26 656 984
O8P18I/S-OSBN 8 18 0.96 19/30 .030 .76 1.203 30.55 814 1221
O10P18I/S-OSBN 10 18 0.96 19/30 .030 .76 1.263 32.08 897 1345
O12P18I/S-OSBN 12 18 0.96 19/30 .030 .76 1.294 32.86 998 1497
O14P18I/S-OSBN 14 18 0.96 19/30 .030 .76 1.345 34.16 1070 1605
O16P18I/S-OSBN 16 18 0.96 19/30 .030 .76 1.442 36.62 1194 1791
O20P18I/S-OSBN 20 18 0.96 19/30 .030 .76 1.525 38.73 1360 2040
O24P18I/S-OSBN 24 18 0.96 19/30 .030 .76 1.721 43.71 1688 2532
O1P16I/S-OSBN 1 16 1.22 19/29 .030 .76 .545 13.84 195 292

O2P16I/S-OSBN 2 16 1.22 19/29 .030 .76 .799 20.29 389 583
O3P16I/S-OSBN 3 16 1.22 19/29 .030 .76 .891 22.63 487 730
O4P16I/S-OSBN 4 16 1.22 19/29 .030 .76 .926 23.52 533 799
O5P16I/S-OSBN 5 16 1.22 19/29 .030 .76 .968 24.58 548 822
O6P16I/S-OSBN 6 16 1.22 19/29 .030 .76 1.025 26.03 612 918
O7P16I/S-OSBN 7 16 1.22 19/29 .030 .76 1.025 26.03 640 960
O8P16I/S-OSBN 8 16 1.22 19/29 .030 .76 1.229 31.21 892 1338
O10P16I/S-OSBN 10 16 1.22 19/29 .030 .76 1.238 31.44 910 1365
O12P16I/S-OSBN 12 16 1.22 19/29 .030 .76 1.290 32.76 970 1455
O16P16I/S-OSBN 16 16 1.22 19/29 .030 .76 1.460 37.08 1250 1875
O20P16I/S-OSBN 20 16 1.22 19/29 .030 .76 1.580 40.13 1465 2197
O24P16I/S-OSBN 24 16 1.22 19/29 .030 .76 1.843 46.81 1855 2780
O1P14I/S-OSBN 1 14 1.94 19/27 .030 .76 .578 14.68 222 333

O2P14I/S-OSBN 2 14 1.94 19/27 .030 .76 .815 20.70 380 570
O3P14I/S-OSBN 3 14 1.94 19/27 .030 .76 .905 22.98 492 738
O4P14I/S-OSBN 4 14 1.94 19/27 .030 .76 .970 24.63 570 855
O5P14I/S-OSBN 5 14 1.94 19/27 .030 .76 1.032 26.21 649 973
O6P14I/S-OSBN 6 14 1.94 19/27 .030 .76 1.143 29.03 776 1164
O7P14I/S-OSBN 7 14 1.94 19/27 .030 .76 1.143 29.03 812 1218
O8P14I/S-OSBN 8 14 1.94 19/27 .030 .76 1.218 30.93 895 1342
O10P14I/S-OSBN 10 14 1.94 19/27 .030 .76 1.285 32.63 1026 1539
O12P14I/S-OSBN 12 14 1.94 19/27 .030 .76 1.442 36.62 1253 1879
O16P14I/S-OSBN 16 14 1.94 19/27 .030 .76 1.572 39.92 1512 2268
O20P14I/S-OSBN 20 14 1.94 19/27 .030 .76 1.790 45.46 1947 2920
O24P14I/S-OSBN 24 14 1.94 19/27 .030 .76 1.985 50.42 2259 3388
O10PR12I/S-OSBN 10 12 3.08 19/25 .030 .76 1.505 28.23 1512 2268
Conductor
Jacket
Tin-coated copper, Exane-125®
Binder Tape (various strandings)
Neoprene Oil Rig/Commercial
Marine
Multiconductor Control Cable
Unarmored
(XLPO/NEO)
600 Volt (14-10 AWG)
UL Marine Shipboard
E83358
Crosslinked polyolefin UL 1309/CSA C22.2 No.245
Spec. DAC1048C
Scope
Exane-125® multiconductor unarmored and sheathed fluids through a wide ambient temperature range.
drill rig control cable is ideally suited for use in These cables also exceed current industry standards
rugged rig applications. These constructions provide a regarding temperature rating and ampacity which pro-
cable with outstanding resistance to mechanical vides important benefits regarding size, weight, tray
abuse, moisture, flame, sunlight, and petrochemical fill and ease of installation.
Features Performance Standards

• Wide insulated conductor temperature • IEEE-45, /IEEE 1580 Type P Construction
range –55°C to 125°C Conductors:
• UL 1309 Marine Shipboard Cable
• Superior mechanical properties (File E83358) Annealed, Tinned copper per ASTM
B33, B8 and B172
• Flexible construction • CSA C22.2 No. 245 Marine
Shipboard• U.S. Coast Guard recog- Insulation:
• Flame retardant nized Irradiated Crosslinked polyolefin
Exane® 125°C*
• Excellent fluid/oil resistance • Canadian Coast Guard recognized
Color Code**:
• Moisture and sunlight resistant • Performance Requirements of IEC 92-3 IEEE 45-1998 Table 8-31
• Type approved ABS, DNV, NVE and Fillers:
Lloyds When required, flame retardant and non-
hygroscopic
• IEC 332-3 Category “A” Flame Test
Binder Tape:
• Insulation ICEA S-95-658 Non-hygroscopic and non-wicking
• IEC 60092-353 Jacket:
• Meets requirements of 46 CFR Parts Black arctic neoprene
110 and 111
** Rockbestos Surprenant rated 125°C, UL 110°C
and IEEE-45 100°C.
** Other color codes available upon request
Exane-125®
Multiconductor Control Cable
Unarmored
(XLPO/NEO) 600 Volt (14-10 AWG)
Spec. DAC1048C
Nominal
O2C14 2 14 1.94 19/27 .030 .76 .380 9.65 78 117
O2C12 2 12 3.08 19/25 .030 .76 .425 10.80 100 150
O2C10 2 10 5.53 27/24 .030 .76 .490 12.45 118 177
O3C14 3 14 1.94 19/21 .030 .76 .390 9.91 98 147
O3C12 3 12 3.08 19/25 .030 .76 .440 11.18 128 192
O3C10 3 10 5.53 27/24 .030 .76 .520 13.21 194 291
O4C14 4 14 1.94 19/27 .030 .76 .430 10.92 118 177
O4C12 4 12 3.08 19/25 .030 .76 .475 12.07 158 237
O4C10 4 10 5.53 27/24 .030 .76 .565 14.35 239 359
O5C14 5 14 1.94 19/27 .030 .76 .475 12.07 145 218
O5C12 5 12 3.08 19/25 .030 .76 .525 13.34 190 285
O5C10 5 10 5.53 27/24 .030 .76 .620 15.75 290 435
O6C14 6 14 1.94 19/27 .030 .76 .515 13.08 174 261
O6C12 6 12 3.08 19/25 .030 .76 .570 14.48 239 359
O6C10 6 10 5.53 27/24 .030 .76 .675 17.15 345 518
O7C14 7 14 1.94 19/27 .030 .76 .515 13.08 192 288
O7C12 7 12 3.08 19/25 .030 .76 .570 14.48 248 372
O7C10 7 10 5.53 27/24 .030 .76 .675 17.15 405 608
O8C14 8 14 1.94 19/27 .030 .76 .560 14.22 212 318
O8C12 8 12 3.08 27/24 .030 .76 .620 15.75 282 423
O8C10 8 10 5.53 37/24 .030 .76 .730 18.54 448 672
O9C10 9 10 5.53 37/24 .030 .76 .795 20.19 522 783
O10C14 10 14 1.94 19/27 .030 .76 .645 16.38 269 404
O10C12 10 12 3.08 27/24 .030 .76 .720 18.29 356 534
O10C10 10 10 5.53 37/24 .030 .76 .895 22.73 589 884
O12C14 12 14 1.94 19/27 .030 .76 .660 16.76 290 435
O12C12 12 12 3.08 19/25 .030 .76 .745 18.82 350 525
O14C14 14 14 1.94 19/27 .030 .76 .695 17.65 352 528
O16C14 16 14 1.94 19/27 .030 .76 .730 18.54 370 555
O16C12 16 12 3.08 19/25 .030 .76 .820 20.83 545 818
O19C14 19 14 1.94 19/27 .030 .76 .770 19.56 455 683
O20C14 20 14 1.94 19/27 .030 .76 .810 20.57 487 731
O20C12 20 12 3.08 19/25 .030 .76 .950 24.13 681 1022
O24C14 24 14 1.94 19/27 .030 .76 .930 23.62 611 917
O24C12 24 12 3.08 19/25 .030 .76 1.050 26.67 790 1185
O30C14 30 14 1.94 19/27 .030 .76 .990 25.15 732 1098
O30C12 30 12 3.08 19/25 .030 .76 1.110 28.19 948 1422
O37C14 37 14 1.94 19/27 .030 .76 1.060 26.92 839 1259
O37C12 37 12 3.08 19/25 .030 .76 1.200 30.48 1215 1823
O44C14 44 14 1.94 19/27 .030 .76 1.190 30.23 1016 1524
O44C12 44 12 3.08 19/25 .030 .76 1.340 34.04 1380 2070
O60C14 60 14 1.94 19/27 .030 .76 1.320 33.53 1375 2063
O60C12 60 12 3.08 19/25 .030 .76 1.530 38.86 1955 2933
O91C14 91 14 1.94 19/27 .030 .76 1.630 41.40 2144 3216
O91C12 91 12 3.08 19/25 .030 .76 1.835 46.61 2790 4185
FINAL DOCUMENTATION
Ideal Rig 135
Section 6.2
Generator House Assembly
www.nov.com
FINAL DOCUMENTATION
Ideal Rig 135
Section 6.3
Generator Set
www.nov.com
210-S637UUT-200FH-HA-1
EBS No. 10512078-001
MOTORS / GENERATORS
INSTRUCTION AND SERVICE

MANUAL FOR ALTERNATING
CURRENT SYNCHRONOUS
GENERATOR
MODEL: S637UUT-200FH-HA
EQUIPMENT FURNISHED
BY
National Oilwell Varco

500 INDUSTRIAL BLVD.
SUGAR LAND TEXAS 77478-2898
TELEPHONE: (281) 240-6111
FAX: (281) 240-5074
October 2010
MANUAL LIST
Manual Title Manual Number
Instruction and Service Manual Concerning

The Specification Details of Generator
Model S637UUT-200FH-HA 210-S637UUT-200FH-HA-1A
Instruction and Service Manual for Alternating

Current Brushless Generator with Two Bearing
Construction 210-GEN2BRG-1
PART I
210-S637UUT-200FH-HA-1A
MOTORS / GENERATORS
INSTRUCTION AND SERVICE

MANUAL CONCERNING
THE SPECIFICATION DETAILS
OF GENERATOR
MODEL: S637UUT-200FH-HA
EQUIPMENT FURNISHED
BY

TELEPHONE: (281) 240-6111
FAX: (281) 240-5074
SPECIFICATIONS
TABLE OF CONTENTS
Paragraph Page
1.1 GENERATOR TECHNICAL DESCRIPTION 1-1
1.1.1 Application 1-1
1.1.2 Ratings 1-1
1.1.3 Bearing 1-1
1.1.3.1 Bearing Lubrication 1-1
1.1.3.2 Bearing Operating Temperature 1-2
1.1.4 Alignment 1-2
1.1.5 Space Heater 1-2
1.1.6 Electrical Connection Junction Box 1-2
1.2 ELECTRICAL SPECIFICATION 1-4
1.2.1 Generator Electrical Data Sheet 1-4
1.2.2 Reactive Capability Curve 1-5
1.3 PARTS LIST 1-6
1.4 DRAWINGS 1-7
General Outline, S637UUT-200 Series G77591
Wk2 for Torsional Analysis G79335
i
SPECIFICATIONS
1.1 GENERATOR TECHNICAL DESCRIPTION
1.1.1 Application
MODEL S637UUT-200FH-HA GENERATOR
1.1.2 Ratings
1,225 Kilowatts
600 Volts
0.7 Power Factor
1,684 Amperes
60 Hertz
3 Phase
1,200 RPM
Refer to the electrical specification provided in this manual for more detailed
electrical rating information.
1.1.3 Bearing
This generator is of two bearing construction. The rotating field and shaft
assembly is supported by a self aligning spherical roller bearing installed at each
end. The bearings are grease lubricated with lip seals and include provisions for
re-greasing during operation.
1.1.3.1 Bearing Lubrication

Grease lubricated anti-friction bearings (NGLI #3)
A high quality NGLI #3 grease is recommended, with the following physical
properties:
Soap Base ...........................................................................................................Lithium

Dropping Point........................................................................................ 300ºF to 450ºF
Worked Penetration Per ASTM D217......................................................... 238 NGLI #3
Operating Temperature Range................................................................... 0ºF to 275ºF
Oxidation Inhibited................................................................................................... YES
Corrosion Inhibited .................................................................................................. YES
The use of the following grease is recommended:

Shell Oil Company - Alvania 3 - Product Code 71013
The generator is furnished with the bearing already packed with the correct
amount of grease for initial operation. Every 2000 hours of operation or 3
months, whichever is sooner, grease should be added to the bearing to insure
prolonged life of the bearing. The bearing housing is equipped with a grease
zerk and a grease vent to facilitate the addition of grease to the bearing.
Approximately two ounces from a grease gun should be added to the bearing at
each re-lubrication. Caution should be taken to avoid over greasing the bearing,
as this can cause the bearing to overheat and result in excessive wear on the
seals of the bearing housing.
1-1
1.1.3.1 Bearing Lubrication (Cont’d)
Should it become necessary to remove the bearing from the generator, it should
be thoroughly inspected for wear or damage prior to re-installation, and replaced
if necessary. The seals of the bearing housing should also be inspected for wear
or damage and replaced if necessary. When re-installing the bearing, the bearing
should be hand packed with grease and the bearing housings should be packed
1/2 to 2/3 full with grease.
Care should be taken to insure that no foreign material is allowed into the grease,
bearing or bearing housing.
1.1.3.2 Bearing Operating Temperature

Monitoring of bearing temperature can provide a warning of an impending failure
of a bearing and prevent costly mechanical damage resulting from bearing
failure. The operating temperature of a bearing can vary depending on load,
speed and the amount of grease in the bearing. Monitoring of bearing
temperature should focus on a sudden increase in bearing operating
temperature, over temperatures which have been observed as normal for a
specific generator. A bearing should be closely monitored if its operating
temperature exceeds 210oF (99oC). The generator should be shut down and the
bearing inspected or replaced if the operating temperature of the bearing reaches
225oF (107oC). The above desired limits are to be determined by measurement
of the temperature of the bearing housing.
1.1.4 Alignment
Refer to the generator alignment procedures provided in the “Instruction and
Service Manual for Alternating Current Brushless Generator with Two Bearing
Construction” for specific details and tolerances for aligning the generator to the
prime mover.
1.1.5 Space Heater

This generator has been provided with a space heater to prevent moisture
absorption in the generator windings when the machine is out of service. The
space heater requires 500 watts of 115 or 230 Volt AC, single phase power. The
space heater should be energized whenever the generator is not in use. This
includes generator storage and all other cases when the generator is not
operating. If the generator is in a humidity controlled environment, then the space
heater does not need to be energized. When the generator is in storage,
provisions shall be made to allow adequate air circulation for moisture removal
and prevention of overheating.
1.1.6 Electrical Connection Junction Box

The generator is equipped with a removable drip proof electrical junction box
located on the non drive end of the generator. The generator stator leads are
terminated in the junction box to copper bus connections which provide facilities
for the customer connection of the generator power output leads.
1-2
1.2 ELECTRICAL SPECIFICATIONS
1.2.1 Generator Electrical Data Sheet
Model: S637UUT-200FH-HA Date: 10/22/10
RATED CONDITIONS, CONTINUOUS
KVA PF KW RPM PHASE HERTZ VOLTS AMPS AMB °C
1750 0.70 1225 1200 3 60 600 1684 55
PHYSICAL CHARACTERISTICS
STATOR ROTOR
ENCLOSURE POLES LEADS CONNECTION
INSULATION INSULATION
Drip Proof 6 6 WYE H H
TOTAL ROTOR WK2 MAX AMORTISSEUR

WEIGHT (LB.) WEIGHT (LB.) (LB-FT2) OVERSPEED WINDING
Copper
12,500 5,083 2,905 25% Connected
Pole to Pole
NOMINAL EFFICIENCY, % TEMPERATURE RISE BY RESISTANCE, °C

RATED 3/4 1/2 GEN GEN EXC EXC
LOAD LOAD LOAD ARMATURE FIELD ARMATURE FIELD
94.8 95.1 94.5 90 90 90 90
EXCITATION REQUIREMENTS, EXCITER FIELD (SERIES / PARALLEL CONNECTIONS)

RATED LOAD 3/4 LOAD 1 /2 LOAD 300% SHT CKT PMG
VDC ADC VDC ADC VDC ADC VDC ADC VAC HZ
74/37 2.4/4.8 65/32 2.1/4.2 50/25 1.6/3.2 160/80 5.5/11.0 N/A N/A
MACHINE RESISTANCES @ 25°C, OHMS DIELECTRIC TEST, VAC FOR 1 MIN

STATOR GEN EXC EXC GEN GEN ALL
PMG
L–L FIELD ARMATURE FIELD ARMATURE FIELD OTHERS
0.0035 2.16 0.135 26.1 N/A 2200 1500 1500
MACHINE CONSTANTS, PER UNIT
Xd X’d X”d Xq SCR X”q X0 X2 Zd
2.112 0.314 0.177 1.459 0.510 0.146 0.012 0.159 2.112
INH
T’do T’d T”d Ta Pr RATED LOAD VOLTAGE TRANSIENT
(SEC) (SEC) (SEC) (SEC) REG (KW / RAD)
(%)
% DIP % RISE
3.01 0.32 0.02 0.04 49.3 2757
23.9 27.6
Form No. 232-B 1-3

1.3 Parts List for Generator Model No. S637UUT-200FH-HA
PART EBS (Oracle) DESCRIPTION QUANTITY RECOMMENDED

NUMBER Part Number PER SPARES
GENERATOR
1030-20-0057 10032517-009 Bearing, Roller NDE 1 1
1030-20-0059 10032517-021 Bearing, Roller DE 1 1
1885-05-0012 10009668-001 Grease, NGLI #3 2 lbs. -
G54502 10015766-001 Rotating Rectifier 1 1
G5550438 10032298-007 Diode, 45A Cathode 3 -
G5550439 10032298-008 Diode, 45A Anode 3 -
G20700 10026266-001 Varistor 1 -

G82149 10008467-001 Exciter Field 1 -
G86187 10008434-001 Exciter Armature 1 -
G21592 10032319-018 Heater, Space 250W 120V 2 -
1810-04-0009 10032346-001 Filter, Element 4 4
6525-66-0009 10020439-001 Switch, Pressure 1 1
1885-11-0033 10018321-001 Adhesive, Filter - 2

Recharging
1-5
PART 2
210-GEN2BRG-1
GENERATORS
SERVICE MANUAL FOR

AC BRUSHLESS GENERATOR
TWO BEARING
CONSTRUCTION
EQUIPMENT FURNISHED
BY

TELEPHONE: (281) 240-6111
FAX: (281) 240-5074
Rev. 01
TABLE OF CONTENTS
Paragraph Page
SECTION 1
INTRODUCTION AND DESCRIPTION
1.1 INTRODUCTION 1-1
1.2 GENERAL DESCRIPTION 1-1
1.3 CONSTRUCTION 1-1
1.3.1 Stator Core 1-1
1.3.2 Rotating Field Poles 1-2
1.3.3 Exciter 1-2
1.3.4 Bearings 1-2
1.3.5 Accessories 1-2
SECTION 2
INSTALLATION
2.1 RECEIVING 2-1
2.2 UNPACKING AND STORAGE 2-1
2.2.1 Unpacking 2-1
2.2.2 Storage 2-1
2.3 INSPECTION 2-2
2.4 LOCATION 2-2
2.5 FOUNDATION 2-2
2.6 FIXED TWO BEARING GENERATOR ALIGNMENT PROCEDURE 2-2
2.6.1 General 2-2
2.6.2 Coupling Recommendations 2-2
2.6.3 Misalignment Definitions 2-3
2.6.3.1 Parallel 2-3
2.6.3.2 Angular 2-4
2.6.3.3 Axial 2-4
2.6.4 Alignment Procedure 2-5
2.6.4.1 Initial Considerations 2-5
2.6.4.2 Alignment Measurement 2-5
2.7 ELECTRICAL CONNECTIONS 2-7
i
Table of Contents (Cont'd)
Paragraph Page
SECTION 3
OPERATION
3.1 PRE-OPERATION EQUIPMENT CHECK 3-1
3.2 SINGLE GENERATOR OPERATING INSTRUCTIONS 3-1
3.3 OPERATING INSTRUCTIONS FOR PARALLELED GENERATORS 3-2
3.4 DIVISION OF KILOWATT POWER LOAD AMONG PARALLELED
GENERATORS 3-2
3.5 DIVISION OF REACTIVE KVA AMONG PARALLELED GENERATORS 3-2
SECTION 4
MAINTENANCE
4.1 PREVENTIVE MAINTENANCE 4-1
4.2 PREVENTIVE MAINTENANCE SCHEDULE 4-1
4.3 GENERATOR CLEANING 4-1
4.3.1 Outside 4-1
4.3.2 Inside 4-1
4.4 WINDING INSULATION 4-2
4.4.1 Extreme Dampness 4-2
4.4.2 Stator 4-2
4.4.3 Method of Drying 4-2
4.4.4 Internal Heat 4-3
4.4.5 Megohmmeter Check 4-3
4.4.6 Maintain Record 4-4
4.5 LUBRICATION 4-4
4.6 OPTIONAL EQUIPMENT 4-4
4.6.1 Air Filters 4-4
SECTION 5
TROUBLE SHOOTING
5.1 GENERAL 5-1
5.2 TROUBLESHOOTING CHART 5-1
ii
SECTION 1
INTRODUCTION AND DESCRIPTION
1.1 INTRODUCTION
This manual contains instructions for installing, operating, maintaining and trouble
shooting of the alternating current synchronous generators built by National Oilwell
Varco in Sugar Land, Texas. This manual is general in scope and designed to be
used with supplementary information, which provides information that applies to a
specific model or series generator.
1.2 GENERAL DESCRIPTION

The alternating current synchronous generators described in this manual are of the
brushless rotating field type of two bearing construction. Two bearing generators
are designed to be directly driven through a flexible coupling by a stationary prime
mover. The generator consists of two principle components, the alternator and the
integral direct connected brushless exciter. The alternator is made up of a rotating
field and a stationary armature, or stator. The brushless exciter consists of a
rotating exciter armature, a stationary exciter field coil assembly, and a rectifier
assembly. The rotating field, the rotating exciter armature and the rotating rectifier
are mounted on the generator shaft and electrically interconnected.
1.3 CONSTRUCTION
National Oilwell Varco generators are carefully designed and constructed to
ensure trouble free operation and maximum service life. The frame is fabricated
of steel members welded to plate end rings and press plates. Steel foot plates
are welded to the frame assembly to provide rigid support of the generator and
maintain its alignment with the prime mover. Lifting provisions are installed on the
frame to facilitate lifting the complete generator with a conventional overhead
hoist. A steel cover is welded to the frame structure to provide additional stiffness
to the frame.
1.3.1 Stator Core

The generator stator core is constructed of segmented electrical steel laminations.
The steel laminations are assembled under pressure to form the stator core. The
stator core is either rigidly welded to the frame structure or secured to the frame
structure with dowel pins. Insulated stator coils constructed of copper magnet wire
are inserted in the stator slots. The stator coils and core slots are insulated with
electrical insulating material. The stator assembly is vacuum and pressure
impregnated with electrical grade varnish and baked to insure proper bonding
qualities, to give high dielectric strength and maximum moisture resistance. Stator
leads are routed to a convenient location on the generator frame.
1-1
1.3.2 Rotating Field Poles
The generator rotating field poles are made of steel laminations which are
assembled under pressure. The field poles are secured to the generator shaft in a
manner which eliminates movement of the poles, even under over-speed
conditions. Field coils of insulated wire are wound directly onto the poles with high
strength epoxy applied between each winding layer. The field coils are supported
and braced for additional physical strength. Amortisseur or damper windings of
copper are embedded in the face of the poles and brazed to copper end rings. The
damper windings prevent hunting during parallel operation with other generators.
The entire rotating field is dipped in electrical grade varnish and baked to ensure
moisture resistance.
1.3.3 Exciter
The integral direct connected brushless exciter provides excitation current to the
rotating field assembly of the generator. The brushless exciter eliminates brush
rigging and sliding contacts which are subject to wear and therefore assures
prolonged, dependable and trouble free operation. The stationary exciter field
consists of a laminated steel core, assembled under pressure, and insulated field
coils installed in the core slots. The exciter field is installed on a stationary bracket
supported by the generator end frame. The exciter armature consists of a stack up
of steel laminations assembled under pressure. Three phase exciter armature
windings are wound on the exciter armature core. The three phase AC output from
the exciter armature is connected to the rotating rectifier assembly. The rotating
rectifier assembly consists of a full wave rectifier bridge and surge protector
mounted on a common insulated disk. The rectified DC output from the exciter
armature is applied to the rotating field of the generator.
1.3.4 Bearings
National Oilwell Varco generators are available with various bearing configurations,
selected and applied in accordance with the application requirements of the
generator. The most popular bearing configurations are grease lubricated anti-
friction bearings, grease lubricated split race anti-friction bearings and oil lubricated
sleeve bearings. Refer to the generator technical description and bearing
lubrication instructions provided in this manual for specific bearing information.
1.3.5 Accessories
National Oilwell Varco generators are available with accessories such as
anti-condensation heaters, resistive temperature devices installed in the stator and
bearing housings, a permanent magnet generator and other customer required
equipment. The generators are also available in open, open drip proof, totally
enclosed water/air cooled and totally enclosed fan cooled configurations. Refer to
the generator technical description provided in this manual for specific information
regarding the accessories and configuration of the generator.
1-2
SECTION 2
OPERATION
2.1 RECEIVING
The synchronous generator is carefully prepared for shipment and can withstand
most shocks and rough handling incurred during transit. Before accepting shipment
from the transportation company, examine the generator carefully to determine if
any damage has occurred during shipment. Unpack the unit and carefully examine
the frame and sheet metal for damage. Inspect for the presence of moisture and
make certain no foreign material such as packing, loose fasteners or dirt have fallen
into the generator during transportation and unpacking. If transportation damage is
noted, determine the extent of the damage, and immediately notify the
transportation company claims office and National Oilwell Varco in Sugar Land,
Texas. Be sure to provide complete and accurate details when reporting damage.
2.2 UNPACKING AND STORAGE

If the generator is received during cold weather, allow the unit to stabilize to room
temperature before removing the protective covering and packing material. This
precaution will minimize the condensation of moisture on the cold surfaces and the
possibility of early malfunctions resulting from wet windings or other insulating
materials.
2.2.1 Unpacking
Unpack the generator with care to avoid damage to the unit. Attach an overhead
crane to the lifting points provided on the generator, lift the unit from the shipping
skid and place it in its mounting location.
CAUTION!
Always make certain extreme care is taken when moving the
generator, to prevent damage to the generator, other objects,
or injury to personnel.
Avoid manhandling the generator and never apply a lifting force to structural points
other than those provided for that purpose.
2.2.2 Storage
If the generator is not to be installed in its operating location as soon as received, it
should be stored in a clean, dry area not subject to sudden changes in temperature
and humidity. Storage at normal room temperature is recommended. The
generator should be covered to protect it against dust, dirt, moisture and other
airborne material while in storage. Consult with National Oilwell Varco in Sugar
Land, Texas for storage recommendations when the generator cannot be stored in
a temperature and humidity controlled area or storage for a period of more than six
months is anticipated.
2-1
2.3 INSPECTION
Before installing the generator, it is recommended that the unit be thoroughly
inspected for indications of damage or potential malfunctions. Carefully examine
the exterior surfaces of the generator for deep scratches, dents, damaged
guards, loose or missing bolts, screws and other attaching parts. Remove the
screened or louvered covers from the ends of the generator and inspect the
generator rotor and stator and other internal components for loose or damaged
windings and lead wires, loosely mounted components, and the presence of
moisture or other foreign material. Remove all shipping materials such as blocks,
straps, tapes, rubber packing, paper or other material used to restrict movement
of the rotor during shipment. Use low pressure compressed air, 25 PSI
maximum, to blow out all packing residue and dust from the interior of the
generator. Turn the rotor by hand to make certain it rotates smoothly and without
binding.
2.4 LOCATION
The generator can be installed in any clean, dry, well ventilated area which allows a
sufficient unobstructed flow of coolant air and provides sufficient accessibility for
operation and maintenance of the unit. Avoid locations which would subject the
generator to excessive moisture, dust, steam, or fumes from acids, alkalies or other
corrosive chemicals. If such exposure cannot be avoided, a strict periodic
inspection and maintenance schedule must be established.
2.5 FOUNDATION
The foundation or support for the generator must be rigid, level and of ample size
and strength to support the weight of the generator and withstand the generator
foundation reaction loads. The foundation must also be adequately designed to
maintain coupling alignment between the generator and prime mover. It is very
important that the foundation is designed in such a manner as to not have any
resonant operating frequencies at or near the operating speed, or at a multiple of
the operating speed of the unit.
2.6 FIXED TWO BEARING GENERATOR ALIGNMENT PROCEDURE

2.6.1 General
Accurate alignment of the generator to the prime mover is essential to insure
proper generator bearing operation and life expectancy. Excessive misalignment
causes vibration, noisy operation, coupling wear, and premature bearing failure.
The following general recommendations are provided to assure that all aspects
of alignment of the generator to the prime mover are considered.
2.6.2 Coupling Recommendations

This generator is equipped with a fixed axial location bearing that is not capable
of absorbing axial thrust. The coupling selected for use in connecting the
generator to the prime mover must be capable of absorbing axial movement and
eliminating the application of axial forces to the fixed axial location bearing of the
generator. A flexible type coupling is recommended to compensate for slight
parallel, angular, and axial misalignment of the shafts. Solid couplings are not
recommended.
2-2
2.6.2 Coupling Recommendations (Cont’d)
It is the responsibility of the prime mover/generator packager to select a suitable
coupling which meets the recommendations of the generator and prime mover
manufacturers. The coupling manufacturers and prime movers recommendations
and tolerances for alignment of the coupling should be adhered to when less
than the tolerances specified in Table 1.
Thermal growth vertically and horizontally with respect to the shaft system and
supporting skid that result from the temperature differential between cold and hot
operating conditions must be considered when selecting and aligning the coupling.
Thermal growth may cause undue stress, hot misalignment, and vibration.
The skid and/or foundation for the prime mover and generator must be rigid
enough to minimize vibration and maintain alignment between the prime mover
and generator shafts within the specified limits. Reactions and displacements
between no load and full load must be considered when selecting and aligning
the coupling. These displacements may cause misalignment, vibration, and
extreme reaction forces on bearings.
National Oilwell in Sugar Land, Texas should be consulted regarding coupling

alignment forces resulting from changes in alignment between the cold and hot
operating conditions or mounting reactions of the structure and the effects of
those forces on bearing operation and life expectancy.
The parallel, angular and axial alignment of the coupling are all effected
concurrently and should be checked any time the generator frame is moved
during the alignment process. Once the Prime Mover/Generator are at final
location and coupling alignment is within specification, it is recommended that the
generator frame be doweled or chocked to the mounting base to insure that no
movement in the alignment occurs during operation.
2.6.3 Misalignment Definitions

There are three basic dimensions of alignment, which are parallel, angular, and
axial. Misalignment can be parallel, angular, axial, or any combination of the
three. An explanation of each type of misalignment follows.
2.6.3.1 Parallel
Parallel (radial) misalignment, Figure 1, is the difference in position of the center
of rotation of one shaft with respect to the center of rotation of the other shaft.
2-3
2.6.3.1 Parallel (Cont’d)
Figure 1 - Parallel Misalignment
2.6.3.2 Angular
Angular (face) misalignment, Figure 2, is the angle one shaft centerline makes
with the other shaft centerline at the coupling connection.
Figure 2 - Angular Misalignment
2.6.3.3 Axial
Axial misalignment, Figure 3, is the end position of one shaft in relation to the
end position of the other shaft.
Figure 3 - Axial Misalignment
2-4
2.6.4 Alignment Procedure
There are several methods to measure the alignment of two connected shafts.
Two methods are:
(a) Two dial indicators.
(b) Dial indicator and micrometer.
The two dial indicator method is recommended and is described in the following
procedure.
2.6.4.1 Initial Considerations

The generator and prime mover should be located and leveled on the mounting
skid. Care should be taken to eliminate “Soft Foot Condition.”
Soft Foot is the condition where the generator does not sit flat on its' base and
only three of the four mounting points support the generator. When the fourth
point is clamped down the generator frame or mounting skid is distorted causing
possible vibration or erroneous alignment information. Soft Foot can be corrected
by loosening each mounting point one at a time, measuring the relative
movement with a dial indicator, and shimming under the foot to eliminate that
relative movement. The relative movement should not exceed 0.005 inch. Shims
with burrs on the edges can contribute to the soft foot condition.
2.6.4.2 Alignment Measurement

Attach the dial indicator bases to one of the coupling halves and locate the dial
indicators to measure as shown in Figure 4. The indicator plunger for one
indicator should be located on the outside diameter, perpendicular to the shaft.
The indicator plunger of the other indicator should be located on the coupling
face as close to the outside diameter as possible. Set the plunger at about half
travel. Rotate the indicators so that they are at the top location. It is suggested to
zero the dial indicator when at the top location for convenience. The coupling hub
should be marked at 0, 90, 180, and 270° and a stationary reference mark placed
or identified on the equipment so that when the shafts are rotated, they can be
indexed through 90° increments. Both shafts should be rotated together. An easy
way to record the measurements is to draw two circles on paper, one for parallel
and one for angular measurements. Also, record the radius of the measurement
point for the angular (face) measurement.
Figure 4 - Dial Indicator Setup
2-5
2.6.4.2 Alignment Measurement (Cont’d)
Rotate the shafts one-quarter turn and record the dial indicator measurements.
Take measurements at 90, 180, 270 and 360 (0°) locations. The dial indicators
should read zero when returning to the top (starting or 0°) location. If the
indicators do not read zero, disregard the measurements and repeat the
procedure. Figure 5 and 6 shows a typical set of measurements and their
corresponding Total Indicator Readings (TIR). Once these measurements are
recorded, the relationship of the measurements to the allowable misalignment in
Table 1 can be determined by subtracting measurements in each plane to find
the Total Indicator Reading (TIR) value.
Figure 5 - Typical Parallel (Radial) Measurements
Figure 6 - Typical Angular (Face) Measurements
2-6
2.6.4.2 Alignment Measurement (Cont’d)
Table 1 lists maximum allowable parallel and angular misalignment for National
Oilwell two bearing generators. After the initial measurements are taken, the
generator must be aligned and shimmed to achieve the acceptable alignment
measurements.
Table 1 - Maximum Allowable Shaft Misalignment for Two Bearing Generators
It is a good practice to first correct the parallel and angular misalignment in the
horizontal plane. Jack screws attached to the skid can be used to adjust the
location in the horizontal plane. Once corrections are made, a new set of
alignment measurements should be taken.
If the alignment in the horizontal plane is within limits, then proceed with
correction in the vertical plane. The proper corrections can be determined
through careful evaluations of the measurements. Corrections for parallel and
angular misalignment may be made together. After any corrections are made in
the alignment, new measurements must be repeated.
Axial alignment depends on the coupling type. The generator and prime mover
should be located so that no axial force can be transmitted to the generator.
Refer to the coupling manufacturer or prime mover/generator packagers’
recommendations for axial alignment specifications.
Once alignment is complete, it is a good practice to record measurements for

future reference.
2.7 ELECTRICAL CONNECTIONS

All electrical connections to the generator should be made in accordance with the
requirements of the National Electric Code and local electrical codes. The generator
frame should be connected to a reliable ground point with a ground wire sized in
accordance with National Electric Code and local electrical code requirements. It is
recommended that flexible conduit be used for all electrical connections to the
generator in order to minimize the effects of vibration. The output to the load of the
generator should always be protected with an overload protection device such as a
circuit breaker or fuses. Sizing and selection of the circuit breaker or fuses should
be in accordance with National Electrical Code and local electrical code
requirements.
2-7
SECTION 3
OPERATION
3.1 PRE - OPERATION EQUIPMENT CHECK

After the generator and control equipment is completely installed and wired, but
before operating the unit for the first time, perform the following inspections.
A. Check all interconnecting wiring against the connection diagrams supplied

with the generator set.
B. Make certain no foreign objects are lodged in the generator. Remove all
shop cloths and tools from the vicinity of all operating equipment.
C. Insure that all covers and guards are properly installed and securely in
place.
D. Be sure that the bearings are appropriately lubricated with grease or oil
per the bearing lubrication instructions provided in this manual.
E. If the generator has been subjected to extreme dampness during
shipment or storage, it may be necessary to dry out the winding prior to
placing the unit into operation. Refer to the MAINTENANCE SECTION of
this manual for procedures for testing winding insulation resistance and
procedures for drying the winding insulation. A generator being placed
into service after being subjected to very low temperatures should be
slowly warmed to prevent condensation.
3.2 SINGLE GENERATOR OPERATING INSTRUCTIONS

Start and operate the generator in accordance with the following general
procedures.
A. Make certain that the load circuit breaker is open, insuring the generator is
disconnected from the load. Insure that all protection equipment is
functional and operational.
B. Start the prime mover in accordance with the manufacturer's instructions.
Bring the generator up to its rated operating speed.
C. After the system is started and while at no load, turn the voltage regulator
on and adjust it until the rated output voltage of the generator is obtained.
D. Connect the generator to the load by closing the load circuit breaker. To
check the voltage regulation, apply the rated power factor load and check
the generator terminal voltage. With full load on the generator, the output
voltage should be within plus or minus two per-cent of the no-load voltage.
E. During operation, the generator should be observed at regular intervals for
any abnormal conditions. If any abnormal conditions are discovered, the
generator should be stopped immediately and the abnormal condition
corrected before serious damage occurs.
F. To stop the generator, first remove the load by opening the circuit breaker,
turn off the voltage regulator, then stop the prime mover in accordance
with the manufacturer's recommendation.
3-1
3.3 OPERATING INSTRUCTIONS FOR PARALLELED GENERATORS
When operating two or more generators in parallel, start each generator in
accordance with steps A, B, and C of the proceeding SINGLE GENERATOR
OPERATING INSTRUCTION.
Adjust the output voltage of each generator to the system bus voltage. Once it
has been determined that the generators have the same phase rotation, and are
synchronized, the load circuit breaker can be closed.
WARNING!
DO NOT CLOSE THE LOAD CIRCUIT BREAKERS UNTIL THE
GENERATORS HAVE BEEN CHECKED FOR PROPER PHASE ROTATION,
ADJUSTED FOR SYNCHRONIZATION AND THE VOLTAGE REGULATION
ADJUSTED TO BRING THE GENERATOR OUTPUT TO SYSTEM BUS
VOLTAGE.
To stop a generator in operation in a system of paralleled generators, remove the

load by opening the load circuit breaker, turn off the voltage regulator, then stop
the prime mover in accordance with the manufacturer’s recommendations.
WARNING!
WHEN DISCONNECTING A GENERATOR FROM A SYSTEM OF
PARALLELED GENERATORS, ALWAYS MAKE SURE THAT THE LOAD
ON THE SYSTEM DOES NOT EXCEED THE LOAD CARRYING CAPACITY
OF THE GENERATORS REMAINING CONNECTED TO THE PARALLEL
SYSTEM.
3.4 DIVISION OF KILOWATT POWER LOAD AMONG PARALLELED

GENERATORS
In order to adjust the division of kilowatt load on paralleled generators, the prime
mover governors must be adjusted in accordance with the manufacturer's
recommendation. Division of kilowatt load or actual power load among
generators operating in parallel is independent of generator excitation. Do not
attempt to vary the amount of kilowatt load carried by paralleled generators by
making adjustments to the voltage regulator.
3.5 DIVISION OF REACTIVE KVA AMONG PARALLELED GENERATORS

Division of reactive KVA among paralleled generators is dependent on generator
excitation. Where an individual generator is taking more or less than its share of
reactive KVA, excitation to the generator must be corrected by the addition of
cross-current compensation or voltage-droop controls to the voltage regulator
circuit. Refer to the cross-current compensation or voltage-droop controls
system manufacturer's recommendations for application and operation of the
controls. Where voltage-droop compensation is utilized, the voltage droop
resistor of each regulator must be set so that each generator in the paralleled
system exhibits the same voltage droop when reactive load is applied.
3-2
SECTION 4
MAINTENANCE
4.1 PREVENTIVE MAINTENANCE

A routine regular preventive maintenance program practiced conscientiously will
ensure peak performance, extended generator life and minimize or eliminate
equipment breakdowns. The following preventive maintenance schedule is a
guide for establishing a preventive maintenance program for generators
operating under standard conditions. Specific operating conditions should be
analyzed by the equipment user and a preventive maintenance program
established accordingly.
4.2 PREVENTIVE MAINTENANCE SCHEDULE

Under standard operating conditions, the following maintenance and inspections
should be performed every 30 days.
A. With the generator stopped, clean the outside of the generator and its
ventilation screens, to remove dirt, dust, oil or other contaminants.
B. With the generator stopped, inspect the generator for loose or damaged
windings, cracked, burned or broken insulation, loose mounting
components, loose hold down bolts, and the presence of moisture or other
foreign material.
C. With the generator stopped, inspect the area surrounding the bearings for
signs of excessive leakage of oil or grease. If oil lubricated, determine that
the oil level is correct. Lubricate the bearings in accordance with the
recommendations set forth in the bearing lubrication instructions provided
in this manual.
D. With the generator stopped, inspect the lead wires and control device
wiring for cracked or damaged insulation and loose terminals.
E. With the generator running, observe any unusual noise or vibration.
F. With the generator running, inspect the generator control and monitoring
devices for correct adjustment and operation.
4.3 GENERATOR CLEANING

4.3.1 Outside
Remove dust, dirt, oil, grease and other foreign material from the outside
surfaces of the generator by wiping with a shop cloth. If necessary to remove
stubborn deposits of grease, oil or similar substances, a clean cloth moistened
with a non-flammable cleaning solvent can be used.
4.3.2 Inside
Clean the inside of the generator by using a vacuum cleaner or dry low pressure
compressed air, 25 PSI maximum, to remove any accumulation of dirt, dust or
other gritty particles. Stubborn deposits of grease, oil or similar substances on
the metal components that are located away and clear of the windings and
4-1
4.3.2 Inside (Cont’d)
insulating components may be cleaned using a clean cloth moistened with a
nonflammable solvent.
CAUTION!
Under no circumstances should the solvent, or solvent
moistened cloth, be allowed to contact the windings or
insulating components.
Deposits of grease, oil or similar substances on the winding or insulating

components should only be removed with a clean dry shop cloth. Consult with
National Oilwell Varco in Sugar Land, Texas if the winding or insulating
components are contaminated to an extent where wiping with a cloth will not
remove the contaminants.
4.4 WINDING INSULATION

4.4.1 Extreme Dampness
If the generator has been subjected to extreme dampness during shipment or
storage, a preliminary period of operation may be required to thoroughly dry all
windings. To determine the need for this drying out procedure, measure the
insulation resistance of the generator stator by connecting a megohmmeter
between any one of the stator terminals and the frame of the machine. The one-
minute reading of stator insulation resistance at an ambient temperature of 40ºC
(104ºF) must be at least:
RATED VOLTAGE OF MACHINE + 1 = MINIMUM RESISTANCE

1000 VALUE IN MEGOHMS
4.4.2 Stator
If the stator insulation resistance measures less than specified for the voltage
rating of the generator, the machine must be dried out until at least the minimum
recommended resistance value is obtained. This drying-out process can be
accomplished by applying either external or internal heat as necessary to obtain
an end-winding temperature of 75ºC (167ºF) by thermometer.
4.4.3 Method of Drying

The easiest and most convenient method of drying out a generator consists of
placing the complete, or partially disassembled, machine in an oven. External
heat also can be applied by placing space heaters beneath the generator so as
to obtain an even distribution of heat along the length of the unit. Care must be
taken to provide adequate air circulation during the drying-out process to insure a
complete and thorough job.
4-2
4.4.3 Method of Drying (Cont’d)
CAUTION!
The temperature of the generator should be raised slowly to avoid
building up excessive vapor or gas pressure which could prove
harmful to the insulation. Do not exceed a temperature rise of 10°C
(18°F) per hour.
4.4.4 Internal Heat

Drying out the winding insulation by the application of internal heat consists of
operating the generator in accordance with the following procedure:
A. If necessary, apply external heat to the unit until the insulation resistance
measures at least 50,000 ohms.
B. Insert a current transformer and ammeter of sufficient range to read full-
load generator current in one of the stator leads.
C. Connect all stator terminals together to short circuit the stator windings.
D. Disconnect the exciter field leads from the external voltage regulator.
Connect a variable source of direct current to the exciter field terminals.
E. Operate the generator at normal speed. Supply just enough excitation
current to cause rated full-load current to flow in the stator windings.
F. Operate under these conditions for sufficient time to insure thorough
drying of the windings. This can be determined by stopping the machine
at one hour intervals and repeating the measurement of stator winding
insulation resistance. The insulation resistance decreases rapidly at first
as the windings heat up, and then increases slowly as the moisture is
dissipated. Terminate the drying out procedure when the measured
resistance shows little change over a two to four hour period of operation.
G. Disconnect the test instruments and variable source of direct current.
Reconnect the internal wiring in accordance with the original configuration.
CAUTION!
Do not hurry the drying-out process. Never permit the temperature of
the generator to exceed the maximum allowable temperature rise
marked on the data plate.
4.4.5 Megohmmeter Check

Ordinarily, the preceding drying-out process will suffice to eliminate moisture
from the rotor windings. Measure the insulation resistance of the rotor windings
by connecting a Megohmmeter to one of the field terminals and to the rotor shaft.
Be sure the field windings are isolated from the exciter either by disconnecting
the leads or by jumpering the exciter (see CAUTION below). The insulation
4-3
4.4.5 Megohmmeter Check (Cont’d)
resistance of the rotor windings should measure at least one megohm. If the
resistance is low, continue the drying-out process until a satisfactory reading is
obtained.
CAUTION
On generators provided with a brushless rotating exciter using a
rotating rectifier unit, disconnect the rotating rectifier before using a
Megger to measure the rotor insulation resistance. Failure to
observe this precaution can cause damage to the rotating rectifier
diodes.
4.4.6 Maintain Record

It is advisable to maintain a record of the insulation resistance measurements for
each generator. These measurements, taken at regular six month or yearly
intervals, will provide a means of detecting a gradual deterioration of the winding
insulation. Such records should list the prevailing conditions, such as the test
voltages, ambient temperature and humidity, at the time of each test, since these
conditions will affect the results.
4.5 LUBRICATION
The bearings are the only components of the generator that require lubrication.
Refer to the bearing lubrication instruction provided in the generator specification
manual for specific bearing lubrication requirements. At each lubrication interval
and during preventative maintenance inspections, the grease or oil seal area and
adjacent shaft area should be inspected for signs of excessive leakage. If
excessive leakage is present, the seals should be replaced and the shaft and
seal sleeves repaired or replaced as necessary.
4.6 OPTIONAL EQUIPMENT
4.6.1 Air Filters
Servicing instructions for air filters (not all models supplied with filters) see
below.
CLEANING:
Wash in sink or large pan with commercial detergent in warm water and rinse
clean.
DRYING:
Allow filter to dry completely so water can flow out of drain hole.
4-4
4.6.1 Air Filters (Cont’d)
RECHARGING:
Spray Type:
Spray filter on both sides with AIRSAN Corporation “FILM-COR” adhesive, or
other suitable adhesive, making sure all the media has been coated.
Liquid Type:
Submerge filter in suitable pan or tank containing “FILM-COR” adhesive, or
other suitable adhesive. Remove immediately and allow to drain overnight
through drain holes provided in frame, at normal room temperature. Filter is
then ready for re-use.
4-5
SECTION 5
TROUBLESHOOTING
5.1 GENERAL
The most important item to keep a unit running with very little down time is to set up
a program for intelligently analyzing the malfunctions, and making the necessary
corrections.
Although regular preventive maintenance inspections are conducted, be alert

between inspections for any signs of generator trouble. When a minor problem is
located, correct it immediately. Minor defects can result in costly repairs and down
time. Some of the more common symptoms, along with probable causes and
helpful remedies, are found in TABLE 5-1.
5.2 TROUBLESHOOTING CHART
TABLE 5-1
TROUBLESHOOTING CHART
SYMPTOM POSSIBLE CAUSES REMEDY
No Open circuit breaker or fuses (if voltage is Check. Reset circuit breaker or replace
Voltage sampled on load side of fuses or circuit fuses if open.
breaker).
Over-voltage, under-voltage, or overload Check for cause of abnormal condition.

devices tripped (when protective devices Correct any deficiencies. Reset devices.
incorporated in circuit). Check Generator Data Plate for nominal
operating values.
Open circuit in exciter field. Check out continuity of exciter field and
leads to voltage control. (Use ohmmeter or
wheatstone bridge). If open in exciter field,
remove exciter field assembly and return
assembly to factory for repair.
5-1
5.2 TROUBLESHOOTING CHART (Cont'd)
No Residual magnetism loss in exciter field poles or a voltage Change the manual adjust potentiometer to full resistance.
Voltage regulator is being used which requires field flashing. Flash field with a 12 volt DC source (Battery) across
(Cont.) Flashing will bring generator voltage to a level which allows terminals of exciter field.
the regulator to operate.
Open circuit in stator windings. Perform a continuity check of the windings. Unit must be
returned to factory for repair if open.
Rotating rectifier circuit open. Check rectifier assembly, replace bad diodes or rectifier
assembly.
Manual voltage adjust circuit open. Check continuity of potentiometer. If open circuit, replace.
Automatic voltage regulator malfunction. Refer to voltage regulator manual for trouble shooting
information.
Generator output leads short circuited. Restore voltage build up by clearing lead.
Alternator field open. If field coils show an open, return to factory for repair.
Surge protector shorted. Replace if shows shorted.
Rotating rectifiers shorted or open. Replace if shows shorted or open.
Exciter armature shorted. Replace if shows shorted.
Leads between exciter armature and generator field shorted. Check and repair.
5-2
Low Voltage adjust rheostat improperly adjusted. Adjust or repair regulator, replace if defective.
Voltage
Voltage regulator defective (if supplied). Adjust rheostat, refer to voltage regulator manual for trouble
shooting information.
Excessive load. When operating 3 wire, three phase & 4 wire, three phase
generators, the load on each leg should be as evenly
balanced as possible and should not exceed the rated
current on any leg. Reduce load.
Line loss. Line wire size may need to be increased.
Connections are warm or hot. High resistance connections. Check and secure connections better.
Field Shorted. Check resistance with an ohmmeter or resistance bridge for

possible shorts in field coils. Shorted alternator field coils
require rotor to be returned to factory for repair.
Power factor low. Do not use motors of larger horsepower rating than is
necessary to carry the mechanical load. Some AC motors
draw approximately the same current regardless of load.
Cut back on the inductive (motor) load.
High area temperatures due to poor ventilation will cause a Check that there is proper ventilation.
weak field.
5-3
Low Generator set is operating at improper speed. Check and repair or replace those items at fault. Check
Voltage input voltages.
(cont.)
Excessive load. Cut back load to rated value.
Fluctuating Generator overloaded. Cut back load to rated value
Voltage
Internal or load connections loose. Clean and secure connections
Fluctuation in speed of prime mover. Monitor voltage and frequency of incoming power when
generator set is electric motor driven. Examine and
troubleshoot engine governor on engine driven generator
sets.
Fluctuation of DC excitation voltage. Examine DC excitation circuit. Repair any defects.
Faulty voltage regulator (if used). Examine regulator. Repair or replace.

High Voltage regulator or voltage adjust rheostat improperly Adjust rheostat and/or voltage regulator.
Voltage adjusted.
Overspeed Adjust prime mover speed.
5-4
Over- Bearing dry or defective. Replace bearing

heating
Shorted or grounded generator field coils. Check field coils for shorts. Replace rotor or return to
factory for repair.
Ventilating screens and air passages dirty and clogged. Clean air passages and screens.
Belt too tight, on belt driven generators. Coupling Adjust belt and or align generator.
misaligned.
Generator and prime mover misaligned. Check and align generator set.
Vibration
Mounting of generator not done properly. Examine and correct defective mounting.
Bearing dry or defective. Replace bearing.
5-5
REVISIONS
REV. ECN # DATE DESIGNER
7 LB LARGE PRESSURE CAP (2)-PLACES SECTION A-A NOTES
1 11-078 5/11/2011 ADH 1) DRIVE KIT GT# 4872/DK TO SHIP LOOSE.
2 12-006 1/9/2012 ADH 20.50 50.25±.13 20.50 .813 HOLE (4) PLACES 1 2) PIPE KIT GT# 79343 TO SHIP LOOSE.
3.00 PIPE KIT TO INCLUDE ALL PIPES AND
.88 MTG HOLE (4)-PLACES 29.01 33.23
(TYP) .813 X 1.250 SLOTS FLEXMASTER COUPLINGS ONLY
31.36 28.53 (12) PLACES 3) MTG. BRKT. ASM GT# 4872A/MBA
TO SHIP LOOSE.
13.00 4) SEE SHEET 3 FOR SHIPPED LOOSE ITEMS
11.50
.75 LIFTING HOLE 7.88 ESTIMATED JW RAD CAPACITY = 46.50 gal.
3.50 2.56 W/ EXPANSION CAPACITY = 9.48 gal.
(2)-PLACES
0 0
1 1.00 (TYP) 3.00 ESTIMATED AC RAD CAPACITY = 21.96 gal.
6.00 1 W/ EXPANSION CAPACITY = 3.60 gal.
22.88 45.50
DRIVE INFORMATION:
1 DIMENSIONS IN VIEW A-A ENGINE RPM: 1200
86.35 FAN RPM: 817
ARE FOR REFERENCE ONLY
FAN HORSEPOWER DRAW:
3.45 36.0 HP @ STD.
2.00 NPT SIGHT GLASS W/ OUT REFLECTOR "JW" 32.5 HP @ DESIGN
CLEAN OUT
DETAIL B WINDOW
SCALE 1 : 5 DETAIL
3.43
.25 NPT HALFCOUPLING W/
PIPE PLUG (9)-PLACES (FOR
27.92 VENTS & LOW LEVEL INDICATORS)
2
43.50 DETAIL C
1.00 NPT HALFCOUPLING W/ PIPE PLUG (2)-PLACES
SCALE 1 : 3.5
86.25
(TYP)
33.42
45.63
57.83
LEVEL SIGHT GAGE W/ INDICATOR BALL "AC" 28.19 "JW"
4.61
4.63
0
3.50 O.D. TUBE W/O BEAD (2)-PLACES "JW"

7.63 2.09
LEVEL SWITCH GAGE AIR FLOW
SPDT RATED 10 AMPS @ 125VAC 96.35
(2)-PLACE 92.85 (TYP)
FAN 72 INCH #72/10-10/29 B
"JW"
/PAG/9WR/SF 2.438/BR RHB
(GT# 79122) C
4.50
FAN HOSE ASM TO BE ATTACHED TO FUEL
ROTATION JW CORE
COOLER PORTS USING 90° PIPE ELBOWS.
66" LONG HOSE W/ .75-14 NPTF MALE 6090
FITTINGS ON TOP & 72" LONG HOSE W/
.50-14 NPTF MALE FITTING ON BOTTOM. 2.35
R36.38 AC CORE
2
2.438 O.D. FAN SHAFT (2)-PASS
W/ KEY N4070
(49.63) GREASE FITTING BRACKET W/ 2 SEE NOTE #4
22.63
FAN CENTER (4)-TEFLON HOSE ASSEMBLIES
(2)-TOP "FAN PILLOW BLOCKS" 2
13.25 +7.00 (2)-BOT "IDLER PILLOW BLOCKS"
7.00 - 5.00 (38.31) "LABELED ACCORDINGLY"
"FOC" 2
2.188 O.D. IDLER SHAFT
W/ KEY
24.30
CRANK SHAFT 2 5.50 2.00
CENTER A CORE
GUARD
8.50
6.50 "AC" 3.06

5.50 "JW"
0 0 .50 NPT HALFCOUPLING W/ PIPE PLUG
8.50 (2) "AC" (1) "JW" (3)-TOTAL "RAD DRAINS"
(7.50) 27.13 (TYP)
1.50
2.50 O.D. TUBE W/O BEAD TYP. "JW" & "AC"
58.50±.13 1.50 80.29 1.75 COATING: BLACK (B)
(2)-PLACES "AC" ESTIMATED UNIT DRY WEIGHT = 4597 LBS.
A ALL TOLERANCES ARE NON-ACCUMULATIVE General
80.63 "JW"
16.38
91.25
15.63 "AC"
55.63 "AC"
0
83.83 "FOC"
GENERAL TOLERANCE STANDARD TOLERANCE ThermoDynamics

A ThermaSys® Company
.50 MTG HOLE UNLESS OTHERWISE SPECIFIED ARE:

3.64
4872A
SHAFT
SUPERCEDE STANDARD TOLERANCES AND ARE:
55.37
56.43
57.12
7.96
CUSTOMER: CUSTOMER REV:

0
10.35
58.37
MTG FEATURE SIZE +/- .03 2 PLACE DIMENSIONS: +/- .19 NOV
(4)-PLACES MTG LOCATION
MTG HOLE LOCATION CTR-CTR
+/- .13 3 PLACE DIMENSIONS: +/- .063
+/- .06 ALL DIMENSIONS SHOWN ARE IN INCHES
CUSTOMER NUMBER: DRAWING NO: ISSUE NO:
CONNECTION SIZE +/- .03 ALL ANGLED DIMENSIONS ARE REFERENCE 4872A P-03
PART NO:
2 CONNECTION LOCATION
CONNECTION LCTN CTR-CTR
+/- .25
+/- .13
THIRD ANGLE PROJECTION DESCRIPTION:
BOLTED RADIATOR ASM W/ BASE
4.50 O.D. TUBE W/O BEAD "JW" THIS PRINT IS PROPERTY OF THERMASYS AND/OR ITS SUBSIDIARIES AND
MUST NOT BE USED IN ANY MANNER DETRIMENTAL TO THEIR INTERESTS
SCALE: 1:11.75
DESIGNED BY:
DATE
08-03-10
DETAILED BY:
SHEET: 1 of 4 D
CHK'D:
TWE TWE
REVISIONS ITEM NO. PART NO. DESCRIPTION QTY.
- See Sheet1 - -
19 39 40 41 1 1 4872A-RJ BOLTED RAD ASM 1
3 12 2 79132 RADIATOR SUPPORT FRAME 1
16 32 32 32 1
1 2 3 4872A-RA BOLTED RAD ASM 1
39 42 41 4 4872-SM1 SIDEMEMBER ASSEMBLY 1
14 6 6 5 4872-SM2 SIDEMEMBER ASSEMBLY 1
12
5 6 4872-TBSC TOP & BOT SUPP CHAN ASSY 2
2 40 7 4872-FOC FUEL COOLER KIT 1
1 8 4872A-BA BACK END ASSY 1
10 12
9 4872-SA SHROUD ASSEMBLY 1
4 DETAIL D 39 10 76571 FAN GUARD (72 IN FAN) 4
SCALE 1 : 2 9 12
39 11 4872A-SGA SHEAVE GUARD ASSEMBLY 1
1 6 12 4872-CG CORE GUARD 2
41 12 13 4872-FSG FAN SHAFT GUARD 1
2
4 40 33 14 4832-LSG LEVEL SWITCH GAGE (SPDT RATED 10 AMPS @ 125VAC) 1
12 15 4872A-ASM ANGLE SUPPORT MOUNT 4
39 12
46 16 4872A-ASB ANGLE SUPPORT BRACE 2
4 41 34 17 5330-CP COVER PLATE 8
4
40 12 12 18 77873 RUBBER GROMMET 1.50 ID 2
20 47 19 SHDCLP-1 SHROUD CLIP 16
4
4 4 20 4031-FSB FG STABILIZER BRKT 4
21 72913 HOSE CLIP SMALL Z.P. 4
36 35 33 22 73602_130 .28 ID x .405 OD RUBBER OVERFLOW HOSE 2
10 10 10 23 73431 .625 ZP STL SAE FLATWASHER 54
40 39 24 73004 .625-11 UNC BOLT x 2.00 LG. ZP GR8 8
4 4 25 70549 .625-11 UNC NYLON INSERT HEXNUT 38
26 70836 .625-11 UNC BOLT x 2.25 LG. ZP GR8 2
27 73003 .625-11 UNC BOLT X 2.75 LG. ZP GR8 6
DETAIL C 28 79277 WASHER BEV .688 x 1.25SQ MMC 91152A035 6
SCALE 1 : 3 29 70839 .625-11 UNC BOLT x 1.75 LG. ZP GR8 22
30 73429 .500 ZP STL SAE FLATWASHER 32
8 39 31 73318 .50-13 UNC BOLT x 1.50 LG. ZP GR8 32
1 5 32 70481 .50-13 UNC NYLON INSERT HEXNUT 32
33 73427 .375 ZP STL SAE FLATWASHER 28
42 34 73052 .375-16 UNC BOLT x .75 LG. ZP GR8 12
5 35 73020 .375-16 UNC BOLT x 1.25 LG. ZP GR8 12
7 36 73002 .375-16 UNC NYLON INSERT HEXNUT 16
41
1 45 37 73056 .375-16 UNC BOLT x 1.75 LG. ZP GR8 2
5 38 73059 .375-16 UNC BOLT x 2.50 LG. ZP GR8 2
25 16 2 2 39 73428 .312 ZP STL SAE FLATWASHER 117
6 2 40 73021 .312-18 UNC BOLT x 1.00 LG. ZP GR8 64
2 35 33 36 41 72903 .312-18 UNC NYLON INSERT HEXNUT 67
29 42 73043 .312-18 UNC BOLT x .75 LG. ZP GR8 33
6 11 2 2 2
43 73044 .312-18 UNC BOLT x 1.25 LG. ZP GR8 2
23 1 39 30 31 32 44 74012 .312-18 UNC HEXNUT 16
15 45 CP LABEL CLEAN OUT PANEL LABEL 2
12 2 16 16 16 46 79765 NYLON SNAP SHANK RIVET 4
4 F
42 44 39 47 79766 TAPE MARKING NONADHESIVE 4
36 2 16 16
2 2
17
37 42 4 23 13
18 8
2 16 1 4 1
2
2 39 23 23
33 24
16 30 4 4
23 2 2
DETAIL J 16 26 24 21
8 25
SCALE 1 : 4 2 2 4
29 31 2
16 25 25 22
8
32 2 2 2 DETAIL E
25 SCALE 1 : 3
8 16 39
4
43
36 38 33 2
2 2 2 41
2
DETAIL F 39 42
23 24 25 SCALE 1 : 5.5 4 4
23 29 25
8 4 4
8 8 8
ALL TOLERANCES ARE NON-ACCUMULATIVE General

UNLESS OTHERWISE SPECIFIED ARE:
4872A
SUPERCEDE STANDARD TOLERANCES AND ARE: CUSTOMER: CUSTOMER REV:
2 PLACE DIMENSIONS: +/- .19 NOV

2 MTG FEATURE SIZE
MTG LOCATION
+/- .03
+/- .13 3 PLACE DIMENSIONS: +/- .063
DRAWING NO: ISSUE NO:
23 27 28 25 MTG HOLE LOCATION CTR-CTR +/- .06 ALL DIMENSIONS SHOWN ARE IN INCHES
CUSTOMER NUMBER:
4872A P-03
1 CONNECTION SIZE +/- .03 ALL ANGLED DIMENSIONS ARE REFERENCE
PART NO:
CONNECTION LOCATION +/- .25 DESCRIPTION:
DETAIL G 6 6 6 6 CONNECTION LCTN CTR-CTR +/- .13
THIRD ANGLE PROJECTION
BOLTED RADIATOR ASM W/ BASE
SCALE 1 : 4.55 THIS PRINT IS PROPERTY OF THERMASYS AND/OR ITS SUBSIDIARIES AND
MUST NOT BE USED IN ANY MANNER DETRIMENTAL TO THEIR INTERESTS
SCALE: 1:11
DESIGNED BY:
DATE
08-03-10 SHEET: 2 of 4 D
DETAILED BY: CHK'D:
TWE TWE
REVISIONS
- See Sheet1 - -
COATING: BLACK (B)
PLACE RIBBONS IN ESTIMATED UNIT DRY WEIGHT = 4597 LBS.

ALL TOLERANCES ARE NON-ACCUMULATIVE
GENERAL TOLERANCE STANDARD TOLERANCE
General
ThermoDynamics
4872A
2 PLACE DIMENSIONS: +/- .19 NOV
THESE 4 LOCATIONS
MTG FEATURE SIZE +/- .03
MTG LOCATION +/- .13 3 PLACE DIMENSIONS: +/- .063
MTG HOLE LOCATION CTR-CTR +/- .06 ALL DIMENSIONS SHOWN ARE IN INCHES
PART NO:
CONNECTION LCTN CTR-CTR +/- .13 BOLTED RADIATOR ASM W/ BASE
DATE
THIS PRINT IS PROPERTY OF THERMASYS AND/OR ITS SUBSIDIARIES AND SCALE: 1:3 08-03-10 SHEET: 3 of 4 D
MUST NOT BE USED IN ANY MANNER DETRIMENTAL TO THEIR INTERESTS DESIGNED BY: DETAILED BY: CHK'D:
TWE TWE
REVISIONS ITEM NO. PART NO. DESCRIPTION QTY.
- See Sheet1 - - 1 4872A-MBA MOUNTING BRACKET ASM 1
2 79343 PIPE KIT CAT 3512C HD 4872A NOV 1
3 4872-DK DRIVE KIT (F44 817 RPM) 1
NOTE:
1. SEE 4872A/MBA FOR MOUNTING BRACKET DETAIL
2. SEE 79343 FOR PIPE KIT DETAIL
3. SEE 4872/DK FOR DRIVE KIT DETAIL
2
1
1
1
3
1
COATING: BLACK (B)

ESTIMATED UNIT DRY WEIGHT = 4597 LBS.
ALL TOLERANCES ARE NON-ACCUMULATIVE General
4872A
MTG FEATURE SIZE +/- .03 2 PLACE DIMENSIONS: +/- .19 NOV
MTG LOCATION +/- .13 3 PLACE DIMENSIONS: +/- .063
MTG HOLE LOCATION CTR-CTR +/- .06 ALL DIMENSIONS SHOWN ARE IN INCHES
PART NO:
CONNECTION LCTN CTR-CTR +/- .13 BOLTED RADIATOR ASM W/ BASE
DATE
THIS PRINT IS PROPERTY OF THERMASYS AND/OR ITS SUBSIDIARIES AND SCALE: 1:7.5 08-03-10 SHEET: 4 of 4 D
MUST NOT BE USED IN ANY MANNER DETRIMENTAL TO THEIR INTERESTS DESIGNED BY: DETAILED BY: CHK'D:
TWE TWE
FINAL DOCUMENTATION
Ideal Rig 135
Section 6.4
VFD/AC Drive
www.nov.com
AC Drive/ VFD System
FINAL DOCUMENTATION
User Manual
Ideal Rig 135
Customer

Rig/Hull
IR 135 11000 Corporate Centre Drive.
Project Manager
N/A Houston, Texas 77041
Purchase Order Number
USA
GPK1000852
Serial Number Phone: (281) 854-0400
N/A
Project Number
FAX: (281) 854-0607
8434
Document Number Rev
10707887-FDD 01
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Document number 10707887-FDD
Revision 01
Page 2
REVISION HISTORY
01 15.04.2013 Final Documentation VNB KM BD

Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved
CHANGE DESCRIPTION

01 Initial Release
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Final Documentation Package Document Number: 10707890-TOC
Ideal Rig 135 Revision: 01
C. Number: GPK1000852 Page: i of ii
Table of Contents
different binders as necessary to adequately document the equipment presented.

Ideal Rig 135
AC Drive/ VFD
Chapter 1 Installation, Operation & Maintenance
Operation and Maintenance ........................................................................................... 1.1

Operation & Maintenance
Spare Parts ...................................................................................................................... 1.2

Spares List – Commissioning/ Operating
Chapter 2 Technical Document & Drawing Package
General Drawings ........................................................................................................... 2.1

Outline/ General Arrangement Drawing
Assembly Drawing
Data ……………… ............................................................................................................. 2.2

Equipment Data
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C. Number: GPK1000852 Page: ii of ii
System Diagram & Specifications ................................................................................. 2.3

Electrical Single Line Diagram
Electrical/Instrument ....................................................................................................... 2.4

Electrical Internal Wiring Diagram
Load List
Calculations .................................................................................................................... 2.5

Short Circuit Analysis
CB Coordination Study
Heat Loss Study
Harmonic Distortion Study
Load Flow Study
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FINAL DOCUMENTATION
AC Drive/ VFD Manual
Chapter 1
Installation, Operation &
Maintenance
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FINAL DOCUMENTATION
Section 1.1
Operation and Maintenance
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CHAPTER 1 INDEX 1.1
INSTALLATION, OPERATION &

MAINTENANCE
REFERENCE REFERENCE DESCRIPTION

8434 OPERATION & MAINTENANCE
This document contains proprietary and confidential information National Oilwell Varco
which belongs to National Oilwell Varco; it is loaned for limited Rig Solutions
purposes only and remains the property of National Oilwell Varco.
Reproduction, in whole or in part; or use of this design or 11000 Corporate Centre Drive
distribution of this information to others is not permitted without the Suite 200
express written consent of National Oilwell Varco. This document is Houston, Texas 77041
to be returned to National Oilwell Varco upon request and in any
event upon completion of the use for which it was loaned. Phone + 281.854.0400
 National Oilwell Varco Fax + 281.854.0607
DOCUMENT NUMBER REV
10707930-IDX 01
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Document number 10707930-IDX
Revision 01
Page 2
Sec Name ID Rev Code
1.1 OPERATION AND MAINTENANCE
NORTH AMERICAN DRIVE SYSTEM RECT 10588373-MAN 01 N04
NORTH AMERICAN DRIVE SYSTEM CHOP 10588375-MAN 01 N04
NORTH AMERICAN DRIVE SYSTEM INV. 10588376-MAN 01 N04
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Technical Manual
North American Drive System Rectifier

2500 ADC Air Cooled
RIG/PLANT REFERENCE REFERENCE DESCRIPTION

North American Drive System
ADDITIONAL CODE SDRL CODE TOTAL PGS
which belongs to National-Oilwell Varco, L.P., its affiliates or
subsidiaries (all collectively referred to hereinafter as "NOV"). It is Rig Solution Group
REMARKS
loaned for limited purposes only and remains the property of NOV. 11000 Corporate Centre Dr.
Reproduction, in whole or in part, or use of this design or Suite 200
distribution of this information to others is not permitted without the
MAIN TAG NUMBER DISCIPLINE Houston, Texas 77041 (USA)
express written consent of NOV. This document is to be returned to
NOV upon request and in any event upon completion of the use for Phone + 281-854-0400
which it was loaned. This document and the information contained Fax + 281-854-0508
CLIENT PO NUMBER and represented herein is the copyrighted property of NOV.
 National Oilwell Varco
CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV
Client Document Number 10588373-MAN 01
www.nov.com
Document number 10588373-MAN
Revision 01
Page 2
REVISION HISTORY
01 09.12.2010 Initial Release AB NHN ML

CHANGE DESCRIPTION

01 First issue
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Revision 01
Page 3
TABLE OF CONTENTS
SAFETY INSTRUCTIONS ........................................................................................................... 4

1.1 General ................................................................................................................... 4
1.2 Safety Symbols ....................................................................................................... 4
1.3 Basic Safety Precautions ........................................................................................ 5
2 SCOPE.............................................................................................................................. 6
3 INTRODUCTION ............................................................................................................... 6
3.1 Abbreviations and Definition ................................................................................... 6
4 HARDWARE DESCRIPTION ........................................................................................... 8
4.1 Main Components................................................................................................... 8
4.2 General Cabinet Construction ................................................................................ 8
4.3 Bridge Design ....................................................................................................... 14
4.3.1 Description ................................................................................................ 14
4.4 Lower Compartment ............................................................................................. 20
4.5 Control Panel ........................................................................................................ 23
4.6 Main DC Bus Compartment .................................................................................. 25
5 ELECTRICAL INSTALLATION ...................................................................................... 27
6 FUNCTIONAL DESCRIPTION AND OPERATION......................................................... 28
6.1 Description ............................................................................................................ 28
6.2 Initial Startup ......................................................................................................... 30
6.3 Normal Operation ................................................................................................. 32
6.3.1 Indicators ................................................................................................... 34
6.4 Air Cooled ............................................................................................................. 34
6.4.1 Repair ........................................................................................................ 35
6.4.2 Fuse Replacement .................................................................................... 35
6.4.3 Phase Cells ............................................................................................... 36
7 TECHNICAL INFORMATION ......................................................................................... 44
7.1 DC Isolation Switches ........................................................................................... 47
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Revision 01
Page 4
SAFETY INSTRUCTIONS
The following safety instructions must be followed when installing, operating and servicing the National
Oilwell Rectifiers. If ignored, damage to may occur to the operator and equipment. Read these safety
instructions before working on the system.
1.1 General
Safety is everyone’s responsibility and must be of primary concern at all times during any
operations or maintenance. Following the guidelines covered in this manual will help
provide for the safety of individuals and insure proper operation of the equipment. It is
important that only trained, qualified personnel, who are well familiar with general
electrical equipment safety procedures operate and/or maintain this equipment.
Unqualified, untrained personnel should not service, install, or operate the equipment.
The safety guidelines in this manual are not a substitute for the owner’s safety policies
and procedures, and should not be taken so. Safety recommendations and safety
procedures in this document should not be considered the minimum requirement for safe
operation and maintenance. Familiarize yourself with all safety, caution, and warning
symbols. Read them carefully and make sure you understand their meaning. If
something is unclear, consult NOV service department. Do not take chances with your
life or the life of others.
1.2 Safety Symbols

There are three types of safety instructions used throughout this manual and on the
equipment: warnings, cautions and notes. Look for these standard safety terms and
conventions that point out items of importance to the safety of the individual as well as
others that may be in the area:
WARNING safety notes MUST be followed carefully.

Failure to do so may result in catastrophic equipment
failure resulting in SERIOUS INJURY or DEATH.
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Revision 01
Page 5
CAUTION safety notes are also very important and

should be followed carefully. Failure to do so may
result in EQUIPMENT DAMAGE and/or PERSONAL
INJURY.
NOTE
NOTE is used to notify personnel of information that
is IMPORTANT but NOT HAZARD RELATED.
1.3 Basic Safety Precautions
1. All doors and covers must be in place while the equipment is energized
2. Do not stand on, or place foreign objects on or inside the cabinet.
3. Do not service the equipment while it is energized. Check warning labels and
schematics to determine whether or not the equipment is fed from multiple sources.
4. Observe lockout/tagout procedures as necessary when servicing the equipment.
5. The main incoming power circuit breaker (CB1) on North American Drive System
rectifiers does not remove all main power from the cabinet. Main power is supplied to
the cabinet from an external source, so main power is always present at the incoming
terminals of CB1, unless the external power source has been de-energized. CB1
removes main power from the main power circuit, below its bottom terminals.
Therefore, it’s essential that the external power source feeding CB1 is de-energized
before attempting to service it.
6. Do not substitute protective devices such as fuses, circuit breakers, or protective
relays with parts other than NOV approved parts.
7. Do not attempt to defeat the operation of protective devices, such as fuses or circuit
breakers
8. Do not allow contamination of any kind in the cabinet. The rectifier is intended to
operate in a clean, dry environment. Liquids, debris, or foreign objects of any kind
should not be allowed to enter the cabinet.
9. Observe all warning labels and signs on or inside the cabinet.
*
Recommended safety conventions. American Petroleum Institute
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Revision 01
Page 6
10. Avoid operation of the rectifier in environmental conditions that are outside the rated
limits
11. Observe all equipment warning and fault indicators, such as lamps, meter displays,
etc. Failure to do so may result in equipment damage or personal injury.
12. Do not attempt to operate the rectifier if it is malfunctioning, damaged, or if a fault is
suspected or indicated by its diagnostic functions.
13. Equipment used in heavy lifting and moving of the unit and accessories during
operations must be sufficiently rated to handle the weights involved.
Promote good safety measures at all times around the equipment and throughout all
phases of operations. It is the equipment owners’ / operators’ responsibility to establish
good safety measures including personnel training and enforcement of safety practices.
2 SCOPE
This manual includes the operation, maintenance, installation, and repair of the North
American Drive System series of rectifiers.
The user should have a copy of the customer specific drawings in order to have a complete
understanding of the equipment, since customer specific documentation may include
options not included in the preceding references.
3 INTRODUCTION
This manual is intended for personnel who plan the installation, commissioning, operation
and service of the North American Drive VFD system. A fundamental knowledge of
electrical terminology, theory, wiring, components, and electrical schematics is prerequisite.
Furthermore, it is assumed that installation and maintenance personnel are able make
measurements with common test equipment such as a digital multimeter, a megohmeter,
and a current probe. It is assumed that these individuals are familiar with working on and
around systems operating at voltage levels up to 1200V and several thousand amperes.
This technical manual includes data and information concerning the NOV air cooled series
of diode rectifiers and their associated components. This manual is written to include all of
these devices and their respective system components.
3.1 Abbreviations and Definition
ACL AC side Line Reactor

AAC Amps AC
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Revision 01
Page 7
ADC Amps DC
DB Dynamic Braking
DWK Draw works
EMC Electromagnetic Compatibility
FC Frequency Converter
FDS Functional Design Specification
GPM Gallons per minute
HMI Human-Machine Interface
HP Horsepower
Hz Hertz
IGBT Insulated Gate Bipolar Transistor
I/O Input/Output
KW Kilowatt
LED Light Emitting Diode
LPM Liter/minute
LPB Lighted Push Button
MP Mud Pump
P&ID Piping & Instrument Diagram
PHE Plate Heat Exchanger
PLC Programmable Logic Controller
PWM Pulse Width Modulation
PSI Pounds per Square Inch
SBC Single Board Computer
SCS Supervisory Control System (PLC, SBC, etc)
SVM Space Vector Modulation
TD Top drive
THD Total Harmonic Distortion
UPS Uninterruptible Power Supply
VAR Volt-Amp Reactive
VFD Variable Frequency Drive
VSDS Variable Speed Drive System
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Revision 01
Page 8
Rectifier An arrangement of solid-state devices that converts AC power to DC power

Operator The person assigned the responsibility of physically operating and
maintaining the equipment
4 HARDWARE DESCRIPTION
The following sections describe the primary components and their purpose.
4.1 Main Components

The function of the rectifier is to convert the 50/60Hz 3 phase AC voltage to DC voltage for
the inverters. The main components in the rectifier and their purpose are defined below:
 ACL (L1) is a 3 phase inductor which conditions the incoming power to the rectifier
bridge. It is also reduces current harmonics injected back the to the main power grid,
and improves current sharing among rectifiers when they feed a common DC bus.
 6 pulse Diode Bridge. The diode bridge provides rectification from AC to DC power.
 Bridge Temp Switch. There are 3 temperature switches providing protection to the
diodes.
 Circuit Breaker (CB01) provides overload protection for the rectifier bridge and ACL.
 Disconnect Switch (DW01) is used to isolate the output of the rectifier bridge from the
DC bus. It is non-load breaking and may not be used to interrupt service of the rectifier.
 The I/O provides feedback to the external supervisory control system.
 Indicator Lamps
4.2 General Cabinet Construction

The rectifier is cabinet is divided into 4 compartments. The upper compartment houses
CB01, DSW01, and the lower compartment contains the ACL. The middle compartment
houses the rectifier bridge assembly, fuses, and control panel, which may be accessed
through the double doors on the front of the cabinet.
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PB01 Shutdown
Disconnect
M01 DC Meter
CB01
Figure 1 2500A Rectifier
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The left front door of the cabinet contains a shutdown push button and a DC voltage meter,
an optional ground fault meter. The details are shown in Figure 2.
PB01 Shutdown
Button
M01 DC Volt Meter
Figure 2 Front Panel Indicators and Controls
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The 4th compartment, located behind the rectifier, houses the common DC bus bars. This
compartment is accessible only from the rear or the top of the cabinet. See Figure 4,for the
location of the DC Bus, AC Bus and Bridge Rectifier. Figure 4-1Shows Control panel. The detailed
construction of the DC bus is shown in Figures 16-18.
Figure 3 2500A Elevation
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DC BAS BAR
AC BUS BAR Rectifier Bridge
Figure 4 2500A Elevation
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Figure 4-1 Control Panel
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4.3 Bridge Design

North American Drive System rectifier bridges are designed to be easily maintained and
repaired. The phase cells containing the diodes can be removed and repaired outside of
the cubicle. All repairs for the rectifier may be made from the front of the cabinet.
If the diodes in a phase cell need to be replaced, NOV recommends returning them to our
factory for repair.
4.3.1 Description
North American Drive System rectifiers are assembled 3 individual phase cells, each
containing (2) 47mm compression-style rectifier diodes, a 200 CFM fan, an RC snubber
circuit, nickel plated copper fin heatsinks, 3 wire RTDs, and temperature limit switches.
Each phase cells is secured to an insulated mounting panel made of ½” Glastic, located
behind a hinged control panel. Figure 6 and 7 show various views of the individual phase
cell, and Figures 6-10 show the entire bridge assembly with the 3 phase cells, fuses, and
DC sub-bus structure as they are mounted on Glastic panel.
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Figure 5 Bridge Assembly - Front View

The phase cells are fastened to the Glastic plate with 4 bolts. Removing the phase cells
first requires removing the 2 fuses and 2 AC phase bus bars installed in front of the rectifier
phase cell. The positive and negative bus bar bolts (2 each) must also be removed to
replace the cell. Replacement of the phase cell fans may be done with the phase cell in
place. Fuses are replaced according to the following diagram. This diagram is also found
on the last page of the assembly drawing.
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Cooling Fan
Heat Sink
Diodes
AC BUS BARS
Figure 6 Air Cooled Diode Phase Cell
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DC BUS BARS
Figure 7 Phase cell assembly
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DC bus bolts. (-)

DC bus sub-structure side shown, most
right. (+) side,
opposite side of cell
Phase cell
Assembly
Figure 8 Air Cooled Bridge Assembly- Isometric View
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DC bus bolts. (-)

Remove bolts to
remove cell
Figure 9 Air Cooled Bridge Assembly –Side View
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4.4 Lower Compartment

Below the bridge assembly, a horizontal divider plate separates the bridge compartment
from the AC line reactor compartment. The reactor compartment houses the reactor, , and
the surge suppressor devices. The surge suppressors are located on the side walls in the
reactor compartment. Figure 11 shows the divider plate.
ACL
Divider Plate
Figure 10 ACL/Line Reactor
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CB Compartment
Bridge/ Control
Compartment
Line Reactor Figure 11 Rectifier Compartments

Compartment
Surge suppressors
Figure 12 shows the general layout of the rectifier’s 3 compartments. The lower
compartment houses the line reactor (Fig 11), the middle compartment houses the rectifier
bridge and controls, and the upper compartment houses the CB and disconnect switches.
In figure 12, the main incomer bus assembly and transition bus from the CB are shown with
respect to the line reactor.
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Incomer
bus;
3x80mm per
phase
Bus Support
members
Incoming
AC Power
Figure 12 2500A Rectifier AC Bus Structure (rear wall)
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4.5 Control Panel
The control panel is mounted on a hinged galvanized steel pan, inside the rectifier’s middle
compartment. The control components are segregated by voltage and power. Components,
fuses, and other devices carrying more than 24V are all mounted on the back of the pan. All 24V
control devices are located on the front of the front of the pan and are easily accessible. The
panel’s electrical schedule is shown in Table 1. Individual parts may be found on the BOM.
Figure 13 Control Panel Detail – Front
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Table 1 Electrical Schedule

Device Rating Circuit
CB02 16A, 480Y/277VAC, 6kIC, 2P UPS Supply TB07 (L1), TB07 (L2)
CB03 16A, 480Y/277VAC, 6kIC, 2P Essential Rig Supply TB07 (L1), TB07 (L2)
CB04, 1A, 240VAC, 10kIC, 2P 24VDC TB05 (+), TB06 (-)
CB06 2A, 480Y/277VAC, 6kIC, 2P
CB07 2A, 480Y/277VAC, 6kIC, 2P
CB09-11 2A, 480Y/277VAC, 6kIC, 2P Rectifier Fan 01-03
CB12 4A, 480Y/277VAC, 6kIC, 2P DB01 (CB01 UVR Power)
CB13 0.2A, 240VAC, 10kIC, 3P Power Meter 120VAC supply
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4.6 Main DC Bus Compartment

The DC bus compartment resides behind the rear wall of the Inverters and Chopper
cabinets and it is connected to Incomer/Rectifier disconnect switch with 4 535 MCM per
phase. The bus is composed of 4 pieces of 10x100mm tin plated copper bus. The positive
and negative bus pieces are mounted edgewise, 2 positive and 2 negative for the 4000A
bus, See Figure 16 and 17for the diagram of the main bus.
.
Figure 14 DC BUS Construction (4000A version shown)
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Figure 15 Rear DC Bus Compartment
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5 ELECTRICAL INSTALLATION
AC is supplied to incomer cabinet through the main ac bus connections figure 19 shows the
AC bus connections.
AC bus connections
L1, L2, L3
Figure 16 AC BUS CONNECTIONS
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Cable connections
CB01
L3
L2
L1
L1
L2
L3
Figure 17 Cable Installation
6 FUNCTIONAL DESCRIPTION AND OPERATION

The following section explains the technical specifications and operation of the rectifier.
6.1 Description
Control power may be externally supplied via either UPS or standard unconditioned rig
power. Standard control power voltage is 120V, 50/60Hz, and is controlled by CB02 and
CB03 on the front side of the control panel.
The main power supply for the rectifier is 3 phase, 50/60Hz, 600/690V and is controlled by
CB01. 600/690V three phase voltage is then converted to 810/932 VDC, and routed to the
main DC bus via the main disconnect switch, DSW01.There are 3 temperature switches
which protect the rectifier from thermal damage. Any of the 3 temperature switches
(TS01,TS02,TS03) will force CB01 to open when the heatsink temperature exceeds the
design temperature.
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Figure 18 Rectifier Bridge Electrical Diagram
Metering for the rectifier is found on the left side door. The DC voltage meter M01, indicates
the presence of DC voltage on the input of DSW01 The meter is connected to the output
phases of the rectifier, and shows the presence of main power on input of the rectifier.
The rectifier is designed to operate with minimal user effort. As long as main power and
control power are available to the rectifier, and the shutdown button PB01 is not in the
lockout position, charging motors for both CB01 and DSW01 will automatically charge the
breaker and the switch. The following conditions are required in order for the rectifier to
energize the DC bus:
• Main power 600/690V must be present on the input of the Main CB terminals
• The UVR 24V power supply must be operational
• The Shutdown button (PB01) must not be in the un-locked position
• The bridge temperature switches TS01-TS03 are closed.
• Control power must be present
• The 120 rig supply power relay (RL02) must be pulled in.
Closing CB01 is accomplished if preceding conditions are met and with .5 delay the
disconnect switch will close. The DSW01 may not be opened unless CB01 is first opened.
In order to disconnect DSW01, PB01 must be pushed. This action will first open CB01,
and after a 0.5s delay, open DSW01, effectively disconnecting the rectifier from input
power and the DC bus. The following conditions will cause the rectifier to shutdown:
• Pushing the “Shutdown” button (PB01)

• Bridge temperature switches are open (any heatsink reaches 150°C)
• Loss of Rig supply Power (RL02 provides this status)
• Pushing the “Open” button on CB01
• Loss of 24VDC supply
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• Loss of UPS supply
6.2 Initial Startup
WARNING: BEFORE APPLYING POWER, MAKE CERTAIN THERE ARE NO FOREIGN

OBJECTS OR DEBRIS OF ANY KIND IN THE RECTIFIER. VERIFY THERE IS NO LOOSE
HARDWARE ANYWHERE INSIDE THE CABINET. VERIFY THERE ARE NO SHORT
CIRCUITS PRESENT ON ANY OF THE RECTIFIER MAIN POWER CIRCUITS AND
CONTROL POWER CIRCUITS BEFORE ENERGIZING THEM. FAILURE TO DO SO MAY
RESULT IN CATASTROPHIC EQUIPMENT FAILURE, SERIOUS PERSONAL INJURY,
OR DEATH.
CAUTION: BEFORE TESTING THE RECTIFIER OR

ANY DEVICES WHICH IT SUPPLIES, MAKE SURE
THAT NO POWER SOURCES ARE CONNECTED TO
IT.
1. Carefully inspect all of the bus in the cabinet and verify there are no foreign objects,
packing material, dirt, or other contamination.
2. Inspect all main bus terminations. Insure there are no loose bolts or hardware. It is
possible for some components to become loose during shipping. Tighten any
connections that are loose or whose torque marks indicate a loosened connection. See
table 2 in the Technical Information section of the manual for a general torque
specification.
3. Inspect all wiring on the control panel and verify there are no loose wires or
components. Some components or wires may become dislodged during shipment. It is
recommended that all wire connections at each termination are checked for tightness
with a screwdriver or appropriate tool as it applies, after the equipment is unpacked.
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4. Using a suitable test instrument, verify there are no short circuits between the positive
and negative DC bus (See Figure 4, DC Sub Bus Structure)
5. Verify there are no short circuits between earth and either the positive or negative DC
buses
6. With the input power source OFF, verify there are no short circuits between the AC
main buses or to earth. This can be accomplished by measuring the bottom terminals
of the ACL See Figure 15.
7. Energize the control power source and close CB02 and/or CB03 as appropriate for the
model and system installation.
8. Verify that all control power CBs are closed. See Table 1.
9. Verify that the rectifier fans (FAN1-3) are powered and rotating in the correct direction.,
CBs 5,6,7. The fans should all be blowing air upward through the phase cells.
10. Verify the CB01 and DSW01 springs are charged. (this should take place as soon as
120V Rig control power is applied to the system)
11. Replace all protective covers and close all doors.
CAUTION: All covers must be replaced and

doors closed before applying main power to the
rectifier.
12. Energize the main power supply.
13. Ensure that the proper system voltage is present on the Circuit Breaker (CB01).
14. If there are any inverters or choppers on the DC bus, make sure they are locked out.
15. Verify that PB01 is pushed IN (not in the lockout position).
*
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16. Close the Circuit Breaker (CB01).
17. Verify that M01, the DC Voltage meter indicates the proper voltage. To check DC
voltage:
VDC = VAC x 1.35. If the input voltage is 600V, the M01 should indicate 590 x 1.35 =
810DC within approximately 3%.
18. Press the Shutdown Button (PB01). Verify that the Circuit Breaker (CB01) opens and
then 0.5 seconds later the Disconnect Switch opens.
19. Re-close CB01 and DSW01
20. With the Circuit Breaker (CB01) and Disconnect Switch (DSW01) both closed, test the
loss of UPS power by opening CB02. Verify that the disconnect switch (DSW01) opens
0.5 seconds later.
21. Re-close CB01 and DSW01
22. Test the loss of Rig Supply by turning off CB03. CB01 should open, and DSW01 drops
out 0.5 seconds later.
23. Test to check that the Disconnect Switch (DSW01) will not close before the Circuit
Breaker (CB01) is closed by depressing its own push to close button.
24. Verify the inputs that are wired into the Wago I/O block. Verify the inputs by the
corresponding LED on the input module (RR1S1). Verify the following inputs:
Terminal Description Completed

1 CB01 Status (on when CB01 closed)
2 DSW01 Status (on when DSW01 is closed)
6.3 Normal Operation
North American Drive System Rectifier starts automatically when PB01 shutdown contact is
in close position and rig supply power is present. The CB and DSW are charged by their
own motors, but the operator is required to close and open the CB and DSW from the front
panel of the rectifier.
CAUTION: Do not open doors or remove covers

unless CB01 is locked out
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1. Push PB01 IN, so that it’s in the locked out position

2. From the front of the hinged control panel, (inside the rectifier cabinet), close
CBs 2 through 7.
3. Verify the following components power up:
1. Rectifier phase cell fans 1-3
2. CB01 and DSW01 charging motors charge the springs
3. M01 meter
4. Verify M01 is able to read DC voltage, and that it indicates that DC voltage is
ON and within the expected range. See the appendix the meter’s operating
instructions.
5. Replace all protective covers and close the doors.

rectifier.
6. Pull PB01 out. Depending on ambient conditions, you should be able to hear
the UVR coil pull in.
7. Close CB01.
8. Verify that M01, the DC voltage meter indicates Vin x 1.35. For a 600V
supply, VDC is approximately 810V; for a 690V system, VDC is
approximately 932VDC.
9. Close DSW01.The main DC bus or DC bus compartment is now energized.
10. To disconnect the rectifier: Push IN PB01. This will cause both DSW01 and
CB01 to open. Control power can only be shut off from CB02 and CB03 on
the control panel inside the rectifier.
*
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WARNING: OPENING THE RECTIFIER CIRCUIT BREAKER, CB01, DOES

NOT REMOVE ALL POWER FROM THE RECTIFIER CABINET. THE
UPPER TERMINALS OF CB01 WILL REMAIN ENERGIZED UNLESS THE
RECTIFIER’S MAIN SUPPLY IS SWITCHED OFF. BEFORE RENDERING
SERVICE OF ANY KIND ON CB01, REMOVE POWER FROM THE
RECTIFIER’S SOURCE.
6.3.1 Indicators
- Green flag on CB/DSW indicate when the circuit breaker and disconnect switch are
closed.
- Red flag on CB/DSW indicate when the circuit breaker and disconnect switch are open.
- The red button labelled “Shutdown” may be used to shut down the rectifier. Depressing
the switch will open both CB01 and DSW01. Main power will still be available on the
input terminals of CB01. This button may be locked in the closed position to prevent
accidental closing of CB01.
6.4 Air Cooled
The air cooled rectifiers are designed to be as maintenance free as possible, however
some components should be cleaned periodically for optimum performance while
preventative maintenance for certain components are also beneficial to minimize downtime.
The following table is a recommended maintenance schedule:
Maintenance Interval Instructions

Clean phase cell heatsinks 1 time every 12 months Blow out dust/dirt with clean
dry air
Clean/Inspect Cabinet door 1 time every 12 months or as Wash with detergent and water
filter necessary, depending on
environment
Inspect all wiring attached to 1 time every 12 months Verify they are tightly
the AC and DC bus bars. terminated; verify the insulation
is not damaged or has come in
contact with any of the bus.
Verify the wires have not pulled
away from the ferrules. Tighten
all connections as necessary.
Replace any damaged wires.
Bridge cooling fans 60,0000 hrs or 7 years Replace
Cabinet roof fan (optional) 40,000 hours or 4 years Replace
Check DC Sub-main Bus and 36 months Tighten as necessary. See
incoming phase bolts Table 1 Bolt Torque
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Specifications
Check fuse nuts 36 months Tighten as necessary. See
Table 1 Bolt Torque
Specifications
Check upper compartment bus 36 months Remove front and roof covers.
terminations at the circuit Tighten as necessary. See
breaker and DC switch. Table 1 Bolt Torque
Specifications
Check Flexibar run-back 36 months Remove DC compartment roof
connection terminations at the covers. Tighten as necessary.
main DC switch. See Table 1 Bolt Torque
Specifications
Check AC Flexibar 36 months Remove DC compartment roof
connections at the reactor covers. Tighten as necessary.
terminals, in the lower See Table 1 Bolt Torque
compartment Specifications
6.4.1 Repair
Repairing the rectifier requires basic hand tools, a DVM, and electrical training. It is
recommended that repairs be performed only by qualified personnel.
6.4.2 Fuse Replacement
The fuses are equipped with indicator switches on the fuse body. A red plunger will be
rejected from the fuse body when it has opened, opening the micro-switch, and tripping
CB01. This switch needs to be removed from the faulted fuse, and set aside. The
following diagram and instructions outline the fuse replacement procedure. It is important
to use the correct tools and follow the procedure exactly. Failure to do so could result in the
fuses not operating properly and causing damage to the rectifier or to devices it supplies.
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6.4.3 Phase Cells

Testing the phase cells: (note this can only be performed with the diodes mounted in the
phase cells)
1. Insure that CB01 and DSW0 are both open, and locked out. Remove control power
from the cubicle by opening CB02 and CB03 on the control panel.
2. Use a DVM to measure the phase voltage at the bridge’s input and output terminals and
verify they measure 0V for both AC and DC terminals.
3. Set the DVM to the diode check mode
4. Place the positive DVM lead on the A phase (L1) input terminal and the negative DVM
lead on the positive DC bus. The DVM should indicate approximately 1V. Repeat the
test by moving the positive lead to the B (L2) and C (L3) input terminals.
5. Repeat step 4 with the positive and negative leads reversed. The diodes should appear
open, or high impedance.
6. Place the negative DVM lead on the A (L1) input terminal, and the positive lead on the
negative DC bus. The DVM should indicate approximately 1V. Repeat the test by
moving the positive lead to the B (L2) and C (L3) input terminals.
7. Repeat step 6 with the positive and negative leads reversed. The diodes should appear
open, or high impedance
8. If any of the tests fails, the diodes should be replaced. If you are not certain, contact the
NOV service department.
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DC BUS +
DC BUS -
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6.4.3.1 Replacing Diodes

In the event that a diodes need to be replaced in one or more of the phase cells, the
following procedure may be used to replace them. This procedure needs to be carried out
in an area free of grease or dirt.
1. Remove the phase cell(s) from the rectifier and place it on a clean working surface.
2. Loosen the clamping nuts (Figs 23, 24) and remove both diodes and take note of the
order in which the pieces are assembled.
3. Follow the instructions below for surface preparation, re-assembly, and clamping.
Figure 19 Phase Cell Exploded Diagram
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Figure 20 Phase Cell
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SURFACE PREPERATION 1
Figure 21 Surface Preparation
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CLAMPING PROCEDURE 1
Figure 22 Clamping Procedure
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CLAMPING DETAILS 1 Clamping

Nuts
Figure 23 Clamp Details
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1. Verify the assembly is completed as per Figure 22.

2. Using a DVM set to diode check, place the positive lead on the common AC input
terminal and the negative lead on the positive DC terminal. The DVM should indicate a
good diode. Reverse the leads and verify the DVM reads open
3. Place the negative lead on the common AC input terminal and the positive lead on the
negative DC terminal. The DVM should indicate a good diode. Reverse the leads and
verify the DVM reads open.
6.4.3.2 Fault Tracing

The rectifier has only one fault indicator on the front panel. The FUSE FAULT LED is
located on the front door. All other faults are conveyed to the SCS via the Wago I/O. The
monitored signals and their meaning are listed in the following table.
PROBLEM POSSIBLE CAUSES REMEDY

1 CB01 will not close PB01 is locked out Remove lockout
2 phase cell micro- Check bridge

switch is open fuses/replace
3 Phase cell Verify all fans are
temperature micro- operational
switch is open
6 CB01 UVR coil (YU) Check UVR supply,
is open DB01
7 CB01 Closing coil Check coil and
(YC) is open wiring
8 DSW01 will not close CB01 aux contact is Check contact and
faulty wiring
9 TD01 time delay relay Check relay and
is faulty wiring
10 DSW01 UVR relay is Check relay and
faulty wiring
11 Rectifier CB trips on Phase Cell Fan(s) Check fan fuses
Overtemperature inoperative and power
(control system display) supply/replace
fuses or fans as
required
Intake filter in door isClean filter
clogged
DC meter is incorrect or Voltage feedback card Check wiring
inoperative PC01 is faulty/wiring
is loose
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PC01 fuses are open Check fuses

Meter is Checking wiring or
damaged/wiring is replace meter
loose

CB03 16A, 480Y/277VAC, 6kIC, 2P Essential Rig Supply TB03 (L1), TB04 (L2)
CB04, 1A, 240VAC, 10kIC, 2P 24VDC TB05 (+), TB06 (-)
CB06 2A, 480Y/277VAC, 6kIC, 2P Cabinet Light
CB07 2A, 480Y/277VAC, 6kIC, 2P Cabinet Heater
CB09-11 2A, 480Y/277VAC, 6kIC, 2P Rectifier Fan 01-03
CB12 4A, 480Y/277VAC, 6kIC, 2P DB01 (CB01 UVR Power)
CB13 0.2A, 240VAC, 10kIC, 3P Power Meter 120VAC supply
1600A, 690VAC/700VAC (IEC/UL),

FA,B,C+/- 200kIC Rectifier Fuses
F01,02,03 10A, 700VAC/DC, 200kIC T01,02,03 600V supply
F04,05 1A, 1000VDC, 100kIC PC01 Voltage Feedback Board input
F06-08 250A, 690VAC, 200kA@660V Phase-to-Neutral Surge Protectors
7 TECHNICAL INFORMATION
This section contains technical data about the rectifiers and subcomponents.
The air cooled Rectifier’s ratings are given in Table 3.

Table 2
AIR COOLED 2500A RECTIFIER
NUMBER OF PHASES 3
RATED POWER 2338 KW
RATED INPUT VOLTAGE 600-690 VAC
RATED INPUT CURRENT 2041 AAC
RATED OUTPUT CURRENT 2500 ADC
RATED OUTPUT VOLTAGE 810-935 VDC
RATED INPUT FREQUENCY 50/60 HZ
AMBIENT TEMPERATURE (NO
DERATING) 45°C
MAXIMIUM AMBIENT TEMPERATURE 55°C
INGRESS PROTECTION- doors closed IP 22
SHORT CIRCUIT RATING 100KA RMS
COOLING METHOD FORCED AIR
DUTY CLASS (IEC 60142-2) 1
MAXIMUM OVERLOAD 150% (60s)
VOLTAGE REGULATION w/3% REACTOR 97.9%
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RECTIFIER DIODE SPECIFICATIONS

Parameter Min Max Unit Note
Peak Repetitive
Voltage 2200 V
Heatsink @85; sinusoidal

Average Forward halfwave; double sided
Current 2693 cooling
2 6
I t 4.62x10 5.61x106 A2s
Operating
Temperature -55C 175C
Storage
Temperature -55C 200C
Mounting Force 19kN 26kN
For Double sided cooling,
120deg conduction; sq.
Rth J-hsnk 0.0255 degC/kW wave
47 (in contact 74 -
Diameter with heatsink) total mm
RTDS
0.9s
100Ω DIN RESPONSE
3 WIRE PLATINUM CLASS A -73C TO 260C TIME
Temp Switch RTD Alarm
PHASE CELL FANS Opens at Temp
200 ft3/min
[400 m3/hour] 120V 50/60Hz 150°C 140°C
Table 3 Bolt Torque Specification
BOLT TORQUE SPECIFICATIONS

BOLT SIZE FLEXIBUS HARDBUS
[N-m] [ft-lb] [N-m] [ft-lb]
M6 x 1.0 6.5 4.8 7.2 5.3
M8 x 1.25 15 11.06 17 12.5
M10 x 1.50 30 22.15 28 20.7
M12 x 1.75 55 40.56 45 33.2
Table 4
SPECIFICATION:SURGE SUPRESSION METAL OXIDE VARISTOR MODULES
Operating Voltage: 600-690V rms
Clamping Voltage: 1000V, measured at 200A short circuit for
8/20uS
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Pulse Lifetime 2000 pulses withstand 4kA short circuit

50/500nS
Surge suppression Standards: IEC61643-1, IEEE C62.41.2 2002
Safety: UL 1440 2nd Edition
Bonding: NEC 250
Operating/Storage Temp -40C to +80C
AC LINE REACTOR SPECIFICATIONS

Rated Current 2040A RMS; 130% Overload
Rated Power 68kVAR
Inductance 15uH
Windings Copper
Core Iron
Insulation rating 220°C
Rated operating temperature 115°C over ambient
Terminals/phase bars Copper; 3 x 3/8 inch (76.2mm x 9.5mm)
Weight 750 lbs (340kg)
Air Flow VAC Hz Power dBA Max Starter Speed

Temp Capacitor
1430 ft3/min 115 50/60 225W 65 60C 20uF 1700
(2430m3/hr)
MAIN BUS BAR SPECIFICATIONS

RATED CURRENT 4000/8000 ADC
NUMBER PER BUS 2P-2N/4P-4N
RATED TEMPERATURE 50°C
RISE
COMPOSITION COPPER – TIN PLATED
YIELD STRENGTH 172MPa / 25,000 psI
WIDTH 100mm
THICKNESS 10mm
BUSBAR BRACING: MATERIAL SPECIFICATIONS
Property Value Unit
Impact Strength 267-374 J/m
Flexural Strength 76-97 MPa
Tensile Strength 57.00 MPa
Continuous Operating 204° Celsius
Temperature
Maximum Temperature 260° Celsius
Flammability UL 94@1/16 inch 35-45
Water Absorption by weight; 0.06 %
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24 hours
168 hours
Arc Resistance >190 seconds
Volume Resistivity 1.29 x 1015 Ω-cm
Dielectric Strength >20 Kv/mm
Comparative Tracking Index >600 Volts
7.1 DC Isolation Switches

The following ratings apply to the ABB 3 and 4 pole DC disconnect switches.
Icw values are applicable for 1s. The peak values are applicable for 10ms.
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Chopper Technical Manual
North American Drive System Air Cooled

North American Drive System
32 which belongs to National-Oilwell Varco, L.P., its affiliates or Rig Solution Group
REMARKS subsidiaries (all collectively referred to hereinafter as "NOV"). It is 11000 Corporate Centre Dr.
loaned for limited purposes only and remains the property of NOV.
Reproduction, in whole or in part, or use of this design or Suite 200
MAIN TAG NUMBER DISCIPLINE
distribution of this information to others is not permitted without the Houston, Texas 77041 (USA)
express written consent of NOV. This document is to be returned to Phone + 281-854-0400
NOV upon request and in any event upon completion of the use for
which it was loaned. This document and the information contained Fax + 281-854-0508
CLIENT PO NUMBER and represented herein is the copyrighted property of NOV.
 National Oilwell Varco
10588375-MAN 01
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REVISION HISTORY
01 22/08/2011 Release AB NHN ML

CHANGE DESCRIPTION

01 First issue
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TABLE OF CONTENTS
1 BRAKING CHOPPER ....................................................................................................... 4

1.1 Overview ................................................................................................................. 4
1.2 HARDWARE DESCRIPTION ................................................................................. 5
1.2.1 Wire, Cable and Materials ........................................................................... 5
2 FUNCTIONAL DESCRIPTION AND OPERATION......................................................... 13
2.1 Basic Operation .................................................................................................... 13
2.2 Pre-charging and Disconnect switch management ............................................... 14
2.3 Charge Controller PLC I/O .................................................................................... 16
2.4 I/O Configuration................................................................................................... 17
2.5 Initial Startup ......................................................................................................... 18
2.6 Normal Operation ................................................................................................. 20
2.6.1 INDICATORS ............................................................................................ 21
3 MAINTENANCE .............................................................................................................. 21
3.1 Maintenance Schedule ......................................................................................... 22
3.2 Fuse Replacement................................................................................................ 22
3.3 Fault Tracing ......................................................................................................... 23
4 TECHNICAL INFORMATION ......................................................................................... 25
4.1.1 Environment .............................................................................................. 26
4.1.2 DERATING ................................................................................................ 27
5 APPENDIX ...................................................................................................................... 28
5.1 Chopper Module ................................................................................................... 28
5.2 Connection instructions ........................................................................................ 29
5.3 DC Isolation Switches ........................................................................................... 32
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1 BRAKING CHOPPER
1.1 Overview
North American Drive System choppers primarily come in 2 ratings, with 2 basic cabinet
configurations:
1. 1 x1200 kW chopper cabinet – 800mm W
2. 2 x 1200 kW chopper cabinet – 800mm W
Air cooled NADS braking choppers modules have 2 ratings, 600kW and 1200kW.
Depending on the model, the individual current ratings for NADS choppers varies. Table 1
summarizes the fundamental ratings of each model.
Table 1
Peak
Current
Maximum Continuous [ADC] - Continuous Peak Power Number of
Model Voltage Current 10s Power [kW] [kW] -10s IGBTs
NOV
single 1,200 1,200 1,700 1,300 1,500 1
NOV dual 1,200 1,200 1,700 1,300 1,500 2
Rated Minimum Recommended

Regulation DC Brake Brake Maximum Brake
Levels Capacitance Resistance Resistance Cable Resistor
Model [VDC] [uF] [Ω] [Ω] Length [m] Cable [mm2]
900,
1000, 4 x 110 single
NOV 1100 1080 0.88 0.65 300 core
As shown in Table 1, NADS choppers have 3 selectable DC bus regulation levels.

Selection is made with a jumper on the controller board.
All chopper modules are constructed with 1700V trench IGBT devices. The Chopper
capacitors are parallel connected metallized film, rated at 1350VDC. The metal film
capacitors do not require periodic re-forming and are considered maintenance free.
Chopper control, protection, and IGBT firing are provided via high speed printed circuit
board controllers. The IGBTs are mounted on forced air cooled aluminium heatsinks.
The front door of each cabinet is outfitted with an analog DC voltmeter, a lockout button, a
red “Fuse Fault” lamp, and a green “DC Bus Charged” lamp. A dual chopper cabinet is
shown in Figure 1:2.
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1.2 HARDWARE DESCRIPTION

Short circuit protection for each chopper module is provided with 2 high Speed 1000A,
1350V semiconductor fuses. The fuses are stud mounted, on both positive and negative
input terminals of the chopper module. Common mode filters are installed on each
individual inverter’s DC input terminals to block high frequency switching noise from
reaching the main AC supply.
Chopper pre-charging is initiated by PB02 push to charge button. Section 2.2 provides a
detailed description of the various precharge methods. In general, precharge is either
handled directly from the main DC bus, or indirectly from the main AC bus.
Once control power is established to the chopper cabinet, the pre-charge circuit will engage
and apply DC voltage to the chopper,closes the DC disconnect switch. In stand-alone
drives, the Charge Controller operates the main rectifier’s circuit breaker. Short circuit
protection for the pre-charge circuitry is handled with 4 miniature DC fuses rated at 30A
100kA and 1000V.
A separate relay is used to test the presence of control power. In the event control power
is lost, the entire pre-charge circuit and disconnect switch return to the safe state – that is,.
If main power is lost, the Charge Controller will open the disconnect switch; when main
power is restored, the precharge circuit will automatically charge the bus and close the
disconnect switch. Therefore if either the main or control power is lost, the pre-charge
circuit and main switch will reset to the safe state. A green ‘DC Bus-charged’ status lamp is
located on the door of each cabinet to notify the operator of the bus status. A red ‘Fuse
Fault’ lamp indicates a blown main inverter fuse.
Main bus isolation is provided for each chopper module with a 2000A, 1000V disconnect
switches. Each is specially labeled for this purpose by the manufacturer. Fault current
withstand rating is 55kA for 1 second, with a peak rating of 126kA for 10mS. See section 5
for technical information. Short circuit protection for the DC isolation switch is provided by
the rectifier fuses. Power is fed to each isolation switch from the main compartment
through the rear wall of the chopper with insulated flexible bus. An indicator lamp is located
on the door of each cabinet to annunciate a faulted fuse.
Control power may be externally supplied to the chopper cabinet via either or both
uninterruptible power and standard rig power. It is recommended that UPS power be
supplied where indicated on the electrical schematics unless the power quality of the
supply can be verified to be stable and within reasonable limits. Control power voltage
requirements are 120/230V, 50/60Hz. All miniature control- power feeder circuit breakers
are rated for branch circuit protection; all downstream circuit breakers are IEC 60947-1
tested and rated for supplemental protection as a minimum.
A power distribution schedule, showing name, voltage, and function of each fuse and circuit
breaker are fixed to the inside of every cabinet. Safety lockouts of main power and control
power are provided and clearly marked.
1.2.1 Wire, Cable and Materials
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Wire and cable insulation is low smoke, halogen free in accordance with IEC 60331, IEC
332-3, and IEEE 1202. Flexbus is low smoke, low halogen and approved by UL, CSA, IEC
439-1 and DNV for marine installations. All terminal blocks, cable raceways, are low
smoke, zero halogen. Unless otherwise marked on schematics, low voltage (defined as
230V or less) control circuit wires are grey 1.5mm2, 1000V insulation, and stranded tinned
copper. Wires connected to neutral are marked with a blue sleeve. All wires directly
connected to either the main DC bus are minimum 4mm2, 3000V, and double insulated.
Wires connected to the main DC bus shall be orange or red.
Earth conductors are 2.5mm2 minimum, with green/yellow insulation. 3 phase supply power
cables are marked L1, L2, L3 and U, V, W at motor terminals. Fuse blocks, miniature CBs,
terminal blocks are clearly marked with Functional name (eg “24V control power”), the
working voltage, and B.O.M. component designation. Wiring terminations are vinyl
insulated ferrules, ring lugs, or locking forks, as are appropriate for each connection. All
wiring is clearly labelled at both ends according to the wiring schematic. Wiring is
segregated in conduits and bundles according to voltage level. Wire fill in conduits and
raceways are according to the manufacturer’s recommendations and accepted industry
standards.
Cabinets are constructed of 1.5mm carbon steel panels and 1.5mm rolled steel frames.
The internal mounting panels are constructed from 2.5mm galvanized steel. Free standing
cabinets are mechanically braced according to Seismic Zone 4. All cabinets are dip coated
in primer with a textured, power coated finish coat. The painting process is according to
DIN EN ISO 20-482, 2815, and 2409. Cabinet walls, dividers, and doors are equipped
with grounding studs and stainless steel or copper braided straps which are bolted to the
cabinet frame with self-tapping screws. Cabinet doors where access is considered touch
safe; e.g. the low voltage compartment, are accessible with a factory provided tool. Access
to higher voltage compartments requires hand tools such as Torx or Phillips head
screwdrivers.
Warning labels are on all access covers both outside and inside the cabinet.
Bus bars are tin plated copper, and dimensioned to maintain a 45°C temperature rise at
rated current. All bolted bus joints are tin plated, joined with stainless steel Belleville
washers, lock washers, and nuts. All hardware and bus are standard metric dimensions.
The bus connections to the circuit breakers shall match the breaker rating. The bus bars
and support systems shall be designed to withstand the thermal and mechanical forces
created during short circuit conditions at the rated momentary and short-time conditions of
the highest rated circuit breaker. A 10mm x 50mm copper earthing bar is solidly bonded to
each cabinet frame with 10 AWG stainless steel support brackets.
Bus supports and insulation materials are flame-retardant, track-resistant, and non-
hygroscopic.
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INDICATOR LAMP
SELECT SWITCH LOCKOUT ENABLE
Figure 1: 2 Chopper Module Cabinet
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Figure 2
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Figure 3
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CONTROL COMPARTMENT
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COMPONENT REAR PAN
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Cabinet construction is IP22 with doors closed, and IP20 with doors open for both marine
and land rig installations. A hinged control panel is mounted in front of the chopper power
modules, and houses all of the auxiliary control components. On the front surface of the
panel, low voltage components (=<120VAC) are installed; components rated from 230V -
690V are installed on the back of the panel. All components with terminals rated above
24V are finger safe. The panel is double sided, made from 2.5mm thick galvanized steel. .
Brake resistor connections are located behind the control pane;. Resistor cable entry is
either top or bottom.
Basic I/O to the supervisory control system is provided, including digital input and analog
input modules. Standard communication protocol is Profibus control with Ethernet
monitoring. Control power may be either 120/230VAC.
2 FUNCTIONAL DESCRIPTION AND OPERATION
This section describes the basic operation of the NADS chopper systems. Refer to
electrical schematics for further details:
• 1054286-SCH-001 – Single Chopper cabinet

• 10544749-SCH-001 – Dual Chopper cabinet
2.1 Basic Operation
Each individual chopper module is capable of independent operation, or in master/follower

mode. In M/F mode, the signal to fire the IGBTs is received from the Master. When acting
independently, the chopper directly measure the DC bus through it’s main DC bus input
terminals, compares it with the selected reference, and determines whether or not to fire its
IGBTs. If the DC bus voltage is higher than the reference, the chopper will fire the IGBTs
until the DC bus level is reduced to the reference.
In Follower mode, the chopper will fire its IGBT according to the Master’s firing signal. The
master signal is transmitted via fiber optic cables between chopper units. In
master/follower mode, if the master chopper should fault or fail, the followers will trigger
their IGBTs to fire at 5% above their selected reference as a safety backup.
The switching frequency of the IGBT is determined solely by the time constant of the RCL
network formed by the DC link capacitance, including the total on-line inverter capacitance,
the braking resistor, and any circuit inductance, which includes the cables, resistor
elements, and DC bus bars. Depending on the system design, the frequency will vary.
The chopper control module is responsible for monitoring resistor current and IGBT
temperature. Current and temperature transducers are integral parts of the chopper
module and if either current or temperature exceeds the preset limits, the chopper will fault,
then, initiate a fault signal to the supervisory control system.
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The following signals are inputs to the chopper:
Table 2
Signal Name Description
Enable 24V = Enable brake
Disable 0V = Disable brake
Master/Follower Select Master = 24V, Follower = 0V
Enable
Fault Dry contactt
DC Bus Feedback 10V/1200V feedback to the control system
Voltage Reference 8.33V/1000V feedback to the control
system
Chopper Current 10V/1250A
Heat Sink Temperature 0.1V/°C
The following signals LEDs are mounted on the control board.

Board Mounted Diagnostic LEDs
LED 1 ENABLE/DISABLE
LED 2 MODEL 1/MODEL 2
LED 3 MASTER/FOLLOWER
LED 4 OVER-TEMPERATURE
LED 5 OVER-CURRENT
LED 6,8 +15V AND +24V PRESENT
LED 7 IGBT CONTROL SIGNAL
LED 9 FAULT
2.2 Pre-charging and Disconnect switch management

To start the chopper as long as the chopper is not locked out with lockout button (SS1, SS3). The
chopper pre-charge sequence applies voltage to the chopper capacitors gradually through a
resistor. This protects the capacitors. Each chopper uses a charge control board to manage the
pre-charge sequence. Monitoring the DC Bus Volts and closing the disconnect switch is
performed by the charge control board. The pre-charge circuit is shown in the Figure 4 below.
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Pre charge board
Disconnect
Switch
Figure 4: Chopper Pre-charge circuit
The Disconnect Switch (DSW01, DSW02) is equipped with a 120VAC charging motor
(DSW01 M), a 120VAC closing coil (DSW01, DSW02 YC), and a 120VAC UVR coil
(DSW01, DSW02 YU).
The charging motor for disconnect switch (DSW01,DSW02 M) will charge the switch
springs as long as rig power is present. The presence of rig power is determined by RL03.
Feedback indicating the charge status for the switch’s springs is input to the PLC.
Before DSW01, DSW02 can close, the UVR coil (DSW01, DSW02YU) must be energized.
The following conditions must be true for DSW01, DSW02 YU to be energized:
• 120/230V Rig Supply is present

• The charge control “Open UVR” contact is closed.
• The chopper fuses are not open
• The main DC bus voltage is available
• UPS Power (120VAC) is present in the cabinet
• Select switch (SS1, SS3) in enable position
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Figure 5: Chopper Disconnect Switch (DSW01) UVR Logic
The following events will open the UVR (DSW01 YU) circuit disconnecting the Chopper
from the DC Bus and prevent the drive from running:
• A blown chopper fuse (RL02)

• Loss of Rig Supply voltage (RL03)
• The chopper is running, but DC Bus Voltage drops below (350VDC) (read by
the Voltage Feedback PCB)
• DC bus charge (RL01) not energize
If the switch springs are charged and the UVR Coils is energized, the charge control will
signal DSW01 (YC) to close the switch. After the disconnect switch (DSW01) is closed, an
aux contact in the switch will signal the charge control that the pre-charge cycle was
completed, and illuminate the “DC Bus Charged” light (PL02).
The Voltage Feedback Card (PC01) reads in the DC Bus Voltage (0-1200VDC). If the DC
Bus Voltage doesn’t completely charge (reach 700VDC) in 2 seconds, the pre-charge
sequence is aborted. Once the pre-charge sequence has been aborted, the Select switch
(SS1) will needed in enable position and depress PB02 in order to re-initiate a precharge
cycle.
If the DC Bus Voltage falls below 350VDC while the chopper is active (enabled), if a
chopper fuse blows, or if any control power to the chopper or the charge controller is lost,
the UVR” contact will drop out and open the main switch. When DC Bus voltage returns,
the pre-charge sequence will occur again automatically.
2.3 Charge Controller PLC I/O

The following inputs are read into the PLC:
• Chopper Enabled
• Resistor Bank Temperature OK (RL01)
• Resistor Bank Pressure OK (RL02)
• Resistor Bank Pressure OK (RL02)
• Chopper Fault Status
The following outputs are controlled by the Wago PLC:
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• Chopper Remote Enable
The DC Bus Voltage may also be read on the DC Bus Volts meter (M01).
2.4 I/O Configuration
The I/O listed in the previous section is wired into a programmable controller which can be
read by the control system.
Each chopper has its own set of I/O. The “X” in the following descriptions refers to the
chopper number (1 or 2). The address map for the I/O is as follows:
Inputs:
%IW0.0 – Chopper X Enabled (on if the chopper is enabled)
%IW0.1 – Resistor Bank X Temperature OK (on if Temperature is okay)
%IX0.2 – Resistor Bank X Pressure OK (on if Air Flow is okay)
%IX0.3 – Chopper X Fault (on if the chopper is faulted)
%IX0.4 – Chopper X Enabled (on if the chopper is enabled)
%IX0.5 – Resistor Bank X Temperature OK (on if Temperature is okay)
%IX0.6 – Resistor Bank X Pressure OK (on if Air Flow is okay)
%IX0.7 – Chopper X Fault (on if the chopper is faulted)
%IX0.8 – DSW01 status

%IX0.9 – DSW02 status
%IX.10 – Spare
%IX.11 – Spare
%IX.12 – Spare
%IX.13 – Spare
%IX.14 – Spare
%IX.15 – Spare
Outputs:
%QX0.0 – Chopper X Remote Enable (a normally closed contact that
will open when the output turns on and will to disable the chopper)
%QX0.1– Chopper X Remote Enable (a normally closed contact that
will open when the output turns on and will to disable the chopper)
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2.5 Initial Startup
WARNING: BEFORE APPLYING POWER, MAKE CERTAIN THERE ARE NO FOREIGN

OBJECTS OR DEBRIS OF ANY KIND IN THE CHOPPER. VERIFY THERE IS NO LOOSE
HARDWARE ANYWHERE INSIDE THE CABINET. VERIFY THERE ARE NO SHORT
CIRCUITS PRESENT ON ANY OF THE CHOPPER MAIN POWER CIRCUITS AND
CONTROL POWER CIRCUITS BEFORE ENERGIZING THEM. FAILURE TO DO SO MAY
RESULT IN CATASTROPHIC EQUIPMENT FAILURE, SERIOUS PERSONAL INJURY,
OR DEATH.
CAUTION: BEFORE TESTING THE CHOPPER OR

ANY DEVICES WHICH IT SUPPLIES, MAKE SURE
THAT NO POWER SOURCES ARE CONNECTED TO
IT.
1. Carefully inspect all of the bus in the cabinet and verify there are no foreign objects,
packing material, dirt, or other contamination.
2. Inspect all main bus terminations. Insure there are no loose bolts or hardware. It is
possible for some components to become loose during shipping. Tighten any
connections that are loose or whose torque marks indicate a loosened connection. See
table 2 in the Technical Information section of the manual for a general torque
specification. The user should consult drawing D25ACCC0AA00000-DAD-01 for
detailed torque specifications.
3. Inspect all wiring on the control panel and verify there are no loose wires or
components. It is recommended that all wire connections at each termination are
checked for tightness with a screwdriver or appropriate tool as it applies, after the
equipment is unpacked.
4. If there are any additional inverters or choppers on the DC bus, make sure they are
locked out.
5. Verify there are no short circuits between the positive and negative DC bus.
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6. Verify there are no short circuits between the positive bus to ground and the negative
bus to ground.
7. Apply control power to the cabinet by closing CB02 and CB03.
8. Verify that DSW01’s, DSW02’s charging motor starts and charges the switch’s springs.
The UVR (YU) coils should also be pulled in.
9. Verify the choppers’ heat sink blowers turn on and are blowing up through the heat
sinks.
10. Energize the main power source.
11. Verify the pilot lights (PL01 and PL02) are functioning by pushing to test.
12. Turn (SS1, SS3) in enable position.
13. When the bus volts reaches 700V, the disconnect switch (DSW01, DSW02) would
close and the pre-charge relay (RL12, RL13) should drop out.
14. Once the chopper is charged, the DC Bus Charged pilot light (PL01, PL03) should be
ON.
15. Verify the voltage output from the Voltage Feedback board (PC02, PC04). The board
should be producing 0-10VDC for a 0-1200VDC input. This would mean that for a
600VAC supply, the DC Bus volts should be reading 810VDC and the board should be
producing 6.75VDC. For a 690VAC system, the board should be producing 7.77VDC
for a DC Bus voltage of 932VDC.
16. Monitor the DC Bus Voltage from the Bus Volts meter (M01). Verify that the DC Bus
volts are being read accurately.
17. Turn (SS1, SS3) to lock-out position to discharge the chopper. Verify when the bus
volts drop below 350VDC, the DC Bus Charged pilot light (PL01, PL03) turns off, the
DSW01, DSW02 drop out.
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18. The chopper has 8 seconds to reach 700VDC. If the chopper does not pre-charge in
time , re-start the sequence, depress PB01, then pull it back out. If the chopper still
does not pre-charge, go to the trouble shooting section.
19. To reset the pre-charge system, depress the Shutdown button (PB01) and then pull
PB01 back out.
20. Verify that the chopper pre-charges correctly once again.
21. Verify the Chopper Voltage setpoint is set correctly on Dipswitch S1. For 900VDC
regulation, close switch S1-1. For 1000VDC regulation, close S1-2. For 1100VDC
regulation close S1-3. Note: If all switches are off, 800VDC regulation is
automatically selected.
22. Replace all covers and close all doors.
2.6 Normal Operation
The chopper can be enabled from a remote source by providing a contact closure between
TB07-07 and TB07-08. This should be jumpered out when it is not being used.
The chopper can also be disabled by the Master Control System. Consult with the control
system and project schematics to determine if choppers are being remotely disabled.
CAUTION: Chopper Cubicles are supplied by multiple voltage sources. Do not

proceed to work on any cubicle unless all voltage sources are locked out. See
D25ACC1-205-SCH-001 (for one chopper) and D25ACC2-205-SCH-001 (for 2
choppers) for further details.
The following steps are required to start the chopper.
1. Push PB01 IN, so that it is in the locked out position.

2. From the hinged control panel (inside the bottom door), close CBs 2 through
11 for single chopper cubicles, and CBs 2 through 13 for dual chopper
cubicles.
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3. Verify that the Fuse Fault light(s) and the Bus Charged light(s) are not
illuminated.
4. The Disconnect Switches will be charged by their own motors when Rig
Supply is present in the cabinet.
5. With the shutdown button(s) depressed, verify the DC Bus Volts meter(s)
read 0V.

rectifier.
6. Disengage the Shutdown button.

7. If power is being supplied to the DC Bus, the chopper will charge and the
disconnect switch will close, connecting the chopper to the DC Bus.
8. Verify the DC Bus Volts meter(s) read the correct DC Bus voltage.
9. To disconnect the chopper from the bus, depress the Shutdown button.
10. The Disconnect Switch will open isolating the chopper from the DC Bus.
WARNING: THE CHOPPER CAPACITORS WILL HOLD A CHARGE EVEN WHEN

DISCONNECTED FROM THE DC BUS. ALLOW 5 MINUTES FOR THE
CAPACITORS TO DISCHARGE BEFORE WORKING IN THE CHOPPER
CUBICLE. VERIFY BY MEASUREMENT THAT NO VOLTAGE IS PRESENT.
2.6.1 INDICATORS
- Red Fault lamps on each cabinet door alert the user when a chopper fuse has cleared a
fault.
- Green lamps indicate when the DC Bus is charged. The light will flash if the chopper
failed to pre-charge.
- The red button labelled “Shutdown” may be used to shut down the chopper.
Depressing the switch will open the disconnect switch. This button may be locked in the
closed position to prevent accidental closing of the disconnect switch.
- The DC Bus Volts meter will read the bus voltage.
3 MAINTENANCE
*
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The air cooled rectifiers are designed to be as maintenance free as possible, however
some components should be cleaned periodically for optimum performance while
preventative maintenance for certain components are also beneficial to minimize downtime.
3.1 Maintenance Schedule

Clean chopper heatsinks 1 time every 12 months Blow out dust/dirt with clean
dry air
environment
Chopper cooling fans 60,0000 hrs or 6 years Replace
Specifications
Table 1 Bolt Torque
Specifications
Specifications
Specifications
3.2 Fuse Replacement
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rejected from the fuse body when it has opened, opening the micro-switch, and tripping the
disconnect switch. This switch needs to be removed from the faulted fuse, and set aside.
The following diagram and instructions outline the fuse replacement procedure. It is
important to use the correct tools and follow the procedure exactly. Failure to do so could
result in the fuses not operating properly and causing damage to the rectifier or to devices it
supplies.
3.3 Fault Tracing
The chopper cubicle has only one fault indicator on the front panel. The FUSE FAULT LED
is located on the front door. All other faults are conveyed to the SCS via the Wago I/O.
The monitored signals and their meaning are listed in the following table.
Refer to electrical schematics for further details during troubleshooting:
• D25ACC1-205-SCH-001 – Single Chopper cabinet

• D25ACC2-205-SCH-001 – Dual Chopper cabinet
Problem Possible Causes Remedy

Disconnect Switch wont Rig Supply not present Check wiring
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close
RL03 faulty Check RL03, check
wiring
TD01 time delay relay is faulty Check relay, check wiring
DSW UVR coil (YU) is faulty Check relay, check wiring
DSW Closing coil (YC) is faulty Check coil, check wiring
DSW is not charged Check motor, check
wiring
Pre-charge fails Precharge Contactor(s) faulty Check contactor(s),
check wiring
Precharge Resistor is faulty Check resistance value,
check wiring
PC01/PC02 fuses open Check fuses
PC02/PC04 voltage feedback Check wiring, replace
boards reading incorrectly/faulty boards
Chopper is not enabled DSW aux contact is faulty Check contact, check
wiring
DC Bus Volts not PC02/PC04 voltage feedback Check wiring, replace
reading or reading board(s) faulty/wiring is loose boards
incorrectly
Fuses are open Check fuses F05-F06 (for
chopper 1) and F11-12
(for chopper 2)
Chopper faults Chopper cooling fan is Check chopper cooling
inoperative fan
Intake filter in door is clogged Clean filter
Loss of power to the chopper Check wiring
control board
Choppers not sharing Faulty fiber optic cable Check fiber optic cable
load correctly
Voltage setpoint set incorrectly Check wiring
Master/Follower selection not set Check wiring
correctly
Resistor value(s) incorrect Verify resistance values
Single Chopper:
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Essential Rig Supply TB03 (L1), TB04
CB03 16A, 480Y/277VAC, 6kIC, 2P (L2)
CB04 1A, 240VAC, 10kIC, 2P 24VDC TB05 (+), TB06 (-)
CB07 2A, 480Y/277VAC, 6kIC, 2P Chopper 01 Blower
Chopper 01 Resistor Temp/Press
CB05 0.5A, 240VAC, 10kA, 2P Switches
F05,06 1000A, 1100V, 100kIC Chopper 01 Fuses

F01-02 30A, 1000VDC, 100kIC Pre-charge Fuses
Dual Chopper:

Essential Rig Supply TB03 (L1), TB04
CB03 16A, 480Y/277VAC, 6kIC, 2P (L2)
CB04 1A, 240VAC, 10kIC, 2P 24VDC TB05 (+), TB06 (-)

F01-02 30A, 1000VDC, 100kIC Pre-charge Fuses
F07-F08 30A, 1000VDC, 100kIC Pre-charge Fuses
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This section contains technical data about the NADS choppers and subcomponents.
The NADS Air Cooled Chopper’s ratings are given below.
AIR COOLED RECTIFIER

NUMBER OF PHASES 2
RATED POWER 1200kW (each chopper)
RATED VOLTAGE 800-1100VDC
RATED CURRENT 1100 ADC (each chopper)
RATED IMPULSE WITHSTAND
8kV
VOLTAGE
RATED PEAK WITHSTAND
220kA
CURRENT
RATED SHORT-TIME
75kA for 1 sec
WITHSTAND CURRENT
RATED DIVERSITY FACTOR 1
AMBIENT TEMPERATURE (NO
40°C
DERATING)
MAX AMBIENT TEMPERATURE 50°C
INGRESS PROTECTION IP22
POLLUTION DEGREE 1
SHORT CIRCUIT RATING 55kA RMS
COOLING METHOD Forced Air
PRODUCT COMPLIANCE IEC 61439-1
Table 3
4.1.1 Environment
The inverter is to be installed in a heated, indoor, controlled environment. The inverter has
been designed for a nominal ambient temperature of 40°C, with a maximum ambient
temperature of 50°C (with derating, see Section 4.1.2).
Operation Storage Transportation

Installation Altitude 0-4000m N/A N/A
Air Temperature 0-50°C, no frost -40 to +70°C -40 to +70°C
allowed
Relative Humidity 5 to 95% no condensation allowed
Contamination No conductive dust allowed
Levels
Atmospheric 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa
Pressure
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4.1.2 DERATING
For every 1°C above 40°, the chopper’s output current must be reduced 1%. Maximum
allowable ambient temperature is 50°C. Maximum derating is 10% of the rated current @
50°C. For every 100m above 1000m, the drive is derated 1%. For operation above 2000m,
the installation must be considered on a case by case basis.
Table 2 0describes the remaining environmental ratings for the NADS choppers.
BOLT SIZE FLEXBUS HARD BUS
M6 X 1.0 6.5 4.8 7.2 2.3
M8 X 1.25 15 11.06 17 12.5
M10 X 1.5 30 22.15 28 20.7
M12 X 1.75 55 40.56 45 33.2
Table 4: Bolt Torque Specification
FLEXIBAR BUS SPECIFICATIONS

RATED CURRENT 1500 ADC
RISE
WIDTH 60mm
THICKNESS 10mm
BUSBAR BRACING: MATERIAL SPECIFICATIONS
Property Value Unit
Temperature
24 hours
168 hours
Table 5: Main Bus Bar Specifications
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5 APPENDIX
5.1 Chopper Module
AIR COOL CHOPPER
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5.2 Connection instructions

J5 is control power connector, a power supply (+24VDC, Ipeak>2 A) is required.
J6 is external control signals connector. Apply +24VDC to J6.1 to enable chopper; apply 0V
to J6.1 to disable and reset chopper. Apply 0V to J6.2 to select mode1 (normal operation);
apply +24VDC to J6.2 to select mode2 (fixed PWM operation). Apply +24VDC to J6.3 to
select master function; apply 0V to J6.3 to select follower function.
A DIP switch SW1 is used to select the regulation voltage.
SW1 SW1 SW1

ON ON ON
1 1 1
2 2 2
3 3 3
Regulation voltage Regulation voltage Regulation voltage

900V 1000V 1100V
Fig.1. Regulation Voltage Selection
A SPDT relay on J7.1-3 indicates a chopper fault. A chopper fault can be reset by
disabling the chopper.
J7 is output signal connector. There are 4 analog feedback signals available for output.
Reference DC bus voltage on J7.6, A 0-8.55VDC signal corresponds to 0-1000V. Real DC
bus voltage on J7.5, A 0-10VDC signal voltage corresponds to 0-1200V. The chopper
current on J7.8, A 0-10VDC signal corresponds to 0-1250A. Also, the temperature on J7.9,
the voltage that is read corresponds to 0.1V/°C.
The chopper is equipped with the following diagnostic LEDs for troubleshooting:
LED Function
1 Enable (ON)/Disable (OFF)
2 Mode 1 (ON)/ Mode 2 (OFF)
3 Master (ON)/Follower (OFF)
4 Over-Temperature
5 Over-Current
6,8 +15V and +24Vpresent
7 IGBT control signal
9 Fault
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LED8
J5 LED6
LED7
Enable (ON)/Disable (OFF)
Mode1(ON)/Mode2(OFF)
J6
Master(ON)/Follower(OFF)
SW2 Over-Temperature
Over-Current
J7
Fault
SW1
Fig.2. Control Board
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+DC
Diode
Module
IGBT
Module Resistor
C Bank
-DC
To From
Follower Master
C G E J8 J3 J2
J1
DC-BUS FB HS Temp Current FB
1 1
Enable/Disable
Gate Drive Board
Model 1/ Model 2
Master/Follower
10 10 Control Board
OVT
OVC
ACK&Fault
J5-Power J6- Control J7 -Out

12 3 1 2 3 4 1 2 3 4 5 6 7 8 91
24VDC GND
GND Temp (0.1V/0C)
Iout (10V/1250A)
Vref (8.55V/1000V)
Enable (24V)/Disable (0V) Vfeedback(10V/1200V
Mode 1 (0V)/ Mode 2 (24V) ) Common
Fault Relay
Master (24V)/Follower (0V) Fault Relay N.C.
GND Fault Relay N.O.
Fig.3. System Schematic
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5.3 DC Isolation Switches

The following ratings apply to the ABB 3 and 4 pole DC disconnect switches used
throughout the Drill Force drives.
Icw values are applicable for 1s. The peak values are applicable for 10ms.
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Inverter Users Manual
Air Cooled AC Drive

User Technical Manual and Information

Nort h American Drive System
49 This doc ument contai ns proprietar y and confidenti al infor mati on National Oilwell Varco
REMARKS
which belongs to Nati onal Oilwell Varco; it is loaned for limited Rig Solution Group
purpos es onl y and remains the property of National Oilwell.
11000 Corporate Centre Dr.
Reproduction, in whole or in part; or us e of this design or
MAIN TAG NUMBER DISCIPLINE distribution of this infor mati on to others is not permitted without the Suite 200
express written c onsent of National Oilwell Varco. This doc ument is Houston, Texas 77041 (USA)
to be returned to Nati onal Oilwell Varco upon request and in any
CLIENT PO NUMBER event upon compl etion of the us e for which it was loaned.
Phone + 281-854-0400
 National Oil well Varco Fax + 281-854-0508
CLIENT DOCUMENT NUMBER
DOCUMENT NUMBER REV
10588376-MAN 01
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REVISION HISTORY
01 10/12/2010 For Information AB NHN ML

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TABLE OF CONTENTS
1 SCOPE............................................................................................................................................. 5
1.1 SAFETY INSTRUCTIONS ................................................................................................ 5
1.1.1 GENERAL ............................................................................................................... 5
1.1.2 SAFETY SYMBOLS .............................................................................................. 5
1.1.3 BASIC SAFETY PRECAUTIONS........................................................................ 6
2 SCOPE............................................................................................................................................. 7
2.1 ABREVIATIONS AND DEFINITIONS ............................................................................. 7
3 HARDWARE DESCRIPTION....................................................................................................... 8
3.1 General Description............................................................................................................ 8
3.2 General Operation ............................................................................................................ 11
3.3 General Construction and Ratings................................................................................. 12
3.4 Pre-charging Mechanisms .............................................................................................. 19
3.4.1 Pre-charge system ............................................................................................... 19
3.4.2 Common DC Bus Charging ................................................................................ 20
3.4.3 Controlled Current Charging .............................................................................. 20
3.4.4 Pre-Charge Control.............................................................................................. 22
3.4.5 Pre-charging Schematic...................................................................................... 24
3.5 Functional Description ..................................................................................................... 25
3.5.1 RDCU INPUTS ..................................................................................................... 26
4 INSTALLATION............................................................................................................................ 26
4.1 Mechanical Installation .................................................................................................... 27
4.1.1 CABLING ............................................................................................................... 27
4.2 ELECTRICAL INSTALLATION....................................................................................... 27
4.2.1 Motor Cable........................................................................................................... 27
4.2.2 Control Power and Field Connections .............................................................. 31
5 INITIAL STARTUP ....................................................................................................................... 31
5.1 Control Power Check ....................................................................................................... 31
5.2 Drive Programming .......................................................................................................... 32
5.2.1 Sizing the drive ..................................................................................................... 32
5.2.2 Download parameters to the drive .................................................................... 33
5.3 Charging The Inverter ...................................................................................................... 33
5.4 Running the drive.............................................................................................................. 34
5.4.1 Performing a motor id run ................................................................................... 34
5.4.2 Entering the Motor Data ...................................................................................... 34
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5.4.3 Parameters for the Motor ID Run ...................................................................... 36

5.4.4 Group 20 LIMITS.................................................................................................. 36
5.4.5 Remove Profibus Control.................................................................................... 37
5.4.6 Run Enable ........................................................................................................... 37
5.4.7 Encoder ................................................................................................................. 37
5.4.8 Start Interlock........................................................................................................ 37
5.4.9 Motor Temperature Compensation ................................................................... 38
5.5 Starting the Motor ID Run ............................................................................................... 38
5.6 ID Run Completed ............................................................................................................ 38
6 TROUBLESHOOTING ................................................................................................................ 39
6.1 General............................................................................................................................... 39
6.1.1 Pre-charge System and Indicators .................................................................... 39
6.2 Inverter Modules ............................................................................................................... 39
6.3 Warning and fault indications ......................................................................................... 39
6.3.1 Programmable protection functions .................................................................. 39
6.3.2 Preprogrammed faults ......................................................................................... 42
6.3.3 Warning messages generated by the drive ..................................................... 43
7 MAINTENANCE ........................................................................................................................... 45
7.1 General............................................................................................................................... 45
7.1.1 Inverter Fuse and Circuit Breaker Schedule.................................................... 45
7.2 Maintenance Schedule .................................................................................................... 46
7.3 Fuse Replacement ........................................................................................................... 47
8 TECHNICAL INFORMATION .................................................................................................... 47
8.1 Enviromental Data ........................................................................................................... 47
8.2 Mechanical Data .............................................................................................................. 48
9 ADDITIONAL DOCUMENT REFERENCES............................................................................ 49
9.1 Vendor Documents........................................................................................................... 49
9.1.1 ABB Documents ................................................................................................... 49
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1 SCOPE
This document is a summary of the basic design and functional specifications for North
American Drive System Inverters. It is to explain the start-up and pre-charge sequence of the
system.
All pilot lights are push-to-test lights.
1.1 SAFETY INSTRUCTIONS

The following safety instructions must be followed when installing, operating and servicing the National
Oilwell Varco Inverters. If ignored, damage to the may occur to the operator and equipment. Read these
safety instructions before working on the system.
1.1.1 GENERAL
Safety is everyone’s responsibility and must be of primary concern at all times during any
operations or maintenance. Following the guidelines covered in this manual will help provide
for the safety of individuals and insure proper operation of the equipment. It is important that
only trained, qualified personnel, who are well familiar with general electrical equipment
safety procedures operate and/or maintain this equipment. Unqualified, untrained personnel
should not service, install, or operate the equipment. The safety guidelines in this manual are
not a substitute for the owner’s safety policies and procedures, and should not be taken so.
Safety recommendations and safety procedures in this document should not be considered
the minimum requirement for safe operation and maintenance. Familiarize yourself with all
safety, caution, and warning symbols. Read them carefully and make sure you understand
their meaning. If something is unclear, consult NOV service department. Do not take
chances with your life or the life of others.
1.1.2 SAFETY SYMBOLS

There are three types of safety instructions used throughout this manual and on the
equipment: warnings, cautions and notes. Look for these standard safety terms and
conventions that point out items of importance to the safety of the individual as well as others
that may be in the area:
WARNING safety notes MUST be followed carefully.

Failure to do so may result in catastrophic equipment
failure resulting in SERIOUS INJURY or DEATH.
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CAUTION safety notes are also very important and

should be followed carefully. Failure to do so may result
in EQUIPMENT DAMAGE and/or PERSONAL INJURY.
NOTE
NOTE is used to notify personnel of information that is IMPORTANT but NOT HAZARD
RELATED
1.1.3 BASIC SAFETY PRECAUTIONS

1. All doors and covers must be in place while the equipment is energized
2. Do not stand on, or place foreign objects on or inside the cabinet.
3. Do not service the equipment while it is energized. Check warning labels and schematics
to determine whether or not the equipment is fed from multiple sources.
4. Observe lockout/tagout procedures as necessary when servicing the equipment.
5. The main disconnect switch, DSW01in inverters does not remove all main power from the
cabinet. Main power is supplied to the inverter from a DC bus, so main power is always
present at the incoming terminals of CB1, unless the external power source/rectifier has
been de-energized. DSW01 removes main power below the switch – e.g. the top of the
inverter, DC submain bus, etc. Therefore, it’s essential that the external power source
feeding DSW01 is de-energized before attempting to service the switch or anything in the
upper compartment where the switch is located.
6. Do not substitute protective devices such as fuses, circuit breakers, or protective relays
with parts other than NOV approved parts.
7. Do not attempt to defeat the operation of protective devices, such as fuses or circuit
breakers
8. Do not allow contamination of any kind in the cabinet. The inverter is intended to operate
in a clean, dry environment. Liquids, debris, or foreign objects of any kind should not be
allowed to enter the cabinet.
9. Observe all warning labels and signs on or inside the cabinet.
10. Avoid operation of the inverter in environmental conditions that are outside the rated
limits
11. Observe all equipment warning and fault indicators, such as lamps, meter displays, etc.
Failure to do so may result in equipment damage or personal injury.
*
Recommended safety conventions. American Petroleu m Institute
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12. Do not attempt to operate the inverter if it is malfunctioning, damaged, or if a fault is

suspected or indicated by its diagnostic functions.
13. Equipment used in heavy lifting and moving of the unit and accessories during operations
must be sufficiently rated to handle the weights involved.
Promote good safety measures at all times around the equipment and throughout all phases
of operations. It is the equipment owners’ / operators’ responsibility to establish good safety
measures including personnel training and enforcement of safety practices.
2 SCOPE
This manual includes the operation, maintenance, installation, and repair of the North
American Drive System series of inverters.
Reference is made throughout the manual to supporting documents. Detailed information

about the circuitry and construction of the inverters is found in the project documents or
drawings:
The user should also have a copy of the customer specific drawings in order to have a
complete understanding of the equipment, since customer specific documentation may include
options not included in the preceding references.
2.1 ABREVIATIONS AND DEFINITIONS

ACL AC side Line Reactor
AAC Amps AC
ADC Amps DC
API American Petroleum Institute
DB Dynamic Braking
DWK Draw works
EMC Electomagnetic Compatibility
FC Frequency Converter
FDS Functional Design Specification
GPM Gallons per minute
HMI Human-Machine Interface
HP Horsepower
Hz Hertz
IGBT Insulated Gate Bipolar Transistor
I/O Input/Output
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KW Kilowatt
LED Light Emitting Diode
LPM Liter/minute
LPB Lighted Push Button
MCA Motor Cable Access
MP Mud Pump
P&ID Piping & Instrument Diagram
PHE Plate Heat Exchanger
PLC Programmable Logic Controller
PWM Pulse Width Modulation
PSI Pounds per Square Inch
SBC Single Board Computer
SCS Supervisory Control System (PLC, SBC, etc)
SVM Space Vector Modulation
TD Top drive
UPS Uninterruptible Power Supply
VAR Volt-Amp Reactive
VSDS Variable Speed Drive System
Rectifier An arrangement of solid-state devices that converts AC power to DC power

Operator The person assigned the responsibility of physically operating and maintaining
the equipment
3 HARDWARE DESCRIPTION
3.1 General Description

The North American Drive System drilling drives are made from 450kW, 486A inverter
modules. Each drilling drive cabinet is assembled with 1, 2, or 3 inverter modules.
1. 900kW, 950A cabinet containing (2) 450kW modules
2. 1350kW, 1400A cabinet containing (3) 450kW modules
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Motors which require a higher power than either a 950kW or 1350kW cabinet can provide are
created by paralleling various combinations of 950kW and 1350kW cabinets. For example, a
motor requiring more than 1400A is powered with (2) 950kW cabinets, a motor requiring 2300A
would use a 950kW cabinet in parallel with a 1350kW cabinet. In this way, any typical drilling
motor can be supplied using only 2 basic cabinet designs.
Table 1
Overall Number Continuous
Width Inverter Number Power Current
Cabinet Type [mm] Modules Cabinets Power [kW] [HP] [AAC]
S2 600 1 1 450 603 486
S2 600 2 1 900 1,206 953
S3 850 3 1 1350 1,810 1,414
S2+S2 1200 4 2 1800 2,413 1,866
S2+S3 1,450 5 2 2250 3,016 2,309
S3+S3 1,700 6 2 2700 3,619 2,741
S2+S2+S3 2,050 7 3 3150 4,223 3,164
S2+S3+S3 2,300 8 3 3600 4,826 3,577
S3+S3+S3 2,550 9 3 4050 5,429 3,980
S2+S2+S3+S3 2,900 10 4 4500 6,032 4,374
S2+(3) x S3 3,150 11 4 4950 6,635 4,758
(4) x S3 3,400 12 4 5400 7,239 5,132
Table 1 shows the North American Drive System possible configurations based on
construction of VFDs from 2 basic cabinet widths; an ‘S2’ cabinet is 600mm and an ‘S3’ is
850mm. Including the bus compartment, all Drill Force drives are 1100mm deep. For height
dimensions, refer to the specific job since as height varies according to cooling method, IP
classification, and electrical room. Figure 1 shows an S2+S2 arrangement of inverters.
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Pre-Charge
Lockout Enable Sw itch
BUS Charged
Figure 1
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3.2 General Operation
In a single cabinet design; i.e. a 450kW or a 1350kW drive, the VFD is considered to be
completely stand-alone in operation. It has all of the necessary components to operate
independently. When the drive is made from 2 or more cabinets, for example (2) 450kW
cabinets, all of the components in each cabinet are identical except for the drive control unit, or
RDCU, and the Branching Unit, or APBU. In this configuration, the ‘master’ cabinet contains
the RDCU and APBU, which and distribute signals, respectively, to the ‘follower’ cabinet. Each
individual cabinet is equipped with its own disconnect switch, power supplies, and charging
circuits so that reduced mode operation is simplified, while inter-connect wiring is minimized.
The charge controller is located in the master cabinet, but all necessary charging and feedback
hardware are included in both the master and follower cabinets. For information about the
charge controller, see section 2.4.1
Protection for each inverter module is provided via 2 high speed 1000A, 1350V semiconductor
fuses. The fuses are mounted in the front of each cabinet, and secured to the bus with studs
for quick removal and reliably connections. Common mode filters are installed on each
individual inverter’s DC input terminals to suppress spurious tripping and block high frequency
switching noise from reaching the main supply.
Inverter pre-charging is accomplished automatically using a 2000A, 1000V DC non-load break

switch and one of 2 precharge techniques. Section 2.4.5 provides a detailed description of the
various precharge methods. In general, precharge is either handled directly from the main DC
bus, or indirectly from the main AC bus.
Once control power is established to the inverter cabinet, and selector switch SS1 is in Enable
position, also PB02 (push to pre-charge is pressed in) the pre-charge circuit will engage and
apply DC voltage to the inverter. In stand-alone drives, the Charge Controller operates
rectifier’s main circuit breaker. Short circuit protection for the pre-charge circuit is handled with
4 miniature DC fuses rated at 100kA and 1000V.
If the inverters have not reached rated voltage within a pre-programmed time, the pre-charge
sequence is aborted before damage occurs to the charging components.
A separate relay is used to test the presence of control power. In the event control power is
lost, the entire pre-charge circuit and disconnect switch return to the safe state – that is, pre-
charge logic returns to “ready” and the main isolation switch is opened. If main power is lost,
the Charge Controller will open the disconnect switch; when main power is restored, the pre-
charge circuit sequence could be resumed to charge the bus and close the disconnect switch.
Therefore if either the main or control power is lost, the pre-charge circuit and main switch will
reset to the safe state. A green ‘DC Bus-charged’ status lamp is located on the door of each
cabinet to notify the operator of the bus status. A red ‘Fuse Fault’ lamp indicates a blown main
inverter fuse.
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3.3 General Construction and Ratings

Normally, each inverter cabinet is connected to a common DC bus, located in an isolated
compartment behind each inverter. Main bus isolation is handled with a 2000A, 3 pole circuit
breaker in which the tripping mechanisms have been removed. Only the outer 2 poles, L1 and
L3 are used. Main DC power is supplied to the switches through the rear wall of the inverter
using insulated, flexible bus. The main switch is used strictly used for isolation, and is specially
marked by the manufacturer for this use. Each is able to withstand a fault of 55,000
symmetrical amperes for 1 second, and a peak fault current of 126kA for 10ms (1/2 cycle at
50Hz). Short circuit protection for the DC isolation switch is provided by either upstream
rectifier fuses. In systems where the total upstream let-thru current exceeds a single switch’s
rating, bus fuses are mounted just above the switch in the bus compartment.
Control power may be externally supplied to inverters via both uninterruptible power and
standard rig power. It is recommended that UPS power be supplied where indicated on the
electrical schematics unless the power quality of the supply can be verified to be stable and
within reasonable limits. Control power voltage requirements are 120/230V, 50/60Hz. A
power distribution schedule, showing name, voltage, and function of each fuse and circuit
breaker is fixed to the inside of every cabinet. Safety lockouts of main power and control
power are provided and clearly marked.
An LCD control keypad is mounted on each cabinet door. Two access ports are provided on
the front of each cabinet door. A fiber optic communication port is located on each inverter
door to facilitate computer hook-up with the drive’s control module, so commissioning and
trouble-shooting are possible without opening the cabinet door. Each inverter door will contain
a permanently fixed, single USB flash drive containing the system documentation, drive
parameters, and troubleshooting/maintenance procedures
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Indicator Lamps
and lockout Enable
Switch
LCD display
Cont roller Keypad
USB Flash Port

And Drive
Programming Port
Figure 2
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DC BUS
Inverter Module
DC BUS
Compartment
Figure 3
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DC Isolation
Switch
Low Voltage
Component Pan
Inverter output
terminals
Figure 4
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Cabinet construction is IP22 with doors closed, and IP20 with doors open. A hinged control
panel is mounted above the inverters in a separate compartment. On the front surface of the
pan, low voltage components (=<120VAC) are installed; on the back of the pan components
rated from 230V -690V are installed. All components with terminals rated above 24V are finger
safe. The panel is double sided, made from 2.5mm thick galvanized steel. The electronic
components mounted on the front surface of the pan are cooled with fans, and protected with a
temperature sensor which monitor and alarm if the compartment housing those components
exceeds 55°C. Air dams fabricated from galvanized steel are mounted around the inverter
modules in the front and rear to prevent exhaust air from re-circulating inside the cabinet or
back through the inverter intake.
Front View of Swing Pan
Figure 3-1
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Rear View of Swing Pan
Figure 5-2
The inverter’s motor terminals are plugged into the inverter manufacturer’s quick connector
sockets devices, which are mounted in the rear of each cabinet. Clearly marked, flexible bus
connects the inverter terminals to the motor termination bars, located in Bottom of inverter
cabinet. The cabinet’s earthing bar is tin plated copper, 10mm x 40mm wide, and is solidly
bonded to the cabinet with tapped M12 screws. It is located in the rear of the inverter cabinet,
and is connected with a single flexible bus to earth bars in adjacent cabinets.
Earth conductors are 2.5mm minimum, with green/yellow insulation. 3 phase supply power
cables are marked L1, L2, L3 and U,V,W at motor terminals. Fuse blocks, miniature CBs,
terminal blocks are clearly marked with Functional name (eg “24V control power”), the working
voltage, and B.O.M. component designation. Wiring terminations are vinyl insulated ferrules,
ring lugs, or locking forks, as are appropriate for each connection. All wiring is clearly labelled
at both ends according to the wiring schematic. Wiring is segregated in conduits and bundles
according to voltage level.
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Cabinets are constructed of 1.5mm carbon steel panels and 1.5mm rolled steel frames. The
internal mounting panels are constructed from 2.5mm galvanized steel. Free standing cabinets
are mechanically braced according to Seismic Zone 4. All cabinets are dip coated in primer
with a textured, power coated finish coat. The painting process is according to DIN EN ISO
20-482, 2815, and 2409. Cabinet walls, dividers, and doors are equipped with grounding
studs and stainless steel or copper braided straps which are bolted to the cabinet frame with
self-tapping screws. Cabinet doors where access is considered touch safe; e.g. the low
voltage compartment, are accessible with a factory provided tool. Access to higher voltage
compartments requires hand tools such as Torx or Phillips head screwdrivers.
Warning labels are on all access covers both outside and inside the cabinet.
Figure 4
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3.4 Pre-charging Mechanisms

North American drive system’s pre-charging method uses the following parts.
1. PC01 pre-charge board
2. RDCU’s inputs and internal relay contacts (x22-11,x25-02-03,x26-02-03)
3. Fuses F01,F02,F03,F04
4. Pre-charge lockout enable switch
5. Drive running RL01,RL07
6. Pre-charge enable relay RL08
7. Pre-charge enable timeout relay RL06
8. PB push to charge
3.4.1 Pre-charge system

The following conditions must be met before pre-charge sequence can be initiated.
1. 120V rig supply is available
2. E-stop relay is energised
3. RL04 fuse status is energised
4. RL03 DC BUS charged relay is on
5. Lockout-Enable switch is in Enable position
6. 24V DC is present
7. Inverter drive is not running(RL01,RL07 are off)
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3.4.2 Common DC Bus Charging

In common DC bus charging, multiple inverters are fed from a common bus in Fig 7.
2500AF 2500AF
100kAI 100kAI
RECTIFIER RECTIFIER
DC BUS
810-932VDC
DC Disconnect DC Disconnect DC Disconnect DC Disconnect
1350KW 1350KW 1350KW 1350KW

1400A 1400A 1400A 1400A
27600uF 27600uF 27600uF 27600uF
M M M M
Figure 7
Each VFD is equipped with its own disconnect switch. The disconnect switch is equipped with
a UVR coil, spring charging coil, and closing coil. The 3 coils, directed by the charge control
system, facilitate the automatic pre-charging of each drive. Individual charging of each drive
allows safe connecting and disconnecting of any inverter from the bus without the need to
remove power from the common bus.
3.4.3 Controlled Current Charging
In this method, the main charging circuit utilizes an IGBT in unison with a small inductor in
order to deliver a controlled current to the inverter capacitor banks. The IGBT is operated as a
simple switch in PWM mode with variable duty cycle. A block diagram of the basic circuit is
shown in Fig 8:
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Figure 8
In order to control current, an integrated PLD chip is used to modulate the IGBT current
through the inductor. A current sensor is used to regulate the current and provide protection to
the circuit board. Fig. 9 is illustrates the principle.
Figure 9
At the onset of a pre-charge cycle, the maximum continuous current does not exceed 15A.
Charge current decreases linearly as the inverter’s capacitor voltage increases. The charging
profiles are shown in the graph below for the smallest and largest individual inverter rating.
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Figure 10
From the graphs of Fig.10, the charge cycles for a single module and 3 module inverters are
shown. It is apparent the longest charge cycle is less than 6 seconds for the 1400A, 3 inverter
module VFD.
3.4.4 Pre-Charge Control

A pre-charge cycle is started provided the following conditions are met:
1. The main DC bus is at rated voltage
2. The Inverter’s lockout-enable switch (located on the front door) is in enable position
3. The inverter is not running
4. 24V Control power is available
5. The main disconnect switch is open
6. The inverter fuses are not open
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If the preceding conditions are all true, when push to charge (PB02) is pressed in RL08 pre-
charge enable relay is energized. RL06,pre-charge time-out relay would energize enabling pre-
charge board (PC01) for .8 second that would start pre-charge sequence. When .8 second is
elapsed the pre-charge time Out relay RL06 close contact terminals (01-04) will open that
would stop enable signal to PC01 stopping pre-charge sequence.
When inverter bus voltage reaches 700 volts, the RDCU’s X26-02, X26-03 open contact will
close energizing DC bus charged relay RL03. Then time-delay relay TD01 will energize
disconnect switch DSW01 after .5 second delay.
When VFD drive is running, a normally open contact of RDCU X25-02, X25-03 will close
energizing Drive running relay RL07. 24 VDC supply to PC01 is removed while RL07 is
energized.
A contact from the inverter’s lockout-enable switch will interrupt the 24V supply to PC01
board. When the lockout position is selected. If an E-stop is issued during the pre-charge
sequence, the charge sequence will continue to complete the cycle, but will not close the main
disconnect until the E-stop relay has been reset.
During operation, if the inverter’s DC voltage falls below 350VDC, the RDCU’s X26-02, X26-
03 bus charge contact will open de-energizing DC bus charged relay RL03 removing main
power from the VFD by dropping DSW01’s UVR coil, thereby causing DSW01 to open. Since
350VDC is below the under-voltage trip threshold for the inverter, the inverter is assumed to be
unloaded and therefore safe to disconnect from the main bus.
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3.4.5 Pre-charging Schematic

Figure 11 shows pre-charge circuit.
Figure 11
For a 3 inverter cabinet, the typical charge time is 3s. Charge time is defined as 95% of the full
DC bus voltage.
When the DC voltage reaches (700V) DC disconnect switch is closed connecting inverter to
the main DC bus, then RL06 and RL07 open up.
During operation, if the inverter’s DC voltage falls below 350VDC, the charge controller will
remove power from by dropping out the DSW01 UVR coil, thereby causing DSW01 to open.
Since 350VDC is below the under-voltage trip threshold for the inverter, the inverter is
assumed to be unloaded and therefore safe to open the disconnect switch.
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3.5 Functional Description

Bringing an inverter on and offline is achieved as long as the inverter is not locked out using
the pre-charge lockout enable selector switch (SS1). Under normal operation, the Charging
sequence must be initiated by operator, connecting, and disconnecting of the VFD from the
common DC bus, or else the rectifier in stand-alone systems.
In common bus drives, the Disconnect Switch (DSW01) is equipped with a 120VAC charging
motor (DSW01 M), a 120VAC closing coil (DSW01 YC), and a 120VAC UVR coil (DSW01 YU).
As long as rig power is present on the inverter, SS1 is in enable position, and PB02 push to
pre-charge is pressed in, the disconnect switch’s charging motor (DSW01 M) will charge the
switch’s spring. 120V control relay RL02 monitors the status of Rig Power for each inverter.
Once DSW01 is charged, an input is received by the RDCU (x22-11) that the disconnect
switch is charged.
The conditions required for DSW01 to close are:
1. The UVR coil in DSW01 (YU) must be energized
2. The charging motor will close the disconnect switch after YC closing coil is energised.
The following conditions must be true for the UVR (DSW01 YU) to be energized:
• No E-Stop
• Rig Supply power is present
• A “lockout” condition (indicated by RL03) is not present. A lockout condition
occurs when lockout position is selected from lockout-enable switch (SS1).
• Before DSW01’s UVR can be energized, the RDCU BUS Charge contact (X26-
02) must be closed and RL03 DC BUS CHARGED must be energised to insure
the VFD’s DC Bus is charged.
Figure 18: Inverter Di sconnect Switch (DSW01) UVR Logic
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The following events will open (YU), which will disconnect the VFD from the DC Bus and
prevent the drive from running:
• A blown drive fuse. A blown fuse will immediately fault the inverter.
• The loss of Rig Supply (RL02); this also will cause a drive E-stop
• The lockout enable switch is in lockout position.
• Drive is running, but DC Bus Voltage drops below (350VDC) (read into Pre-
charge controller)
• A field initiated Emergency Stop
In addition, the loss of UPS supply or the 24VDC supply will cause the VFD to stop. Loss of
either supply will kill power to the RDCU, APBU and the Pre-charge controller.
Emergency Stop is initiated from the field as shown in Fig 19. The standard Drill Force inverter
does not allow E-stop from the inverter door. The E-stop logic is such that any number of E-
stop switches may be connected in series, so that a local equipment room E-stop may be
provided if desired.
Figure 19
3.5.1 RDCU INPUTS

As a standard, motor control with the inverter is managed with Profibus. In standard systems,
the following signals are an input to RDCU and they are provided to the supervisory control
system.
• Inverter Fuse Status
• Disconnect switch status
When DC BUS is charged the relay output contact of RDCU (X26-02, X26-03) is closed
energising RL03 that would turn on (PL01) BUS CHARGED green light. If one of the inverter
fuses blows, the “Fault” light (PL02) light (red) will illuminate.
4 INSTALLATION
This section contains guidelines for installing NORTH AMERICAN DRIVE SYSTEM Inverter
systems. This installation section is not intended to be a step-by-step procedure for installing
the system, but more of an overall guide to aid in the installation. It will be necessary to refer to
system drawings and documents for specific details about sub-systems. Once the system has
been installed, the start up procedure should be followed.
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Any information not contained in this document can be found in the system manual or the
system drawings. Any personnel involved in the installation and start up of this system should
read all the documentation to before proceeding with any part of system installation and start-
up.
4.1 Mechanical Installation

The VSDS system should only be lifted according to the job specific requirements. The
systems may vary depending on customer requirements. Most systems are designed to be
lifted either by forklift, or crane. Most systems lifted by forklift are provided with a lifting base
with forklift fork accommodations typically in the base of the system. Systems that require a
crane for movement typically have lifting bars or eyes for overhead lifting.
Some systems will include shipping splits which are used to reduce the length and weight of
the shipping sections. It is important to ensure that the individual shipping splits are placed in
the correct orientation and bolted tightly together.
4.1.1 CABLING
4.1.1.1 Marine Installations

Motor cables are terminated in each inverter cubicle.
Field cables, such as encoders, auxiliary/control power, etc, may be landed on the terminal
blocks provided and dedicated to each items. Refer to the project drawing package for project
specification.
4.2 ELECTRICAL INSTALLATION
4.2.1 Motor Cable

The following section provides general guidelines that should be observed before applying
power to the VSDS.
It is important to ensure the VSDS system has the adequate ground connections. For stand
alone systems installed in drilling modules, ensure that the base of the systems is seam
welded to the deck. Also ensure that the cubicle frames are bolted (with star washers if
cubicles are painted metal) properly to the system base. For systems which include a drive
house, ensure that the proper size grounding conductor is installed to the dedicated ground
bus on the house.
Ensure the required control connections (encoders, profibus, fiber, etc.) are connected per the
job specific drawings. Also ensure that the shielding on these signals is correct. Prior to
applying power to any external devices, ie..encoders, ensure that supply voltages are
acceptable and within device tolerances.
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The input and output power connections vary from system to system, so it is important to refer
to your job’s electrical drawings in conjunction with this manual. Table 3 contains main
terminal markings.
Terminal Designator Definition Connected to

B+ Positive DC bus + DC main bus
B- Negative DC bus - DC main bus
U Inverter output phase A Motor phase A
V Inverter output phase B Motor phase B
W Inverter output phase C Motor phase C
Table 3 Inverter Main Terminal Designations
Motor cables should be sized according to the cable schedule provided in the document
package. As a general rule, the cable insulation should be rated for 1000V minimum and a
temperature rise of 90°C. If not specified in the cable schedule, the ampacity of the cable
should be adequate to carry the full load current of the motor. Depending on the certification
authority, the cable may need to accommodate overload ratings of the motor.
It is recommended that multi-core, shielded VFD cable be used to connect the inverter to the
motor(s). For a 600V system, this cable is typically rated for 2000V, and a minimum of a 95
degree Celsius temperature rise. Be sure to consult the factory if unsure about cable sizes or
ratings. See job specific drawings for exact termination point for input and output cables.
The following list of guidelines should be observed before connecting any cable to the inverters
1. Before connecting the motor cables to the inverter, a qualified electrician or service
technician should perform insulation tests on the cable. Check both the phase to
ground insulation resistance and the phase to phase insulation resistance. In both
cases, the resistance should be equal to or greater than 1 MΩ
2. Before connecting the cables to the motors, be sure a qualified electrician or service
engineer tests the motor insulation. The phase to ground and phase-to-phase insulation
resistance should be a minimum of 1 MΩ. The test voltage should be appropriate for
the motor’s rated voltage.
3. Do not route the motor cables near other cables, such as supply or control cables.
Avoid placing the motor cables in long parallel lines with other cables wherever
possible. If motor cables are to be run along other cables, the following table is a
guideline to use for establishing minimum distance between cables:
DISTANCE BETWEEN CABLES SHIELDED CABLE

0.3m (1 foot) Less than or equal to 50m (164 feet)
1.0m (3.3 feet) Greater than 50m (164 feet)
Table 4 Cable Spacing Guideline
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4. Wherever possible, motor cables should cross other cables at 90° angles
Special care must be given to the motor cables. They are unlike standard three phase cables.
Each motor cable contains three earth conductors as well as an overall shield.
Figure 25 VFD Motor Cable Drawing – End View
The three phase conductors are connected to the inverter and motor using crimp style lugs and
stainless steel hardware (except in the case where plugs are used). The PE wires and overall
shield should be connected as per the diagram below.
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Figure 26 VFD Motor Cable Connection Diagram
Care should be taken to ensure that the earth cables or overall shield does not make contact
with the phase conductors. This condition will create an electrical short in the cable and
damage either the motor or the inverter.
A solid connection to chassis ground must be established for the earth cables as well as the
shield wire. These wires should be connected to an unpainted surface using crimp style lugs
and stainless steel hardware. The length of these wires should be kept to the shortest length
that is possible. The three earth cables are to be connected at both the motor and AC drives
ends to provide the system earth connection. It is recommended that the shield be connected
to earth at the inverter ground bar and at the motor. In both cases, it is advantageous for the
shield to be grounded to both chassis the full circumference of the cable. It is not
recommended to twist the shield into a “pigtail” and use cable lugs to ground them, or the
shield will not be effective.
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Verify that all motor cables are tightly bolted to the phase terminals before energizing the
inverter. It is advisable to go over the entire system and check each connection point for
loose connections. During shipment, some screws or bolts may have loosened due to
vibration.
4.2.2 Control Power and Field Connections

Control and 120/230V power is typically connected to TB-07 in inverter cabinets.
1. UPS supply 120/230V
2. Rig power supply 120/230V
3. Encoder
4. Emergency stop
5. Motor heater
The project specific schematics should be consulted for more details on the location and type
of field wires.
5 INITIAL STARTUP
5.1 Control Power Check

For the following checks, use the electrical drawings to determine the proper polarity, phasing,
transformer primary and secondary ratings and power supply levels as applicable for the
specific installation
1. Connect a 120VAC power source (refer to electrical drawings for voltage rating) between
TB07-16 and TB07-17. Energize the power source.
2. Verify that the proper voltage is on the incoming side of CB03. Close CB03. Check voltage
levels on the incoming sides of all branch CBs and fuses and close them until all branch or
feeder CBs and fuses are closed.
3. Connect 120VAC UPS power source between TB07-14 and TB07-15. Energize the power
source.
4. Verify that the proper voltage is on the incoming side of CB02. Close CB02. Check voltage
levels on the incoming sides of all branch CBs and fuses and close them until all branch or
feeder CBs and fuses are closed.
5. Ensure all control power voltage levels are correct to each component accordi ng to the
electrical drawings.
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5.2 Drive Programming

The following procedure is a general instruction on how size the ABB inverter module which is
installed in the inverter cabinet. Most or all of this was performed at the factory; however it is
provided as a reference in case the inverter firmware is upgraded or repairs are made and the
original files are corrupted or lost. NOV strongly recommends contacting our service
department for assistance. This should be performed by an experienced, trained technician.
Especially important: Motor and drive parameters are project specific, and these should be
installed by an individual who is familiar with the control system’s required parameters and
scaling, machine limitations, system voltage, and motor information.
5.2.1 Sizing the drive

1. Obtain the latest firmware from Team Center.
2. Choose the correct backup package for air-cooled.
3. Download the backup package to the drive using Drive Windows.
4. These are blank backup packages. They contain only factory default parameters. The size
of the drive is blank (no modules).
5. The drive must now be sized according to the number of modules.
a. Enter parameter code 564 into parameter 16.03 PASS CODE
b. The drive size is entered into 112.26 for air cooled drives
c. The drive size is entered according to the following chart:
Air Cooled Icont. Max (A) I max (A)

NR0580_7 R8i 486 727
NR1160_7 2xR8i 953 1425
NR1740_7 3xR8i 1414 2116
NR2320_7 4xR8i 1866 2792
NR2900_7 5xR8i 2300 3450
NR3490_7 6xR8i 2760 4140
NR4070_7 7xR8i 3220 4830
NR4650_7 8xR8i 3680 5520
NR5230_7 9xR8i 4140 6210
NR5810_7 10xR8i 4600 6900
NR6390_7 11xR8i 5060 7590
NR6970_7 12xR8i 5520 8280
6. Make sure parameter 95.02 FUSE SWITCH CTRL is OFF. The fault that will appear if
95.02 is not set to OFF is “INV DISABLE”
7. Cycle power on the RDCU.
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NOTE: In order for the backup packages to be downloaded to the drive, the drive node number must
be set to 1 (parameter 70.02 CHANNEL 3 ADDR).
5.2.2 Download parameters to the drive
Obtain the drive parameters from NOV or locate the Drive Windows backup file (.dwp) in the
on board USB or your company’s records. Using Drive Windows, download the parameters to
the drive.
5.3 Charging The Inverter
1. If the inverter control power is not already on, switch it on. Make sure all control CBs on the
control panel are closed. Refer to the inverter schematic for details.
2. If the main DC bus is not already energized, switch on the rectifiers and verify that the
proper DC bus level is present.
3. If there are any additional inverters or choppers on the DC bus, make sure they are locked
out.
4. Verify the pilot lights (PL01 and PL02) are functioning by pushing to test.
5. With pre-charge lockout enable switch select enable and at PB02 press in push to pre-
charge button to pre-charge inverter BUS. The inverter should begin the pre-charge
sequence.
6. With voltage on the DC Bus, the drive should charge up. When the bus volts reaches 700V,
the RDCU energises RL03 (DC BUS CHARGED) relay and the disconnect switch (DSW01)
should close.
7. Once the drive is charged, the Bus Charged pilot light (PL01) should be ON.
8. Check the DC Bus Voltage from the keypad. Verify that the value read on the keypad is
within 5% of the actual voltage displayed by the rectifier’s DC volt meter.
9. Select lockout on pre-charge lockout enable switch to discharge the drive. When the bus
volts drops below 350VDC, the Bus Charged pilot light (PL01) should turn off, the
disconnect switch (DSW01) should drop out. This is the ready state for the pre-charge
circuit and DSW01.
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5.4 Running the drive
5.4.1 Performing a motor id run

A Motor ID run must be performed before any other action is taken with the drive. The motor
data should be entered from the information found on the motor nameplate or as advised by
NOV engineering.
5.4.2 Entering the Motor Data

The motor data can be entered in two ways. The first is by going to Parameter group 99 and
entering the data as it appears on the motor nameplate. The second method is to press the
“Func” button on the Control Panel and then selecting “Motor Setup.” This will begin the Start-
up Assistant which will guide you through the motor setup.
The parameters should be setup as follows:
• 99.01 Language English or English AM

If “English” is chosen, the motor nominal power must be in kilowatts, and if
“English AM” is chosen, the nominal power is in horsepower.
• 99.02 Application Macro

This should be set to “Factory” unless the drive will be acting as a slave drive. In
a slave drive, this is set to “T-Ctrl” (Torque Control)
• 99.03 Application Restore No
• 99.04 Motor Control Mode DTC

In most cases DTC (Direct Torque Control) will be suitable.
• 99.05 Motor Nominal Voltage (off motor nameplate)
• 99.06 Motor Nominal Current (off motor nameplate)
• 99.07 Motor Nominal Frequency (off motor nameplate)
• 99.08 Motor Nominal Speed (off motor nameplate)
• 99.09 Motor Nominal Power (off motor nameplate)
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5.4.2.1 Motor ID Run

Once motor parameters have been entered or changed from their previous
settings, the inverter controller will force the user to perform and ID run of some
kind. The following guidelines explain the basic steps for performing a successful
ID run.
WARNING: THE FOLLOWING PROCEDURE REQUIRES

CAREFUL ATTENTION TO SAFETY. BEFORE
PERFORMING AN ID RUN, MAKE CERTAIN THE
FOLLOWING MINIMUM SAFETY MEASURES ARE
CARRIED OUT ONLY BY QUALIFIED PERSONNEL
CAUTION: THE MOTOR ID RUN WILL CAUSE THE

MOTOR TO SPIN AT MAXIMUM SPEED. BE CERTAIN
THE INVERTER’S EMERGENCY STOP CIRCUIT IS
OPERATING PROPERLY BEFORE ATTEMPTING IT.E-
STOP AN EXTERNAL SIGNAL INTO THE INVERTER.
SAFETY PRECAUTIONS:
1. Make certain all personnel who have access to the motor or tool are aware of
your intent to perform and ID run, and are well clear of the motor and tool.
2. If the ID run is to be performed with an uncoupled motor, make sure qualified
personnel have properly uncoupled the motor from the tool and secured all
parts and tools, so they may not come into contact with any rotating parts
connected to the motor.
3. Verify the system emergency stop circuit which controls the inverter is
functioning properly. Do not attempt the ID run unless the Emergency Stop
circuit has been tested and proven to stop the inverter. Note: This E-Stop is
not on the inverter, it is an external signal which activates the RL05, the
emergency stop relay. A properly functioning E-Stop circuit will remove 24V
from pin X22-11 on the RDCU (interlock) and it will stop The VFD drive.
4. When the ID run is complete, be certain to remove all power from the inverter
before attempting to re-connect the motor to the tool.
*
Recommended safety conventions. American Petroleu m Institute
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• 99.10 Motor ID Run Standard

The “Standard” ID run will achieve the best accuracy.
Typically this is ID run is used whenever possible on a drawworks or top drive, or
a tool where high torque accuracy is important. In order to perform the Standard
ID Run, the motor should be uncoupled from the load. Standard ID runs can be
performed with the motor coupled, but motor model accuracy may not be as
good. Standard ID runs generally give better results than the ID Mag run, even if
the TD motor is coupled.
The procedure will take about 1 minute, however times will vary so do not be
alarmed. If the motor ID Run has not completed within 5 minutes, then look at
Group 20 limits as described below that may interfere with the ID Run profile.
The drive will spin the motor and will run between 50% and 80% of the motor
nominal speed, so make sure it is safe to spin the motor. Note, that the motor is
accelerated at a very fast ramp during the ID Run, thus the motor will tend to rock
do to the rotor interia. Make sure that the motor is solidly fixed to its mounting
base or tool. The Motor ID Run is always operated in the Forward direction
according to the drive phasing, so make sure the motor rotation is correct for
what the machine calls “Forward Rotation”.
Before performing the ID run, other parameters must be checked. See the
following section.
• 99.10 Motor ID Run ID Mag

o The ID Mag may be performed where uncoupling of the motor is not
possible. Typically this ID run is used on pumps, and is sufficient to
produce good motor performance for the application.
5.4.3 Parameters for the Motor ID Run

The following information regarding limits apply to the ID run only. Be sure to restore these to the
project specific values after the ID run is complete.
5.4.4 Group 20 LIMITS
Go to Parameter Group 20 “Limits” and check the following parameters:
• Parameter 20.02 Maximum Speed

The default for this is motor nominal speed. It should be kept there for the ID run.
• Parameter 20.03 Maximum Current

The default for this is two times the motor nominal current. For the ID run it needs to be
greater than the nameplate value
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• Parameter 20.04 Torque Max Lim 1

This needs to be at least 100%. It is best to keep it at default (300%) for the ID run.
• Parameter 20.05 Overvoltage Control

This should be set turned ON for the ID run. Under normal operation of the drive, if
there is a chopper and brake resistor in the system, this should be turned off in order for
the chopper to turn on.
5.4.5 Remove Profibus Control

If the Profibus is connected to the drive during the ID Run, the Supervisory Control System
may overwrite some values. To prevent this from happening, unplug the profibus cable.
If the ID Run is going to be performed from the keypad, put the controller in “Local” mode by
pressing the “LOC-REM” button. An “L” should appear in the upper left hand corner of the
display. If running from Drive Windows, the controller needs to be in Remote mode. Press the
“LOC-REM” button until an “R” appears in the upper left hand corner of the display.
To prevent a “COMM Fault” on the controller, change parameter 30.18 COMM FLT FUNC to
NO.
5.4.6 Run Enable

In Parameter Group 16 “System Control Inputs,” set parameter 16.01 “Run Enable” to “YES”
during the ID run.
5.4.7 Encoder
If an encoder is being used for speed feedback, the encoder must be disabled during the ID
run. By default, the encoder is not Activated, Parameter 98.01 ENCODER MODULE will be
set to “NO”. If the encoder feedback was already enabled by setting parameter 98.01 to a
value other than “NO”, then disable the encoder feedback by going to Parameter Group 50
“Encoder Module” and set Parameter 50.06 “Encoder FB Sel” to “Internal” during the ID run.
If motor rotation has been proven to be correct, then while the ID Run is running it is
also beneficial to check the encoder wiring. To do this, compare ACTUAL SIGNALS 2.18
SPEED MEASURED (Encoder measured RPM) to 1.02 SPEED (drive’s internal calculated
speed). Both numbers should be approximately equal and with the same polarity. If rpm does
not match then check accuracy of encoder configuration in Group 50 ENCODER MODULE or
look for improper wiring or encoder supply voltage (RTAC-01 module does not work with 5V
DC encoder signals). If polarity is opposite, and motor rotation is correct, then swap “A” for “B”
and “A-“ for “B-“ on the encoder feedback wiring. Note, “Z and Z-“ wires are unused in the ABB
drives.
5.4.8 Start Interlock

The Start Interlock must be active to start the ID run. To do this, place a jumper between
X22:8 and X22:11.
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5.4.9 Motor Temperature Compensation

If the motor temperature compensation function is being used, this must be disabled during the
ID Run. To disable, change parameter 35.07 MOT MOD COMPENSAT to NO.
5.5 Starting the Motor ID Run
WARNING: Before starting an ID Run, always verify that the motor is free to operate.
Verify no personnel are in the area. Also verify that no tools or debris are in the path of
the motor.
In order to start the motor ID run, put the Keypad in the Local mode by pressing the “Loc/Rem”
key on the Panel. An “L” should appear in the upper left hand corner of the display. Return to
Parameter Group 99 and change parameter 99.10 “Motor ID Run” and choose “Standard.”
Once this is chosen, the screen should read “**Warning** ID Run Sel.” After pressing the
green button to start the ID run the screen will read “**Warning** Motor Starts.” During the ID
Run, the screen will read “**Warning** ID Run.” By pressing the “ACT” key on the keypad, you
can monitor the drive current and speed. When the ID run finishes, the screen will read
“**Warning** ID Done.”
5.6 ID Run Completed
Once the ID run has been completed, the parameters that have been changed can be returned
to their original values. Now the drive can be customized for the current application.
1. Retest the Emergency Stop. Start the motor from the control system or the keypad.
Depress the E-Stop button the drive should stop and 0.5 seconds later, the disconnect
switch (DSW01) should open.
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6 TROUBLESHOOTING
6.1 General
Before attempting to trouble shoot the inverter, make certain you have a copy of the relevant
schematic.
It is a good idea to familiarize yourself with the control power sources and circuit breakers, as
well as the 0V and ground reference points so that connections can be checked in those
locations.
6.1.1 Pre-charge System and Indicators

The inverter has 2 indicator lamps on the front panel. The FAULT LED (Red) , and BUS
CHARGED (Green) is located on the front door.
6.2 Inverter Modules

The following troubleshooting guideline is intended to act as an aid to fault tracing in the
inverter. The majority of fault tracing is done through the inverter’s keypad. The information
provided deals with the most common problems you may encounter. Therefore, a familiarity
with the drive’s keypad/LCD display and how to navigate through its various menus is essential
to being able to isolate the source of a problem.
Due to the complex and unique operating environment in which this equipment operates, it is
impossible to anticipate every possible problem and solution. If the equipment continues to
present problems, or if the type of trouble exhibited by the equipment is not covered in this
section, please contact your nearest National Oilwell Varco representative to arrange service.
6.3 Warning and fault indications

The inverter modules are equipped with an internal system for indicating abnormal or failure
conditions. In the event the drive detects an undesirable condition, it will display a warning or
fault message on the control panel display. The latest warnings and faults are recorded
together in the Fault History along with a time stamp identifying when the event occurred.
Once the fault has been traced to its cause and then corrected, the drive may be reset. The
drive can be reset by pressing the RESET key on the keypad, by digital input or fieldbus, or
powering down the drive.
6.3.1 Programmable protection functions
AI<Min
AI<Min function defines the drive operation if an analogue input signal falls below the
preset minimum limit.
Settings
Parameter 30.01.
Panel Loss
Panel Loss function defines the operation of the drive if the control panel selected as
control location for the drive stops communicating.
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Settings
Parameter 30.02.
External Fault
External Faults can be supervised by defining one digital input as a source for an
external fault indication signal.
Settings
Parameter 30.03.
Motor Thermal Protection –NOT USED FOR NOV DRILLING TOOLS
The motor can be protected against overheating by activating the Motor Thermal
Protection function and by selecting one of the motor thermal protection modes
available.
The Motor Thermal Protection modes are based either on a motor temperature thermal model
or on an over temperature indication from a motor thermistor.
Motor temperature thermal model NOTE: For open frame, externally cooled drilling
motors, this function should never be activated. This applies to all Drawworks, Top
Drive, and Mud Pump tools. If not certain about the motor type, contact NOV service.
The drive calculates the temperature of the motor on the basis of the following assumptions:
1. The motor is in the ambient temperature of 30 _C when power is applied to the drive.
2. Motor temperature is calculated using either the user-adjustable or automatically
calculated motor thermal time and motor load curve (see the figures below). The load
curve should be adjusted in case the ambient temperature exceeds 30 °C.
Figure 27 Motor Thermal Load Curves
Use of the motor thermistor

It is possible to detect motor overtemperature by connecting a motor thermistor (PTC)
between the +24 VDC voltage supply offered by the drive and digital input DI6. In
normal motor operation temperature, the thermistor resistance should be less than 1.5
kohm (current 5 mA). The drive stops the motor and gives a fault indication if the
thermistor resistance exceeds 4 kohm__
Settings
Parameters 30.04 to 30.09.
www.nov.com
Revision 01
Page 41
Note: It is also possible to use the motor temperature measurement function. See the
subsection Motor temperature measurement through the standard I/O. See
Stall Protection
The drive protects the motor in a stall situation. It is possible to adjust the supervision
limits (frequency, time) and choose how the drive reacts to the motor stall condition
(warning indication / fault indication & stop the drive / no reaction).
Settings
Underload Protection
Loss of motor load may indicate a process malfunction. The drive provides an under-
load function to protect the machinery and process in such a serious fault condition.
Supervision limits – under-load curve and under-load time - can be chosen as well as
the action taken by the drive upon the under-load condition (warning indication / fault
indication & stop the drive / no reaction).
Settings
Motor Phase Loss
The Phase Loss function monitors the status of the motor cable connection. The
function is useful especially during the motor start: the drive detects if any of the motor
phases is not connected and refuses to start. The Phase Loss function also supervises
the motor connection status during normal operation.
Settings
Parameter 30.16.
Earth Fault Protection
The Earth Fault Protection detects earth faults in the motor, the motor cable or the
inverter.
This protection is based on earth leakage current measurement with a summation
current transformer at the input of the converter with the following provisions:
o An earth fault in the mains does not activate the protection.
o In an earthed (grounded) supply, the protection activates in 200 microseconds.
o In floating mains, the mains capacitance should be 1 microfarad or more.
o The capacitive currents due to screened copper motor cables up to 300 metres
do not activate the protection.
Settings
Parameter 30.17.
Communication Fault
The Communication Fault function supervises the communication between the drive
and an external control device (e.g. a fieldbus adapter module).
Settings
Supervision of optional IO
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Revision 01
Page 42
The function supervises the use of the optional analogue and digital inputs and outputs
in the application program, and warns if the same input (output) is used for two
purposes simultaneously.
Settings
Parameter 30.22.
6.3.2 Preprogrammed faults

Overcurrent
The overcurrent trip limit for the drive is 3.5 · I2hd (rated output current, heavy-duty use
rating).
62
DC overvoltage
The DC overvoltage trip limit is 1.3 ·U1max, where U1max is the maximum value of the
mains voltage range. For 400 V units, U1max is 415 V. For 500 V units, U1max is 500
V. For 690 V units, U1max is 690 V. The actual voltage in the intermediate circuit
corresponding to the mains voltage trip level is 728 VDC for 400 V units, 877 VDC for
500 V units, and 1210 VDC for 690 V units.
DC undervoltage
The DC undervoltage trip limit is 0.65 · U1min, where U1min is the minimum value of
the mains voltage range. For 400V and 500V units, U1min is 380V. For 690 V units,
U1min is 525V. The actual voltage in the intermediate circuit corresponding to the mains
voltage trip level is 334VDC for 400V and 500V units, and 461VDC for 690V units.
Drive temperature
The drive supervises the inverter module temperature. If the inverter module
temperature exceeds 115 °C, a warning is given. The temperature trip level is 125 °C.
Short circuit
There are separate protection circuits for supervising the motor cable and the inverter
short circuits. If a short circuit occurs, the drive will not start and a fault indication is
given.
Input phase loss
Input phase loss protection circuits supervise the mains cable connection status by
detecting intermediate circuit ripple. If a phase is lost, the ripple increases. The drive is
stopped and a fault indication is given if the ripple exceeds 13%.
Ambient temperature
The drive will not start if the ambient temperature is below -5 to 0 °C or above 73 to 82
°C (the exact limits vary within the given ranges depending on drive type).
Overfrequency
If the drive output frequency exceeds the preset level, the drive is stopped and a fault
indication is given. The preset level is 50 Hz over the operating range absolute maximum
speed limit (Direct Torque Control mode active) or frequency limit (Scalar Control active).
Internal fault
If the drive detects an internal fault the drive is stopped and a fault indication is given.
www.nov.com
Revision 01
Page 43
6.3.3 Warning messages generated by the drive
Figure 28 Drive Warning Messages
Warning Cause What to do

ACS800 TEMP Drive IGBT temperature is excessive. Fault trip Check ambient conditions.
(4210) limit is 100%. Check air flow and fan operation.
Check heatsink fins for dust pick-up.
Check motor power against unit power.
COMM MODULE Cyclical communication between drive and Check status of fieldbus communication. See
(7510) master is lost. chapter Fieldb us control, or appropriate
(Programmable Fault fieldbus adapter manual.
Function) Check parameter settings:
- group 51 COMM MODULE DATA (for fieldbus
adapter)
- group 52 STANDARD MODBUS (for
Standard Modbus Link).
Check Fault Function parameters.
Check cable connections.
Check if master can communicate.
DC OVER VOLT Excessive intermediate circuit DC voltage. Check that overvoltage controller is on
(3210) DC overvoltage trip limit is 1.3 · U1max, where (parameter 20.05).
U1max is maximum value of mains voltage Check mains for static or transient overvoltage.
range. For 400 V units, U1max is 415 V. For Check brake chopper and resistor (if used).
500 V units, U1max is 500 V. Actual voltage in Check deceleration time.
intermediate circuit corresponding to mains Use coast-to-stop function (if applicable).
voltage trip level is 728 VDC for 400 V units Retrofit frequency converter with brake
and 877 VDC for 500 V units. chopper and brake resistor.
CUR UNBAL xx Drive has detected excessive output current Check there are no power factor correction
(2330) unbalance in inverter unit of several parallel capacitors or surge absorbers in motor cable.
(programmable connected inverter modules. This can be Check that there is no earth fault in motor or
Fault Function caused by external fault (earth fault, motor, motor cables:
30.17) motor cabling, etc.) or internal fault (damaged - measure insulation resistances of motor and
inverter component). xx (1...12) refers to motor cable.
inverter module number. If no earth fault can be detected, contact your
local ABB representative.
ENCODER A<>B Pulse encoder phasing is wrong: Phase A is Interchange connection of pulse encoder
(7302) connected to terminal of phase B and vice phases A and B.
versa.
ENCODER ERR Communication fault between pulse encoder Check pulse encoder and its wiring, pulse
(7301) and pulse encoder interface module and encoder interface module and its wiring and
between module and drive parameter group 50 ENCODER MODULE
settings.
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Revision 01
Page 44
IN CHOKE TEMP Excessive input choke temperature Stop drive. Let it cool down.
(FF81) Check ambient temperature.
Check that fan rotates in correct direction and
air flows freely.
MOTOR STALL Motor is operating in stall region due to e.g. Check motor load and drive ratings.
(7121) excessive load or insufficient motor power. Check Fault Function parameters.
(programmable
Fault Function
30.10.30.12)
PANEL LOSS Control panel or DriveWindow selected as Check panel connection (see appropriate
(5300) active control location for drive has ceased hardware manual).
(programmable communicating. Check control panel connector.
Fault Function Replace control panel in mounting platform.
30.02) Check Fault Function parameters.
Check DriveWindow connection.
REPLACE FAN Running time of inverter cooling fan has Replace fan.
(4280) exceeded its estimated life time. Reset fan run time counter 01.44.
SHORT CIRC Short-circuit in the motor cable(s) or motor. Check motor and motor cable.
(2340) Check there are no power factor correction
capacitors or surge absorbers in the motor cable.
Output bridge of the converter unit is faulty Consult ABB representative.

NO COMMUNIC ATION Cabling problem or a hardware malfunction on the Check Panel Link connections.
(C) Panel Link. Press RESET key. The panel rest may take up to
half a minute, please wait
(4) = Panel type not compatible with version of the Check panel type and version of the drive
drive application program. application program. The panel type is printed on
the cover of the panel. The application program
version is stored in parameter 33.03.
(7510) master is lost. chapter Fieldb us control, or appropriate
(programmable fieldbus adapter manual.
Fault Function Check parameter settings:
30.18, 30.19) - group 51 COMM MODULE DATA (for fieldbus
adapter), or
CURR MEAS Current transformer failure in output current Check current transformer connections to Main
measurement circuit. Circuit Interface Board, INT.
DC UNDERVOLT (3220) Intermediate circuit DC voltage is not sufficient Check mains supply and fuses.
due to missing mains phase, blown fuse or
rectifier bridge internal fault.
DC undervoltage trip limit is 0.6 · U1min, where
U1min is minimum value of mains voltage
range. For 400 V and 500 V units, U1min is
380 V. For 690 V units, U1min is 525 V. Actual
voltage in intermediate circuit corresponding to
mains voltage trip level is 307 VDC for 400 V
and 500 V units, and 425 VDC for 690 V units.
www.nov.com
Revision 01
Page 45

versa.
between module and drive parameter group 50 ENCODER MODULE
settings.
EARTH FAULT Load on the incoming mains system is out of Check motor.
(2330) balance due to fault in the motor, motor cable or Check motor cable.
an internal malfunction. Check there are no power factor correction
capacitors or surge absorbers in the motor cable.
7 MAINTENANCE
7.1 General
The air cooled rectifiers are designed to be as maintenance free as possible, however some
components should be cleaned periodically for optimum performance while preventative
maintenance for certain components are also beneficial to minimize downtime.
7.1.1 Inverter Fuse and Circuit Breaker Schedule

CB02 16A, 480Y/277VA C, 6kIC, 2P UPS Supply TB01 (L1), TB02 (L2)
CB03 16A, 480Y/277VA C, 6kIC, 2P Essential Rig Supply TB 03 (L1), TB04 (L2)
CB04, CB 05
(optional) 1A, 240VAC, 10kIC, 2P 24VDC TB05 (+), TB06 (-)
CB15 (optional) 4A, 480Y/277VAC, 6kIC, 2P 230:120VA C Transformer T01
CB16 (optional) 5A, 480Y/277VAC, 6kIC, 2P Line Filter SP02
F01-04 30A, 1000VDC, 100kIC Pre-charge fuses

F05-10 1000A, 1250V, 100k IC Inverter Fus es
F13-14 (optional) 1800ADC, 1000VDC, 120kA DC Bus Fuses
www.nov.com
Revision 01
Page 46
7.2 Maintenance Schedule

Clean chopper heatsinks 1 time every 12 months Blow out dust/dirt with clean
dry air
environment
Chopper cooling fans 60,0000 hrs or 7 years Replace
Specifications
Table 1 Bolt Torque
Specifications
Specifications
Units with parallel connected APBU branching Remove cover. Replace
Inverter modules: unit – Memory backup battery battery with a new CR 2032
Locate the APBU unit. Switch renewal battery.
off the power to the unit. Every 6 years

Specifications
Inspect Resistor Bank(s) 1 time every 12 months Verify Resistance value is
correct. Ensure resistance
elements are insulated from
ground.
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Revision 01
Page 47
7.3 Fuse Replacement

rejected from the fuse body when it has opened, opening the micro-switch, and tripping the
disconnect switch. This switch needs to be removed from the faulted fuse, and set aside. The
following diagram and instructions outline the fuse replacement procedure. It is important to
use the correct tools and follow the procedure exactly. Failure to do so could result in the fuses
not operating properly and causing damage to the rectifier or to devices it supplies.
8.1 Enviromental Data

Ambient temperature rating for the Drill Force drive systems is 40°C, at 1000m above sea
level, without derating. For every 1°C above 40°, the VFD’s output current must be reduced
1%. Maximum allowable ambient temperature is 50°C; so that maximum derating is 10% of
the rated current. For every 100m above 1000m, the drive is derated 1%. For operation above
2000m, the installation must be considered on a case by case basis.
The following table describes the remaining environmental ratings for the inverter module:
www.nov.com
Revision 01
Page 48
Table 4
Environmental Limits Operation Storage Transportation
Humidity 5-95% No Condensation
NO Conductive dust
Contamination Levels Chemical gases;
Allowed; Chemical Gases: Class 2 Cat2
Classifications Class 3, Cat2;
Chemical Gases: Class 3 Solid Particles:
IEC 60721-3-3, IEC 60721- Solid Particles;
Cat2 Class 2s2
3-1, IEC 60721-1 Class 1S3
Solid Particles: 3S2
1mm
1mm
2 5-13.2 1mm
5-13.2 Hz,7ms ,13.2-100 2 2
Vibration IEC 60068-2 Hz,7ms ,13.2-100 2-9 Hz,15ms ,9-200Hz sinusoidal
Hz sinusoidal
Hz sinusoidal
Shock IEC 60068-2-29 Not allowed 100m/s 2,11ms 100m/s 2,11ms
Free Fall Not allowed 100mm 100mm
Storage: -40C to
Operation: 0-50C (32- Transportation: -40C to 70C (-40F
Air Temperature 70C (-40F to
122F); no frost to +158F)
+158F)
8.2 Mechanical Data

BOLT SIZE FLEXBUS HARD BUS
M6 X 1.0 6.5 4.8 7.2 2.3
M8 X 1.25 15 11.06 17 12.5
M10 X 1.5 30 22.15 28 20.7
M12 X 1.75 55 40.56 45 33.2
Table 5: Bolt Torque Specification
DC BUS BAR SPECIFICATIONS

RATED CURRENT 2000ADC
RISE
WIDTH 80mm
THICKNESS 10mm
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Revision 01
Page 49
MAIN BUSBAR BRACING: MATERIAL SPECIFICATIONS

Property Value Unit
Temperature
24 hours
168 hours
Table 6: Main Bus Bar Specifications
DC Isolation Switch short circuit ratings are in the table below.
9 ADDITIONAL DOCUMENT REFERENCES
9.1 Vendor Documents
9.1.1 ABB Documents

3AFE 64486853 – Pulse Encoder Interface Module RTAC-01
3AFE 64504215 – Profibus DP Adapter Module RPBA-01
3AFE68464251 - APBU-44C(E) PPCS Branching and Datalogger Unit
601933/616 – ABB Electronic Delay
3AFE 64492209 - RDCO-01/02/03 DDCS Communication
3AFE64527592 - ACS800 Standard Control Program 7.x
3AFE 64636324 - Hardware Manual RDCU Drive Control Units
www.nov.com
FINAL DOCUMENTATION
Section 1.2
Spare Parts
www.nov.com
CHAPTER 1 INDEX 1.2
INSTALLATION, OPERATION &

MAINTENANCE

8434 SPARE PARTS
DOCUMENT NUMBER REV
10707932-IDX 01
www.nov.com
Revision 01
Page 2
1.2 SPARES LIST / COMMISSIONING / OPERATING / INSURANCE
SPARE PARTS LIST 10620338-SPL 02 N08
www.nov.com
SPARE PARTS LIST
NOV - Galena Park

VFD House
Ideal Rig 135 J258434 NOV - Galena Park

ADDITIONAL CODE SDRL CODE TOTAL PGS This document contains proprietary and/or confidential National Oilwell Varco
information of National Oilwell Varco (NOV). It is loaned for Rig Solutions - Western Hemisphere
4
limited purposes only. Any reproduction, in whole or in part, or 5100 N. Sam Houston Pkwy. W.
REMARKS use, or disclosure of the contents to others shall be in Houston, TX 77086
accordance with the terms and conditions agreed upon with
NOV. Any use, reproduction, or disclosure beyond the terms
MAIN TAG NUMBER DISCIPLINE Phone: 281-569-3000
and conditions of the release is prohibited without the express
written consent of NOV. The burden of proof that NOV consent
CLIENT PO NUMBER has been issued within the provisions of this paragraph lies with
the recipient. This document is to be returned to NOV or its
destruction certified upon request by NOV and in any event upon
CLIENT DOCUMENT NUMBER completion of the use for which it was loaned. Except for the
limited purposes agreed upon between NOV and the recipient,
Client Document Num. no licenses or other rights are granted or conferred upon
recipient, expressly, implied or otherwise, under any of NOV’s
patents, trademarks, trade secrets, copyrights, or other
intellectual property rights. All rights pertaining to this document
and its contents are expressly reserved and retained by NOV.
©National Oilwell Varco, all rights reserved.
DOCUMENT NUMBER REVISION
10620338-SPL 02
www.nov.com
Document Number: 10620338-SPL
Revision: 02
REVISION HISTORY
02 25.04.2103 Update Rig ID JAR BD JAR

01 02.05.2012 Initial Release JAR BD JAR
Rev. dd.mm.yyyy Reason For Issue Prep. Check Appr.
CHANGE DESCRIPTION
Revision Change description

01 First issue
02 Update Rig ID from 137 to 135
www.nov.com Page: 2
SPARE PARTS LIST
EQUIPMENT DESCRIPTION
Engineering Contactor: National Oilwell Varco INQUIRY NO: DOC. NO: 10620338-SPL
Supplier's Name and Address: National Oilwell Varco
5100 N. Sam Houston Pkwy. W. Customer Rig Ref. BOM No. NOV Part No.
Houston, TX 77086 NOV - Galena Park Ideal Rig 135
Phone Number: 281-569-3000
Supplier's Contact Person: After Sales Spare Parts: Wayne Vaughan (Extension #5972) TAG No. PO No. Currency Ref. / Ser. No.
Email: wayne.vaughan@nov.com USD
COMMISSIONING TWO YEAR OPER.
MATERIALS DATA
SPARES SPARES
Quantity to be Ordered
Delivery Time for Parts

Unit Price (__) USD
Recommended
Recommended
(In Weeks)
(Currency)
Item No.
Item /
Description of the Recommended Spare Parts NOV Part No.
Ref. No.
1 CB- 16AT,2P, 240VAC, KIC 10040321-001 1

2 RLY- 24VDC,2A2B0C, 10A,IEC DE 10040429-001 1
3 PB-OPER,BLK,STOP,F/8000 LINE 10040873-001 1
4 PB-OPER,RED,STOP,F/8000 LINE 10040874-001 1
5 SW-MICRO,SPDT,F/BUSS TYPE K 10041312-001 1
6 SUPPRESSOR-SURGE, 6-240VDC 10042050-001 1
7 SUPPRESSOR-SURGE, 72-240VAC 10042086-001 1
8 RLY-120VAC,4A0B0C, 10A,IEC 10042138-001 1
9 RELAY 24VDC 4AOBOC 10 A 10042140-001 1
10 PLC-SIE,CONN,PROFI,90DEG, W/PG 10042406-001 1
11 RLY-24VDC,2A2B0C, A,PLC,CTR 10042417-002 1
12 SW-MICRO SW,TWO FORM C CONT 10042467-001 1
13 FUSE- 1. A, 1000VDC,100KIC 10042480-001 10 10
14 RLY- 24DC/21-21,2 PC,RSC 10043520-001 1
15 PC BOARD-ENCODER CARD FOR USE 10044171-001 1
16 BRANCHING UNIT,APBU,ABB 10044443-001 1
17 PC BOARD-MOTOR CONTROL UNIT 10044446-001 1
18 PC BOARD-PROFIBUS MODULE,ABB 10044500-001 1
19 MODULE-FIBER,DDCS ACS800 10044530-001 1
20 AC DRIVE CONTROL PANEL 10044564-001 1
21 CONTR-1350A;3P;690V;100-250VAC/D 10044590-001 1
22 RLY-120AC 2PDT & BASE 10044918-001 1
23 PB-CONTACT BLOCK 1NO 10045092-001 1
24 PL-DIODE BLOCK FUW ABB MCBH 10045176-001 1
25 PWR SPLY- 85-264VAC,90-375VDC 10045380-001 1
26 CB-2500AF,E3,3P,690VAC, 75KIC 10049527-050 1
27 CB-UVR(YU),24VDC,FOR E1 THRU 10049598-001 1
28 CB-CHARGING MOTOR,100/130V FOR 10049618-001 1
29 PB-CAP, ,PDLCK ATCHMNT 10049864-001 1
30 1200VDC VOLTAGE FDBK (View) 10050029-001 1
31 RELAY RTEP1AD24 TIME ADJ DELY 10056909-001 1
32 PLC-8PT, 24VDC INPUT MODULE 10064178-039 1
33 INVERTER-450 KW,690V,486A,AIR 10065574-001 1
34 PC BOARD-ENCODER CARD,ENCODER 10066109-001 1
35 CB- 2AT,2P,480Y/277VAC,6KIC 10066128-001 1
36 INDUCTOR- 15UH,2000A, 690V 10066595-001 1
37 DIODE-BRIDGE,1PH,1600V,40A 10066597-001 1
38 RECT-SINGLE PHASE,690V,2600A 10066768-001 1
39 PWR SPLY- 24V , 5. A,INPUT 10066883-001 1
40 CB-MINATURE,1A,240V,2P,DIN 10066977-001 1
41 PL- 24V,LED,RED,PUSH TO TEST 10066989-001 1
42 PL- 24V,LED,GRN,PUSH TO TEST 10066990-001 1
43 1000A,1000V,SEMICONDUCTOR 10067394-001 1
44 FUSE- 10. AAC,690VAC IEC 10067458-001 10 10
45 FUSE-1000. A, 1100V,M12 THREAD 10067479-001 10 10
46 METER-VDC,0-1200,10VDC INPUT 10067627-001 1
47 SW-KEY;3POS;MAINTAINED;LEFT 10068128-001 1
48 CB-MINATURE,0.5A,240V,2P,DIN 10078121-001 1
49 SW 2 POSITION,MAIN,NON ILLUMIN 10517427-001 1
50 SW PADLOCK 10517441-001 1
www.nov.com Page 3
SPARE PARTS LIST
EQUIPMENT DESCRIPTION
Engineering Contactor: National Oilwell Varco INQUIRY NO: DOC. NO: 10620338-SPL
Supplier's Name and Address: National Oilwell Varco
5100 N. Sam Houston Pkwy. W. Customer Rig Ref. BOM No. NOV Part No.
Houston, TX 77086 NOV - Galena Park Ideal Rig 135
Phone Number: 281-569-3000
Supplier's Contact Person: After Sales Spare Parts: Wayne Vaughan (Extension #5972) TAG No. PO No. Currency Ref. / Ser. No.
Email: wayne.vaughan@nov.com USD
COMMISSIONING TWO YEAR OPER.
MATERIALS DATA
SPARES SPARES
Delivery Time for Parts

Unit Price (__) USD
Recommended
Recommended
(In Weeks)
(Currency)
Item No.
Item /
Description of the Recommended Spare Parts NOV Part No.
Ref. No.
51 XFMR- 100 VA, 600/690AC:28VAC 10525973-001 1

52 DC Bus Voltage Monitor Board (View) 10536169-001 1
53 CHOPPER-AC,1-MODE,1200A,1100V (View) 10537032-001 1
54 XDCR-CURRENT;LEM;1000AAC/DC 10541172-001 1
55 DC PRECHARGE,PCA,W/RELAY BOARD (View) 10542237-001 1
56 SW-DC,3P,2000AF,IEC,FIXED,HR 10633571-001 1
57 CB-UVR(YU),120VAC,4/ EATON MAG 10633696-001 1
58 CB-CLOSING COIL,120VAC/DC,4/ EATON 10633698-001 1
59 CB-CHARGING MOTOR,120VAC,4/EATON 10633701-001 1
60 CB-TIME DELAY UVR,120VAC,4/EATON 10635356-001 1
61 SW-DC,3P,2500AF,IEC,FIXED,HR 10636263-001 1
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
www.nov.com Page 4
FINAL DOCUMENTATION
Chapter 2
Technical Documentation &
Drawing Package
www.nov.com
FINAL DOCUMENTATION
Section 2.1
General Drawings
www.nov.com
CHAPTER 2 INDEX 2.1
TECHNICAL DOCUMENT & DRAWING

8434 GENERAL DRAWINGS
DOCUMENT NUMBER REV
10707933-IDX 01
www.nov.com
Revision 01
Page 2
2.1 OUTLINE/ GENERAL ARRENGEMENT DRAWING
8434-GEN&INC/REC LINE-UP 10620263-GAD 02 B01
8434-AIR COOL VFD LINE-UP 10620268-GAD 01 B01
8434-480VAC MCC ELEVATION 10620273-GAD 01 B01
8434-VFD/GEN HOUSE 10620338-GAD 01 B01
ASSEMBLY DRAWING
BASE-A,440,100-60-60-60-60-100, 10534196-ASM 01 B02
MAIN BUS- (2)10X100mm CU,(4)GEN, 10535846-ASM 01 B02
60A-BOP CUSTOMER SUPPLY PWR 10551812-ASM 02 B02

BOX
IDEAL RIG-KIT-HOUSE GROUNDING 10560061-ASM 01 B02
8434-MCC I/O AUXILIARY CONTROL 10620305-ASM 01 B02
IDEAL RIG-TDS-11 AUX COMPONENTS 10620312-ASM 01 B02
8434-AC PLUG PANEL 10620313-ASM 01 B02
8434-(4) GENERATOR PLUG PANEL 10620318-ASM 01 B02
8434-VFD/GEN HOUSE 10620338-ASM 01 B02
8434 INC/RECT 1,600/690V,2500ADC 10622061-ASM 01 B02
8434 INC/RECT 2,600/690V,2500ADC 10622062-ASM 02 B02
8434 (2)INV 1 TD/RT,900KW/953AAC 10622066-ASM 01 B02
8434 (3)INV 2 DWA,1400KW/1414AAC 10622068-ASM 02 B02
www.nov.com
Revision 01
Page 3
2.1 ASSEMBLY DRAWING (Cont.)
8434 (3)INV 3 DWB,1400KW/1414AAC 10622069-ASM 02 B02
8434 (3)INV 4 MP1,1400KW/1414AAC 10622070-ASM 02 B02
8434 (3)INV 6 MP3,1400KW/1414AAC 10622072-ASM 02 B02
8434 CUB-ASSIGNMENT,TD/RT 10622073-ASM 01 B02
8434 (2)CHOPPER,1200KW 10622074-ASM 01 B02
IDEAL RIG ACCESSORY VFD LINE-UP 10623618-ASM 02 B02
8434-GEN 1 10625487-ASM 02 B02
8434-GEN 2 10625488-ASM 02 B02
8434-GEN 3 10625490-ASM 02 B02
8434-GEN 4 FUTURE 10625491-ASM 01 B02
8434-GEN 4 , M-KIT 10625493-ASM 02 B02
8434 - CAT BATTERY PACKAGE 10625507-ASM 01 B02
www.nov.com
TOP VIEW
DETAIL A
SCALE: 1/100
RIGHT SIDE VIEW
FRONT VIEW
BASE FOOTPRINT
8 7 6 5 4 3 2 1
]24.121[ 00.4803
]97.79[ 00.4842
]71.47[ 00.4881
]55.05[ 00.4821
]96.251[ 32.8783
]83.171[ 79.2534
]6.961[ 79.7034
]50.91[ 79.384
]63.2[ 00.06
]95.0[ 00.51
]0[ 00.0
1
∅8.50 [∅0.33] THROUGH HOLE
D (64 PLCS) D
1068.00 [42.05]
1068.00 [42.05]
1008.00 [39.68] 1053.00 [41.46]
1051.50 [41.4]
65.00 [2.56] (TYP)
816.50 [32.15]
784.00 [30.87] 6 65.00 [2.56] (TYP)
∅8.50 [∅0.33]
(TYP)
5 5 5 5 6
751.50 [29.59]
18.27 [0.72] 18.33 [0.72]
534.00 [21.02]
2 3 3 3 3 4 4 4 4 4 3 3 3 3 2
383.45 [15.1]
332.65 [13.1]
∅14.27 [∅0.56] (TYP)

104.05 [4.1]
60.00 [2.36]
16.50 [0.65] (TYP)
15.00 [0.59]
16.500.00
[0.65]
C 0.00 [0]
[0]
16.50 [0.65] (TYP) C
15.00 [0.59] (TYP) 60.00 [2.36] (TYP) ∅14.27 [∅0.56] THROUGH HOLE(22 PLCS)
1
4351.47 [171.32]
4367.94 [171.97]
4154.21 [163.55]
4126.63 [162.47]
3955.18 [155.72]
3982.76 [156.8]
3766.60 [148.29]
3779.56 [148.8]
3416.47 [134.51]
3595.15 [141.54]
3608.11 [142.05]
3333.20 [131.23]
3351.47 [131.95]
2733.20 [107.61]
2751.47 [108.33]
2816.47 [110.88]
2216.47 [87.26]
2151.47 [84.7]
2133.20 [83.98]
1616.47 [63.64]
1533.20 [60.36]
1551.47 [61.08]
]2 1016.47 [40.02]
732.37 [28.83]
759.95 [29.92]
933.14 [36.74]
951.47 [37.46]
372.34 [14.66]
385.30 [15.17]
560.92 [22.08]
588.50 [23.17]
200.89 [7.91]
213.85 [8.42]
0.00 [0]
16.50 [0.65]
]46
]55.361[
]89.
]7.4
]
]62.
]23.171[
]79.171[
]
]
]92.841
]16.7
]33.8
]88.0
]
]
]27.551
]32.13
]59.13
]8.841[
]74.261
]
]
]6
]8
]15.43
]45.14
]50.24
]8.651[
]
TOP VIEW
TYP
15.00 [0.59] (TYP) 60.00 [2.36] (TYP) ∅14.27 [∅0.56] THROUGH HOLE(22 PLCS)
0.00 [0]
16.500.00 [0]
16.50 [0.65] (TYP)
[0.65] G
15.00 [0.59]
60.00 [2.36]
16.50 [0.65] (TYP)
104.05 [4.1]
)PYT( ]65.0∅[ 72.41∅
332.65 [13.1]
383.45 [15.1]
B B
G
534.00 [21.02]
TYP
18.27 [0.72] 18.33 [0.72]
751.50 [29.59]
784.00 [30.87] 65.00 [2.56] (TYP)
(TYP)
∅8.50 [∅0.33]
816.50 [32.15]
65.00 [2.56] (TYP)

TYP
G
1051.50 [41.4]
1008.00 [39.68] 1053.00 [41.46]
1068.00 [42.05]
1068.00 [42.05] (64 PLCS)
∅8.50 [∅0.33] THROUGH HOLE
3878.23 [152.69]
4307.97 [169.6]
4352.97 [171.38]
483.97 [19.05]
1284.00 [50.55]
3084.00 [121.42]
1884.00 [74.17]
2484.00 [97.79]
15.00 [0.59]
60.00 [2.36]
0.00 [0]
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION WHICH BELONGS TO NATIONAL-
OILWELL, L.P.. IT IS LOANED FOR LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF NATIONAL-
OILWELL, L.P.. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF THIS DESIGN OR DISTRIBUTION OF THIS
INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN CONSENT OF NATIONAL-OILWELL,
L.P.. THIS DOCUMENT IS TO BE RETURNED TO NATIONAL-OILWELL, L.P. UPON REQUEST AND IN ANY EVENT
UPON COMPLETION OF THE USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION
CONTAINED AND REPRESENTED HEREIN IS THE COPYRIGHTED PROPERTY OF NATIONAL-OILWELL, L.P.
Project Logo:
RIG SOLUTIONS
A BOTTOM VIEW 1530 WEST SAM HOUSTON PKWY NORTH A
HOUSTON, TEXAS 77043
TITLE:
BASE-A,440,100-60-60-60-60-100,
IR-G-G-G-G-IR
Material:
UNLESS OTHERWISE SPECIFIED:

Reference DWG:
DIMENSIONS ARE IN MILLIMETERS [INCHES]
SCALE: PROJECTION: SIZE: SHEET:
D
TOLERANCE First Used On:
7881 1/200 1 of 2
INCHES .X±.1 .XX±.02 .XXX±.005 FRAC±1/8 ANG±1/2%
01 03/18/11 RELEASED SR KWS PJP
Certified Correct for Project Noted: DRAWING NUMBER: REVISION:
MILLIMETERS .X±2.5 .XX±.51 .XXX±.127 ANG±1/2%
Rev. Date: Reason for issue: MadeChk'dAppr. By: Date: 10534196-ASM 01
03-18-11/3:57pm 8 7 6 5 4 3 2 1 STD3422D REV0

8 7 6 5 4 3 2 1
Bill of Materials for "10534196-001; BASE-A,440,100-60-60-60-60-100,"

Find
Qty. UoM Oracle No. Description Reference Designator
10 No.
10 68
51 .00
.50
10
42 00
.51 1 28.66 FT 10042470-001/01 STL C- 3 X 6.00;A-36 2@171.97
.05 .0
[
TYP
10 6841 00 95.0
[
.0.04
81
10042470-001/01
[
7 08 0 2 6.48 FT STL C- 3 X 6.00;A-36 2@38.86
]
6
75 84. .50
[
.00
]
42
]
1.5 00 .05 .06
[
0 3 39
3 2. G .68 00 3 18.18 FT 10042470-001/01 STL C- 3 X 6.00;A-36 8@27.27
29 0.8 15
[
TYP
[
D D
]
TYP .59 7 .2
[
63
[
]
]
]
4 4 16.19 FT 10068092-001/01 STL TS-4.00 X 3.00 X .375;A36 5@38.86
]
.38
]
10 79
G 53
38 .00 .91 10068092-001/01 STL TS-4.00 X 3.00 X .375;A36
[
33 3. 53 50
5 6.54 FT 4@19.62
2.6 45 4.0
0 41
]
5 15 .46
[
21
.1
10068092-001/01 STL TS-4.00 X 3.00 X .375;A36
[
13 .02 SEE DETAIL "B" 6 5.86 FT 2@35.14
[
.1
]
[
]
10
]
]
16
4.0
5
10 1 each 10067318-001/01 PAINT-GRAPHITE GRAY;POLYESTER
0.0 .50 4.1
0
[
SEE DETAIL "A" 0

0 .6516.50
[ ]
60
]
15 .0 1
[
0.6
.00 06.50
]
[
2
]
21
P
0.0 0 .35
(T
0
Y
.6
0 .59 6 P .48
[
)
[
[
00
]
(T
0
] Y
)
.0
[
]
.05
6
1
5
5.0 [2
0
]
[
.5
0
55
(T
6
0.5
]
.2 P)
1
[
Y
[0
0
7
.7
]
]
]
P
(T
2
.0
6
0
Y
5
[
5
[2
0.0
)
0
.5
0.6
]
(T
6
]
∅8 P)
Y
.5
.50
60
[
(T [∅
0 Y
.00 P) .3
0
6
.3
2.3
3
1
1
]
8
[0
[
3
1
.7
TYP
7.9 .42
]
2
]
P
(T
Y
]
9 8
[
0.8 5 81
.66 7 .48
[
20 13.8 14 00
.1
]
2 G
4 15
[
2.3 30 .47
[
71
[
37 5.
38 .08
]
]
22 .17
]
2 23
[
0.9 TYP
56 0 .83
[
5
]
.
58
8 28 .92
]
7 29
[
2.3
P)
(T
Y
73 5
.5
]
[
6
9 .74
[∅
0
.
9 42
]
.2
7
75 36
∅1
4
.46 .48
]
4 37 00
[
3.1 .02
]
3 7 40 .79
[
9 1.4
[
5 7 97
[
9 6.4
]
1
10
∅1
4.2
7
.36 03
]
60 .08 ∅0
.48
C ] .56
C
] [
0 61 4 00
[
.2 3.6 TH
33 47 1
[
]
.12
[
15 51. OU
.47 24
[
R
15 1 6 H
G
HO
]
16 LE
22
(
L TYP
S
P
C
] )
.98
83 .7 G
84
]
.20 .26
]
33 .47
[
21 1 87
5
21 7
[
6. 4 83
22
1 .87
32
1
.25
[
96
]
1
7.6 3
]
10 08.3
]
1 8
.20 7 0.8
]
3 11
[
3 4
27 751.
.47
[
2 6 61
28
1 6.9 3
8
]
∅
]
3
1.2 5
]
13 31.9
]
1
.20
1 4.5
]
[
33 1.47 13
[
3
3 35
.47 4
[
1.5 05
]
3 16
4 14 2.
]
3
5 14
[
9 5.1 11 9
[
8.2 .8
]
35 8.
14 148
]
0
36
.60 .56
[
[
6 2
6 9 5.7
]
37 377 15 6.8
]
.18 15
[
5 6
[
5 7
39 2.7 2.4 5
]
8
39 16 63.5
]
1
.63
[
26 4.21
[
1
B 4 15 2
1.3 7 B
]
4 17 71.9
]
1
.47 94
[
1
[
5 .
43 367
4
NOTE
4.1] 1.
2.
.335
.562
HOLE DRILL
THROUGH HOLE
FOR M10 TAP.
16.50 [0.6 65.00 [2.56] (TYP)

5] (TYP)
.65]
.36] %8.50 [%0.33] (TYP)
TOP FLANGE
].5 9] 5]
16.50 [0.6
(TYP)
%14.27 [%0.56] (TYP)
[0] BOTTOM FLANGE
65.00 [2.56] (TYP)
∅8.50 [∅0.33]
(TYP)
15.00 [0.5
9] (TYP) THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION WHICH BELONGS TO NATIONAL-
60.00 [2.3 OILWELL, L.P.. IT IS LOANED FOR LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF NATIONAL-
6] (TYP) 18.27 [0.72] 18.33 [0.72] OILWELL, L.P.. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF THIS DESIGN OR DISTRIBUTION OF THIS
INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN CONSENT OF NATIONAL-OILWELL,
L.P.. THIS DOCUMENT IS TO BE RETURNED TO NATIONAL-OILWELL, L.P. UPON REQUEST AND IN ANY EVENT
UPON COMPLETION OF THE USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION
CONTAINED AND REPRESENTED HEREIN IS THE COPYRIGHTED PROPERTY OF NATIONAL-OILWELL, L.P.
RIG SOLUTIONS
A DETAIL A 1530 WEST SAM HOUSTON PKWY NORTH A
SCALE: 1/75 HOUSTON, TEXAS 77043
[0]
.65]
TITLE:
91]
HOLE PATTERN TYPICAL FOR BASE-A,440,100-60-60-60-60-100,

ITEM 3 TOP OF UNIT ONLY.
IR-G-G-G-G-IR
DETAIL B
SCALE: 1/75
SCALE: PROJECTION: SIZE: SHEET:
1/200 D 2 of 2
DRAWING NUMBER: REVISION:
10534196-ASM 01
03-18-11/3:57pm 8 7 6 5 4 3 2 1 STD3422D REV0

R-
R-
BOM Line Level Find No. Quantity Revision uom Item Id
10520796-001/01@RSOne-KIT-HARDWARE,GEN,JOB7856 (view) 0 01 Each 10520796-001
10040542-001/01@RSOne-RIVET-POP;3/16 DIA;1/2"GRIP RA x 70 1 1 70 01 Each 0000-6817-80
10067071-001/02@RSOne-SCREW-12 X 1/2;UNSLOT;HEX WASHER x 1501 3 150 02 Each P250002-0012-95
10520737-001/01@RSOne-BOLT-M6X1.00X16mm,SLOTTED x 8 1 5 8 01 Each 10520737-001
10067055-001/01@RSOne-BOLT-M6X1.00X12mm;HEX HD;STL; GR x 20 1 6 20 01 Each P250002-0012-77
10067623-001/01@RSOne-BOLT-M6X1.00X25MM;HEX HD;STL; GR x 42 1 7 42 01 Each P250002-0025-04
10067052-001/01@RSOne-BOLT-M8X1.25X16mm;BTN HD;STL; GR x 10 1 9 10 01 Each P250002-0012-74
10067771-001/01@RSOne-BOLT-M8X1.25X20MM;HEX HED;STL;GR x 16 1 10 16 01 Each P250002-0027-16
10067030-001/01@RSOne-BOLT-M10X1.50X25mm;HEX HD;STL;GR x 4 1 11 4 01 Each P250002-0012-39
10067042-001/01@RSOne-BOLT-M10X1.50X70mm;SKT CAP;DIN91 x 8 1 12 8 01 Each P250002-0012-63
10067833-001/01@RSOne-BOLT-M12X1.75X70MM;HEX HD; GR x 12 1 13 12 01 Each P250002-0028-98
10067007-001/01@RSOne-BOLT-M10X1.50X16mm;HEX HD;S/S;GR x 9 1 14 9 01 Each P250002-0012-09
10067928-001/01@RSOne-BOLT-M10X1.5X35mm;HEX HD;S/S; GR x 9 1 16 9 01 Each P250002-0030-60
10067380-001/01@RSOne-BOLT-M6X1.00X30MM;HEX HD;S/S; GR x 6 1 17 6 01 Each P250002-0020-77
10067770-001/01@RSOne-BOLT-M6X1X40MM;HEX HD;S/S;GR A4 x 15 1 18 15 01 Each P250002-0027-15
10067481-001/01@RSOne-BOLT-M12X1.75X65MM;HEX HD;S/S;GR x 15 1 23 15 01 Each P250002-0022-80
10067018-001/01@RSOne-BOLT-M12X1.75X80mm;HEX HD;S/S; x 20 1 27 20 01 Each P250002-0012-22
10067781-001/01@RSOne-BOLT-M12X1.75X100MM;HEX HD;S/SGR x 121 28 12 01 Each P250002-0027-37
10067053-001/01@RSOne-NUT-M6X1.00;HEX HD;STL;GR CL8;C/ x 8 1 42 8 01 Each P250002-0012-75
10067019-001/01@RSOne-NUT-LOCK;M6X1.00;HEX HD;S/S; GR x 30 1 44 30 01 Each P250002-0012-23
10067050-001/01@RSOne-WASHER-FLAT;M6;STL;GR DIN125; ZI x 90 1 63 90 01 Each P250002-0012-71
10067034-001/01@RSOne-WASHER-FLAT;M10;STL;GR DIN125;ZI x 12 1 65 12 01 Each P250002-0012-48
10067025-001/01@RSOne-WASHER-FLAT,M10,S/S,GR A4 x 24 1 66 24 01 Each P250002-0012-33
10067023-001/01@RSOne-WASHER-FLAT;M6;S/S;GR A4 x 54 1 67 54 01 Each P250002-0012-31
10067059-001/01@RSOne-WASHER-BELLEVILLE,M10,S/S,GR A x 18 1 80 18 01 Each P250002-0012-82
10067057-001/01@RSOne-WASHER-BELLEVILLE;M6;S/S;GR A4OD x 60 1 81 60 01 Each P250002-0012-80
10067060-001/01@RSOne-WASHER-BELLEVILLE;M12;S/S;GR A4; x 244 1 83 244 01 Each P250002-0012-83
10067044-001/01@RSOne-WASHER-LOCK;M6;DIN127B;SPLIT TY x 81 1 91 81 01 Each P250002-0012-65
FINAL DOCUMENTATION
Section 2.2
Data
www.nov.com
CHAPTER 2 INDEX 2.2

8434 DATA
DOCUMENT NUMBER REV
10707934-IDX 01
www.nov.com
Revision 01
Page 2
2.2 EQUIPMENT DATA
HAMMOND XFMR RoHS 10621832-CER 01 D01

DECLARATION
HAMMOND COLD START 10621832-PRO 01 D01
PROCEDURE
HAMMOND XFMR EC 10621892-CER 01 D01
DECLARATION
ABB - EMAX - TECHNICAL 1SDC200006D0202 01 D01
CATALOGUE
EMAX DC LOW VOLTAGE 1SDC200012D0201 01 D01
SWITCH
TMAX T4-T5 T GENERATION 1SDC210004B0202 01 D01
TMAX T4 INSTALLATION 1SDH000436R0.001-L0501 01 D01

MANUAL
ABB E-MAX CB INSTRUCTION 1SDH000460R0002-L2234 02 D01
MANUAL
RDCO-DDCS COMMUNICATION 3AFE64492209 A D01
PROFIBUS-DP ADAPTER 3AFE64504215 F D01

MODULE
ACS800 STANDARD CONTROL 3AFE64527592 I D01
PROGRAM
ACS-800 MASTER/FOLLOWER 3AFE64590430 A D01
GUIDE
ACS800 MULTI DRIVE 3AFE64783742 C D01
INSTALLATION
ACS800-104 INVERTER MODULE 3AFE64809032 E D01
ABB ELECTRONIC DELAY 601933/616 01 D01
1000KVA XFMR B201581 0 D01

600:480,3PH,50/60HZ
BRAKING RESISTOR D25T&B RESISTOR-CAL-001 01 D01
CALCULATION
RESISTOR BANK DATASHEET D25T&B RESISTOR-DAS-001 03 D01
WATER TEST FOR RESISTOR D25T&B RESISTOR-REP-001 01 D01

BANK
www.nov.com
Revision 01
Page 3
2.2 EQUIPMENT DATA
1000KVA XFMR EDB201581 0 D01

600:480,3PH,50/60HZ
112.5KVA XFMR EDB201586 0 D01
600:208/120,3PH,50
DRILLING RIG & MARINE CABLE EXANE-125 01 D01
CH-FREEDOM 2100 MCC IB8926-1A 01 D01

MANUAL
HAMMOND XFMR UP TO 750KVA IOMGDD1 02 D01
XFMR
HAMMOND XFMR IOMGPOW 02 D01
INSTALLATION,
RES-1200KW RESISTOR BANK LB0036 08 D01
W/304
SAFETY&INSTRUCTION MANUAL LB0036-MAN 01 D01
HAMMOND XFMR SEISMIC OSH-FDD759 01 D01

APPROVAL
RDCU HARDWARE MANUAL RDCU C D01
www.nov.com
NOV PART NO.:
10621832-CER
RoHS Declaration
Hammond Transformer RoHS

Declaration Certificate of Compliance
REFERENCE CUSTOMER
Transformer Hammond
This document contains proprietary and/or confidential

information of National Oilwell Varco (NOV). It is loaned for National Oilwell Varco
limited purposes only. Any reproduction, in whole or in part, or
use, or disclosure of the contents to others shall be in Rig Solutions
accordance with the terms and conditions agreed upon with 11000 Corporate Centre Drive
NOV. Any use, reproduction, or disclosure beyond the terms Suite 200
and conditions of the release is prohibited without the express Houston, Texas 77041
written consent of NOV. The burden of proof that NOV consent U.S.A
has been issued within the provisions of this paragraph lies
with the recipient. This document is to be returned to NOV or Phone +1-281-854-0400
its destruction certified upon request by NOV and in any event Fax +1-281-854-0607
upon completion of the use for which it was loaned. Except for
the limited purposes agreed upon between NOV and the
recipient, no licenses or other rights are granted or conferred
upon recipient, expressly, implied or otherwise, under any of
NOV’s patents, trademarks, trade secrets, copyrights, or other
intellectual property rights. All rights pertaining to this
document and its contents are expressly reserved and
retained by NOV. ©National Oilwell Varco, all rights reserved.
DOCUMENT NUMBER REV
10621832-CER 01
www.nov.com
Document number 10621832-CER
Revision 01
Page 2
REVISION HISTORY
01 07.11.2011 For Information RA BD BD

www.nov.com
January 1, 2006
Certificate of Compliance – RoHS Declaration
Hammond Power Solutions Inc. is an environmentally responsible company.

Hammond Power Solutions Inc. is in compliance with the Restriction of the
use of Certain Hazardous Substances (RoHS) in electrical and electronic
equipment in accordance with:
Directive 2002/95/EC of the European Parliament and the Council of

January 27, 2003
Jeff Perry
Jeff Perry
Manufacturing Engineer
595 Southgate Drive, Guelph, Ontario N1G 3W6

Phone: (519) 822-2441 Fax: (519) 822-9701 Web Site: www.hammondpowersolutions.com
NOV PART NO.:
10621832-PRO
Cold Start Procedure
Hammond Transformer Cold Start

Procedure
REFERENCE CUSTOMER
Transformer Hammond

DOCUMENT NUMBER REV
10621832-PRO 01
www.nov.com
Document number 10621832-PRO
Revision 01
Page 2
REVISION HISTORY

www.nov.com
Cold Start Procedure:
• Minimum ambient temperature designed for is -40C based on

Environment Canada data Extreme Minimum Temperatures for Wiarton
ON (-36.4C on 18-Jan-1977) and Lucknow ON (-36.7C on 05-Feb-
1918).
• Do not energize transformer if coils are below -40C. You can energize
but not load until minus 25C.
• Use heater strips to warm to -40C.
• Do not load transformer if coils are below -25C.
• Heaters to be switched on and off at customer’s power supply.
• Heating time will be reduced if the enclosure ventilation openings are
covered, but they must be open before loading the transformer.
• Provisions to install a temperature probe in each coil is provided.
• Power by others.
1100 Lake Street, Baraboo, Wisconsin 53913

NOV PART NO.:
10621892-CER
EC Declaration of Conformity
Hammond Transformer EC Declaration

of Conformity
REFERENCE CUSTOMER
Transformer Hammond

DOCUMENT NUMBER REV
10621892-CER 01
www.nov.com
Document number 10621892-CER
Revision 01
Page 2
REVISION HISTORY

www.nov.com
EC Declaration of Conformity
We, Hammond Power Solutions Inc.
595 Southgate Dr. 1100 Lake St.

Guelph, Ont. Baraboo, Wisconsin
Canada, N1G 3W6 U.S.A., 53913
Declare that the following product;

Model: Type K & J, Three Phase Power, Distribution and Drive Isolation Transformers
Type F & G, Single Phase Power, Distribution and Drive Isolation Transformers
Have been manufactured in accordance with the following European Standards

and Technical specifications:
IEC 60076-11, 2004-05: Power Transformers, Part 11, Dry Type Transformers
And is in conformity with:
The Low Voltage Directive 2006/95/EC
Signed at : Guelph, Ontario, Canada

on the 4th day of Feb. 2009
Signature
Name: Watson Wong

Senior Electrical Designer
R&D Engineering
595 Southgate Drive, Guelph, Ontario N1G 3W6

NOV PART NO.:
1SDC200006D0202
Technical catalogue Emax
Low voltage air circuit-breakers
Preliminary - 1SDC200006D0202
The new Emax air circuit-breakers are the result of ABB
SACE’s constant commitment to look for new solutions, and
of the know-how it has developed over the years. This is an incredibly innovative high quality
circuit-breakers range, designed to satisfy all application requirements. The innovation of the new
Emax is really outstanding from all points of view: completely re-engineered releases fitted with
latest generation electronics, improved performances with the same dimensions and new applications
to fulfil the latest market needs. The new electronics open a window on a world of extraordinary
solutions, with connectivity options never before seen in the market. Discover the great advantages
of ABB SACE’s new Emax. The evolution has been going on since 1942.
Continuing the tradition of ABB SACE, the new Emax range offers
performances at the top of its category. The Emax range offers you a great
advantage: with the increased performances, you can use the smaller
circuit-breaker frames, obtaining considerable savings both in
economic terms and in physical space within the switchgear. Emax E1
now offers current ratings up to 1600A, whilst Emax E3 is enhanced
by version V with top of the range performances. Always aware of
the rapid changes in the market, ABB SACE has made some specific
versions to cover new applications and simplify retrofitting
operations.
The new Emax range shines like a light from within: the new generation of protection releases is
fitted with the latest advances in electronics, offering individual bespoke solutions for control and
protection. The new releases, which are amazingly versatile and simple
to use, offer important innovations, such as the brand-new intuitive
operator interface allowing complete control of the system with
just a few simple keystrokes. Furthermore, there are new
protections, new alarms and connection to handheld and
laptop PCs using Bluetooth technology. The re-
engineered hardware architecture allows flexible and
precise configuration. With the new Emax it is no longer
necessary to completely replace the release - simply add
the module which satisfies your requirements: a great
advantage, both in terms of flexibility and customisation.
The new Emax have received innumerable
international certifications and approval by
the major shipping registers.
Careful selection of materials, meticulous assembly and a rigorous testing stage make the new Emax
an extremely reliable and sturdy product, able to
withstand high dynamic and thermal stresses for
longer than any other circuit-breaker in its
category. With the new standardised system
of accessories studied and made for the new
Emax, work becomes easier, convenient, safe
and rapid. Furthermore, ABB SACE puts a
highly specialised and rapid customer
assistance service at your disposal. The new
Emax give you that pleasant feeling of security
which only such a reliable product is able to do.
Main characteristics
Contents
Overview of the SACE Emax family
Fields of application ............................................................................................................. 1/2
Construction characteristics
Structure of the circuit-breakers .......................................................................................... 1/4
Operating mechanism .......................................................................................................... 1/5
Operating and signalling parts ............................................................................................ 1/6
Fixed parts of withdrawable circuit-breakers ...................................................................... 1/7
Utilization category ............................................................................................................... 1/8
Versions and connections ................................................................................................ 1/9
Electronic releases
General characteristics ...................................................................................................... 1/10
Versions available ................................................................................................................ 1/12
Rating plugs ......................................................................................................................... 1/13
Compliance with Standards
Standards, approvals and certifications .............................................................................. 1/14
A design dedicated to Quality and respect for the environment ........................................ 1/15
ABB SACE 1/1

Overview of the SACE Emax family
Fields of application
E1 E2
Automatic circuit-breakers E1B E1N E2B E2N E2S E2L
Poles [No.] 3-4 3-4
4p c.-b neutral current-carrying capacity [% Iu] 100 100
Iu (40 °C) [A] 800-1000- 800-1000- 1600-2000 1000-1250- 800-1000- 1250-1600
1250-1600 1250-1600 1600-2000 1250-1600-
2000
1 Ue [V~] 690 690 690 690 690 690
Icu (220...415V) [kA] 42 50 42 65 85 130
Ics (220...415V) [kA] 42 50 42 65 85 130
Icw (1s) [kA] 42 50 42 55 65 10
(3s) [kA] 36 36 42 42 42 –
Automatic circuit-breakers with full-size neutral conductor

Poles [No.] Standard version Standard version
4p c.-b neutral current-carrying capacity [% Iu]
Iu (40 °C) [A]
Ue [V~]
Icu (220...415V) [kA]
Ics (220...415V) [kA]
Icw (1s) [kA]
(3s) [kA]
Switch-disconnectors E1B/MS E1N/MS E2B/MS E2N/MS E2S/MS

Poles [No.] 3-4 3-4 3-4 3-4 3-4
Iu (40 °C) [A] 800-1000- 800-1000- 1600-2000 1000-1250- 1000-1250-
1250-1600 1250-1600 1600-2000 1600-2000
Ue [V~] 690 690 690 690 690
Icw (1s) [kA] 42 50 42 55 65
(3s) [kA] 36 36 42 42 42
Icm (220...440V) [kA] 88.2 105 88.2 121 143
Automatic circuit-breakers for applications up to 1150 V AC E2B/E E2N/E

Poles [No.] 3-4 3-4
Iu (40 °C) [A] 1600-2000 1250-1600-
2000
Ue [V~] 1150 1150
Icu (1150V) [kA] 20 30
Ics (1150V) [kA] 20 30
Icw (1s) [kA] 20 30
Switch-disconnectors for applications up to 1150 V AC E2B/E MS E2N/E MS

Poles [No.] 3-4 3-4
Iu (40 °C) [A] 1600-2000 1250-1600-
2000
Ue [V~] 1150 1150
Icw (1s) [kA] 20 30
Icm (1000V) [kA] 40 63
Switch-disconnectors for applications up to 1000 V DC E1B/E MS E2N/E MS

Poles [No.] 3-4 3-4
Iu (40 °C) [A] 800-1250 1250-1600-2000
Ue [V-] 750 (3p)-1000(4p) 750 (3p)-1000(4p)
Icw (1s) [kA] 20 25
Icm (750V) [kA] 42 52.5
(1000V) [kA] 42 52.5
Sectionalizing truck E1 CS E2 CS
Iu (40 °C) [A] 1250 2000
Earthing switch with making capacity E1 MTP E2 MTP

Iu (40 °C) [A] 1250 2000
Earthing truck E1 MT E2 MT
Iu (40 °C) [A] 1250 2000
(*) The performance at 1000V is 50kA.
1/2 ABB SACE

E3 E4 E6
E3N E3S E3H E3V E3L E4S E4H E4V E6H E6V
3-4 3-4 3-4
100 50 50
1000-1250- 800-1000-1250- 800-1250-
1600-2000- 1600-2000- 1600-2000- 4000- 3200-4000-
2500-3200 2500-3200 2500-3200 2500-3200 2000-2500 4000 3200-4000 3200-4000 5000-6300 5000-6300
690 690 690 690 690 690 690 690 690 690 1
65 75 100 130 130 75 100 150 100 150
65 75 85 100 130 75 100 150 100 125
65 75 75 85 15 75 100 100 100 100
65 65 65 65 – 75 75 75 85 85
E4S/f E4H/f E6H/f

Standard version 4 4 4
100 100 100
4000 3200-4000 4000-5000-6300
690 690 690
80 100 100
80 100 100
80 85 100
75 75 100
E3N/MS E3S/MS E3V/MS E4S/MS E4H/MS E4H/f MS E6H/MS E6H/f MS

3-4 3-4 3-4 3-4 3-4 4 3-4 4
1000-1250-1600- 800-1250-1600- 4000-5000- 4000-5000-
2500-3200 2000-2500-3200 2000-2500-3200 4000 3200-4000 3200-4000 6300 6300
690 690 690 690 690 690 690 690
65 75 85 75 100 85 100 100
65 65 65 75 75 75 85 85
143 165 286 165 220 220 220 220
E3H/E E4H/E E6H/E

3-4 3-4 3-4
1250-1600-2000- 4000-5000
2500-3200 3200-4000 6300
1150 1150 1150
30 (*) 65 65
30 (*) 65 65
30 (*) 65 65
E3H/E MS E4H/E MS E6H/E MS

3-4 3-4 3-4
1250-1600-2000- 4000-5000
2500-3200 3200-4000 6300
1150 1150 1150
50 65 65
105 143 143
E3H/E MS E4H/E MS E6H/E MS

3-4 3-4 3-4
1250-1600-2000-2500-3200 3200-4000 4000-5000-6300
750 (3p)-1000(4p) 750 (3p) - 1000 (4p) 750 (3p) - 1000 (4p)
40 65 65
105 143 143
105 143 143
E3 CS E4 CS E6 CS
3200 4000 6300
E3 MTP E4 MTP E6 MTP

3200 4000 6300
E3 MT E4 MT E6 MT
3200 4000 6300
ABB SACE 1/3

Structure of the circuit-breakers
The sheet steel structure of the Emax air circuit-breaker is ex-

tremely compact, considerably reducing overall dimensions.
Safety is improved by using double insulation of the live parts
and total segregation between phases.
The sizes have the same height and depth for all the circuit-
breakers in each version.
The depth of the withdrawable version is suitable for installation
1 in switchgear 500 mm deep.
The width of 324 mm (up to 2000 A) in the withdrawable version
allows the apparatus to be used in switchgear compartments
400 mm wide. Their compact dimensions also mean they can
replace air circuit-breakers of any size from earlier series.
1SDC200019F0001
1SDC200018F0001
1/4 ABB SACE

Operating mechanism
The operating mechanism is of the stored energy type, oper-

ated using pre-charged springs.
The springs are charged manually by operating the front lever
or using a geared motor, supplied on request.
The opening springs are charged automatically during the clos-
ing operation.
With the operating mechanism fitted with shunt closing and
opening releases and the geared motor for charging the springs, 1
the circuit-breaker can be operated by remote control and, if
required, co-ordinated by a supervision and control system.
➁ OPENING ➀ OPENING
➂ OPENING
➀ CLOSING ➁ CLOSING
1SDC200020F0001
1SDC200021F0001
The following operating cycles are possible without recharging
the springs:
– starting with the circuit-breaker open (0) and the springs
charged:
closing-opening
– starting with the circuit-breaker closed (I) and the springs
charged:
opening-closing-opening.
The same operating mechanism is used for the entire series
and is fitted with a mechanical and electrical anti-pumping
device.
ABB SACE 1/5

Operating and signalling parts
Caption
Fixed version
1 Trademark and size of circuit-
breaker
2 SACE PR121, PR122 or PR123
release
13
1 3 Pushbutton for manual
opening
4 Pushbutton for manual
2 closing
5 Lever to manually charge
closing springs
3 4 6 Electrical rating plate
7 Mechanical device to signal
1 circuit-breaker open “O” and
closed “I”
9 8 Signal for springs charged or
discharged
9 Mechanical signalling of
5 overcurrent releases tripped
10 Key lock in open position
11 Key lock and padlock in racked-
7 8 in/racked-out position (for
withdrawable version only)
12 Racking-in/out device (for
6 13 Terminal box (for fixed version
only)
1SDC200032F0001
14 Sliding contacts (for withdraw-

able version only)
15 Circuit-breaker position
indicator: racked-in/ test isolated
/racked-out / connected/test
isolated/disconnected (for
Withdrawable version Note:

“Racked-in” refers to the position in which
both the power contacts and auxiliary
contacts are connected; “racked-out” is the
position in which both the power contacts
and auxiliary contacts are disconnected;
“test isolated” is the position in which the
power contacts are disconnected, whereas
the auxiliary contacts are connected.
1SDC200033F0001
14
3 4
10
5
8
7
6
15
11 12
1/6 ABB SACE

Fixed parts of withdrawable circuit-breakers
The fixed parts of withdrawable circuit-breakers have shutters

for segregating the fixed contacts when the circuit-breaker is
withdrawn from the compartment. These can be locked in their
closed position using padlock devices.
Caption
1 Sheet steel supporting
structure 1
2 Single earthing clamp
mounted on the left for E1, E2
and E3, double earthing
clamps for E4 and E6
3 Safety shutters (protection
rating IP20)
4 Terminal support base
5 Terminals (rear, front or flat)
6 Contacts signalling that the
circuit-breaker is racked-in,
test isolated, racked-out
7 Sliding contacts
8 Padlock device for safety
shutters (on request)
9 Fastening points (4 for E1, E2,
E3 and 6 for E4, E6)
7
6
1 4
5
3
1SDC200022F0001
ABB SACE 1/7

Utilization category
Selective and current-limiting circuit-breakers

Selective (non current-limiting) circuit-breakers are classified
in class B (according to the IEC 60947-2 Standard). It is impor-
tant to know their Icw values in relation to any possible delayed
1 trips in the event of short-circuits.
The current-limiting circuit-breakers E2L and E3L belong to

class A. The short-time withstand current Icw is not very impor-
tant for these circuit-breakers, and is necessarily low due to the
operating principle on which they are based. The fact that they
belong to class A does not preclude the possibility of obtaining
the necessary selectivity (e.g. current-type or time-type selec-
tivity).
The special advantages of current-limiting circuit-breakers
should also be underlined. In fact, they make it possible to:
– significantly reduce the peak current in relation to the pro-
spective value;
– drastically limit specific let-through energy.
The resulting benefits include:
– reduced electrodynamic stresses;
– reduced thermal stresses;
– savings on the sizing of cables and busbars;
– the possibility of coordinating with other circuit-breakers in
the series for back-up or discrimination.
9 8 7 6b 6a 9 8 7 6
Caption
1 Sheet steel supporting
structure
1SDC200023F0001
1SDC200024F0001
2 Current transformer for

protection release
3 Pole group insulating box
5b 4 Horizontal rear terminals
5-5a Plates for fixed main
5a 5 contacts
5b Plates for fixed arcing
2 2 contacts
10 10 6-6a Plates for main moving
4 4 contacts
6b Plates for moving arcing
contacts
3 3 7 Arcing chamber
11 11 8 Terminal box for fixed
1 1 version - Sliding contacts
for withdrawable version
9 Protection release
Selective circuit-breaker Current-limiting circuit-breaker 10 Circuit-breaker closing and
opening control
E1 B-N, E2 B-N-S, E3 N-S-H-V, E2 L, E3 L
11 Closing springs
E4 S-H-V, E6 H-V
1/8 ABB SACE

Versions and connections
All the circuit-breakers are available in fixed and withdrawable,

three-pole or four-pole versions.
Each series of circuit-breakers offers terminals made of silver-
plated copper bars, with the same dimensions, regardless of
the rated currents of the circuit-breakers.
The fixed parts for withdrawable circuit-breakers are common
to each model, regardless of the rated current and breaking
capacity of the relative moving parts, except for the E2S circuit- 1
breaker which requires a specific fixed part.
A version with gold-plated terminals is available for special re-
quirements, linked to use of the circuit-breakers in corrosive
environments.
The availability of various types of terminals makes it possible
to build wall-mounted switchgear, or switchgear to be accessed
from behind with rear connections.
For special installation needs, the circuit-breakers can be fitted
with various combinations of top and bottom terminals.
Furthermore new dedicated terminal conversion kits give Emax
maximum flexibility, allowing horizontal terminals to be changed
to vertical or front ones and vice versa.
Fixed circuit-breaker
1SDC200025F0001
1SDC200026F0001
1SDC200027F0001
Horizontal rear terminals Vertical rear terminals Front terminals
Withdrawable circuit-breaker
1SDC200028F0001
1SDC200029F0001
1SDC200030F0001
1SDC200031F0001
Horizontal rear terminals Vertical rear terminals Front terminals Flat terminals
ABB SACE 1/9

Electronic releases
General characteristics
The overcurrent protection for AC installations uses three types of electronic release series:
PR121, PR122 and PR123.
The basic series, PR121, offers the whole set of standard protection functions, complete with a
user-friendly interface.
It allows discrimination of which fault caused the trip by means of the new led indications.
PR122 and PR123 releases are of new concept modular architecture. It is now possible to have
a complete series of protections, accurate measurements, signalling or dialogue functions, de-
1 signed and customisable for all application requirements.
The protection system is made up of:
• 3 or 4 new generation current sensors (Rogowsky coil);
• external current sensors (i.e. for external neutral, residual current or source ground return
protection);
• a protection unit selected among PR121/P, PR122/P or PR123/P with optional communication
module via Modbus or Fieldbus plug network (PR122/P and PR123/P only), as well as via a
wireless connection;
• an opening solenoid, which acts directly on the circuit-breaker operating mechanism (sup-
plied with the protection unit).
1SDC200034F0001
1/10 ABB SACE

General specifications of the electronic releases include:
• operation without the need for an external power supply
• microprocessor technology
• high precision
• sensitivity to the true R.M.S. value of the current
• trip cause indication and trip data recording
• interchangeability among all types of releases
• setting for neutral configurable: 1
– OFF-50%-100%-200% of phase setting for circuit-breakers E1, E2, E3 and E4/f,
E6/f full-size versions, and E4-E6 with external neutral protection;
– OFF-50% for standard E4 and E6.
The main performance features of the releases are listed below.
PR121
PR121/P PR121/P PR121/P

Protection
PR122
PR122/P PR122/P PR122/P PR122/P

Protection Rc
For all versions U OT M
New modules available:

Measuring opt. UV OV RV RP UF OF
Communication opt.
Signalling opt.
Bluetooth (wireless link) opt.
PR123
PR123/P PR123/P
Protection
For all versions OT D U UV OV RV RP M UF OF
New modules available:

Communication opt.
Signalling opt.
Bluetooth (wireless link) opt.
ABB SACE 1/11

Electronic releases
Versions available
Features
Protection functions PR121 PR122 PR123
Protection against overload with
inverse long time-delay trip ■ ■ ■
Selective protection against short-circuit inverse
or definite short time-delay trip ■ ■ ■
Second selective protection against short-circuit inverse
1 or definite short time-delay trip ■
Protection against instantaneous short-circuit
with adjustable trip current threshold ■ ■ ■
Protection against earth fault residual ■ ■ ■
source ground return ■ ■
Residual current (1)
opt.(2) ■
Rc
D Protection against directional short-circuit with adjustable time-delay ■
U Protection against phase unbalance ■ ■
OT Protection against overtemperature (check) ■ ■
UV Protection against undervoltage opt.(3) ■
OV Protection against overvoltage opt.(3) ■
RV Protection against residual voltage opt.(3) ■
RP Protection against reverse active power opt.(3) ■
M Thermal memory for functions L and S ■ ■
UF Underfrequency opt.(3) ■
OF Overfrequency opt.(3) ■
Measurements
Currents (phases, neutral, earth fault) ■ ■
Voltage (phase-phase, phase-neutral, residual) opt.(3) ■
Power (active, reactive, apparent) opt.(3) ■
Power factor opt.(3) ■
Frequency and peak factor opt.(3) ■
Energy (active, reactive, apparent, meter) opt.(3) ■
Harmonics calculation (display of wave forms and harmonics module) ■
Event marking and maintenance data

Event marking with the instant it occurred opt.(4) ■ ■
Chronological event storage opt.(4) ■ ■
Counting the number of operations and contact wear ■ ■
Communication with supervision system and centralised control

Remote parameter setting of the protection functions, unit configuration, communication opt.(5) opt.(5)
Transmission of measurements, states and alarms from circuit-breaker to system opt.(5) opt.(5)
Transmission of the events and maintenance data from circuit-breaker to system opt.(5) opt.(5)
Watchdog
Alarm and trip for release overtemperature ■ ■
Check of release status ■ ■ ■
Interface with the user

Presetting parameters by means of dip switches ■
Presetting parameters by means of keys and LCD viewer ■ ■
Alarm signals for functions L, S, I and G ■ ■ ■
Alarm signal of one of the following protections: undervoltage, overvoltage,
residual voltage, active reverse of power, phase unbalance, overtemperature opt.(3) ■
Complete management of pre-alarms and alarms for all the self-control protection functions ■ ■
Enabling password for use with consultation in “READ” mode
or consultation and setting in “EDIT” mode ■ ■
Load control
Load connection and disconnection according to the current passing through the circuit-breaker ■ ■
Zone selectivity
Can be activated for protection functions S, G and (PR123 only) D ■ ■
(1) requires a homopolar toroid for residual current protection; (2) the RC function is available with PR122LSIRc or with PR122LSIG and module PR120/V; (3) with PR120/V;
(4) with BT030 communication unit; (5) with PR120/D-M
1/12 ABB SACE
Electronic releases
Rating plugs
A new concept for setting the current ratings
Rating plugs
Type of Rated In [A]
circuit-breaker current Iu 400 630 800 1000 1250 1600 2000 2500 3200 4000 5000 6300
800
E1B 1000-1250
1600
1
800
E1N 1000-1250
1600
1600
E2B
2000
1000-1250
E2N 1600
2000
800
1000-1250
E2S
1600
2000
1250
E2L
1600
2500
E3N
3200
1000-1250
1600
E3S
2000
2500
3200
800
1000-1250
1600
E3H 2000
2500
3200
800
1250
1600
E3V
2000
2500
3200
2000
E3L
2500
E4S, E4S/f 4000
3200
E4H, E4H/f
4000
3200
E4V
4000
4000
E6H, E6H/f 5000
6300
3200
4000
E6V
5000
6300
ABB SACE 1/13

Standards, approvals and certifications
SACE Emax circuit-breakers and their accessories conform to

the international IEC 60947, EN 60947 (harmonized in 28
CENELEC countries), CEI EN 60947 and IEC 61000 Standards,
and comply with following EC directives:
– “Low Voltage Directive” (LVD) no 73/23 EEC
– “Electromagnetic Compatibility Directive” (EMC) nr. 89/336
EEC.
1 The main versions of the apparatus are approved by the follow-
ing Shipping Registers:
– RINA (Italian Naval Register)
– Det Norske Veritas
– Bureau Veritas
– Germanischer Lloyd
– Loyd’s Register of Shipping
– Polskj Rejestr Statkow
– ABS (American Bureau of Shipping)
– RMRS (Russian Maritime Register of Shipping)
– NK (Nippon Kaiji Kyokai)
The Emax series also has a range which has undergone certifi-
cation according to the severe American UL 1066 Standards.
Furthermore, the Emax series is certified by the Russian GOST
(Russia Certificate of Conformity) certification organization, and
is certified by China CCC (China Compulsory Certification)
Certification of conformity with the aforementioned product

Standards is carried out in compliance with European Standard
EN 45011 by the Italian certification body ACAE (Associazione
per la Certificazione delle Apparecchiature Elettriche - Asso-
Note: Contact ABB SACE for a list of ciation for Certification of Electrical Apparatus), recognized by
approved types of circuit-breakers,
approved performance data and the
the European organization LOVAG (Low Voltage Agreement
corresponding validity Group).
1/14 ABB SACE

A design dedicated to Quality and respect
for the environment
Quality, environment, health and safety have always been ABB SACE’s major commitment. This
commitment involves every function of the company, and has allowed us to achieve prestigious
recognition internationally.
The company’s quality management system is certified by RINA, one of the most prestigious
international certification boards, and complies with ISO 9001-2000 Standards; the ABB SACE
test facility is accredited by SINAL; the plants in Frosinone, Patrica, Vittuone and Garbagnate
Monastero are also certified in compliance with ISO 14001 and OHSAS 18001 standards for 1
health and safety in the workplace.
ABB SACE, Italy’s first industrial company in the electro-mechanical sector to achieve this, has
been able to reduce its raw material consumption and machining scrap by 20% thanks to an
ecology-centred revision of its manufacturing process. All of the company’s Divisions are in-
volved in streamlining raw material and energy consumption, preventing pollution, limiting noise
pollution and reducing scrap resulting from manufacturing processes, as well as in carrying out
1SDC200039F0001
periodic environmental audits of leading suppliers.
ABB SACE is committed to environmental protection, as is also evidenced by the Life Cycle
Assessments (LCA) of products carried out at the Research Centre: this means that assess-
ments and improvements of the environmental performance of products throughout their life
cycle are included right from the
initial engineering stage. The
materials, processes and pack-
aging used are chosen with a
view to optimising the actual en-
vironmental impact of each prod-
uct, including its energy effi-
ciency and recyclability.
ABB SACE 1/15

The Ranges
Contents
SACE Emax automatic circuit-breakers ........................................................................... 2/2
2
Automatic circuit-breakers with full-size neutral conductor ....................................... 2/4
Switch-disconnectors ....................................................................................................... 2/5
Automatic circuit-breakers for applications up to 1150V AC ...................................... 2/6
Switch-disconnectors for applications up to 1150V AC ............................................... 2/7
Switch-disconnectors for applications up to 1000V DC .............................................. 2/8
Sectionalizing truck ........................................................................................................... 2/9
Earthing switch with making capacity ............................................................................ 2/10
Earthing truck ..................................................................................................................... 2/11
Other versions .................................................................................................................... 2/11
ABB SACE 2/1

SACE Emax automatic circuit-breakers
Common data
Voltages
1SDC200076F0001
1SDC200077F0001
Rated service voltage Ue [V] 690 ~
Rated insulation voltage Ui [V] 1000
Rated impulse withstand
voltage Uimp [kV] 12
Operating temperature [°C] -25....+70
Storage temperature [°C] -40....+70
Frequency f [Hz] 50 - 60
Number of poles 3-4
Versions Fixed - Withdrawable
E1 E2
2 Performance levels B N B N S L
Currents: rated uninterrupted current (at 40 °C) Iu [A] 800 800 1600 1000 800 1250
[A] 1000 1000 2000 1250 1000 1600
[A] 1250 1250 1600 1250
[A] 1600 1600 2000 1600
[A] 2000
[A]
[A]
Neutral pole current-carrying capacity for 4-pole CBs [%Iu]
100 100 100 100 100 100
Rated ultimate breaking capacity under short-circuit Icu
220/230/380/400/415 V ~ [kA] 42 50 42 65 85 130
440 V ~ [kA] 42 50 42 65 85 110
500/525 V ~ [kA] 42 50 42 55 65 85
660/690 V ~ [kA] 42 50 42 55 65 85
Rated service breaking capacity under short-circuit Ics
220/230/380/400/415 V ~ [kA] 42 50 42 65 85 130
440 V ~ [kA] 42 50 42 65 85 110
500/525 V ~ [kA] 42 50 42 55 65 65
660/690 V ~ [kA] 42 50 42 55 65 65
Rated short-time withstand current Icw (1s) [kA] 42 50 42 55 65 10
(3s) [kA] 36 36 42 42 42 –
Rated making capacity under short-circuit (peak value) Icm
220/230/380/400/415 V ~ [kA] 88.2 105 88.2 143 187 286
440 V ~ [kA] 88.2 105 88.2 143 187 242
500/525 V ~ [kA] 75.6 75.6 84 121 143 187
660/690 V ~ [kA] 75.6 75.6 84 121 143 187
Utilisation category (according to CEI EN 60947-2) B B B B B A
Isolation behaviour (according to CEI EN 60947-2) ■ ■ ■ ■ ■ ■
Overcurrent protection
Electronic releases for AC applications ■ ■ ■ ■ ■ ■
Operating times
Closing time (max) [ms] 80 80 80 80 80 80
Breaking time for I<Icw (max) (1) [ms] 70 70 70 70 70 70
Breaking time for I>Icw (max) [ms] 30 30 30 30 30 12
Overall dimensions
Fixed: H = 418 mm - D = 302 mm L (3/4 poles) [mm] 296/386 296/386
Withdrawable: H = 461 mm - D = 396.5 mm L (3/4 poles) [mm] 324/414 324/414
Weights (circuit-breaker complete with releases and CS, excluding accessories)
Fixed 3/4 poles [kg] 45/54 45/54 50/61 50/61 50/61 52/63
Withdrawable 3/4 poles (including fixed part) [kg] 70/82 70/82 78/93 78/93 78/93 80/95
(1) Without intentional delays; (2) The performance at 600V is 100kA.
E1 B-N E2 B-N-S E2 L
Rated uninterrupted current (at 40 °C) Iu [A] 800 1000-1250 1600 800 1000-1250 1600 2000 1250 1600
Mechanical life with regular ordinary maintenance [No. operations x 1000] 25 25 25 25 25 25 25 20 20
Operation frequency [Operations/hour] 60 60 60 60 60 60 60 60 60
Electrical life (440 V ~) [No. operations x 1000] 10 10 10 15 15 12 10 4 3
(690 V ~) [No. operations x 1000] 10 8 8 15 15 10 8 3 2
Operation frequency [Operations/hour] 30 30 30 30 30 30 30 20 20
2/2 ABB SACE

1SDC200080F0001
1SDC200078F0001
1SDC200079F0001
E3 E4 E6
N S H V L S H V H V 2
2500 1000 800 800 2000 4000 3200 3200 4000 3200
3200 1250 1000 1250 2500 4000 4000 5000 4000
1600 1250 1600 6300 5000
2000 1600 2000 6300
2500 2000 2500
3200 2500 3200
3200
100 100 100 100 100 50 50 50 50 50
65 75 100 130 130 75 100 150 100 150

65 75 100 130 110 75 100 150 100 150
65 75 100 100 85 75 100 130 100 130
65 75 85 (2) 100 85 75 85 (2) 100 100 100
65 75 85 100 130 75 100 125 100 125

65 75 85 100 110 75 100 125 100 125
65 75 85 85 65 75 100 130 100 100
65 75 85 85 65 75 85 100 100 100
65 75 75 85 15 75 100 100 100 100
65 65 65 65 – 75 75 75 85 85
143 165 220 286 286 165 220 330 220 330
143 165 220 286 242 165 220 330 220 330
143 165 187 220 187 165 220 286 220 286
143 165 187 220 187 165 187 220 220 220
B B B B A B B B B B
■ ■ ■ ■ ■ ■ ■ ■ ■ ■
■ ■ ■ ■ ■ ■ ■ ■ ■ ■
80 80 80 80 80 80 80 80 80 80
70 70 70 70 70 70 70 70 70 70
30 30 30 30 12 30 30 30 30 30
404/530 566/656 782/908

432/558 594/684 810/936
66/80 66/80 66/80 66/80 72/83 97/117 97/117 97/117 140/160 140/160
104/125 104/125 104/125 104/125 110/127 147/165 147/165 147/165 210/240 210/240
E3 N-S-H-V E3 L E4 S-H-V E6 H-V

800 1000-1250 1600 2000 2500 3200 2000 2500 3200 4000 3200 4000 5000 6300
20 20 20 20 20 20 15 15 15 15 12 12 12 12
60 60 60 60 60 60 60 60 60 60 60 60 60 60
12 12 10 9 8 6 2 1.8 7 5 5 4 3 2
12 12 10 9 7 5 1.5 1.3 7 4 5 4 2 1.5
20 20 20 20 20 20 20 20 10 10 10 10 10 10
ABB SACE 2/3

Automatic circuit-breakers with full-size neutral
conductor
The Emax range of automatic circuit-breakers with full-size neutral conductor is used in special
applications where the presence of third harmonics on individual phases can lead to a very high
current on the neutral conductor.
1SDC200058F0001
Typical applications include installations with loads having high harmonics distortion (comput-
ers and electronic devices in general), lighting systems with a large number of fluorescent
lamps, systems with inverters and rectifiers, UPS, and systems for adjusting the speed of elec-
tric motors.
This range includes standard circuit-breakers with full-size neutral conductor in sizes E1, E2,
E3. Models E4 and E6 are available in the “Full size” version up to rated currents of 6300A.
Models E4/f and E6/f are available in fixed and withdrawable four-pole versions. These models
can all be fitted with all accessories available for the Emax range, with the exception, on the E6/f
model, of the mechanical interlocks made using flexible wires and 15 external auxiliary contacts,
which are therefore incompatible.
2 All the models can be fitted with all the available versions of electronic protection relays, in the
standard version.
E4S/f E4H/f E6H/f
Rated uninterrupted current (at 40 °C) Iu [A] 4000 3200 4000

[A] 4000 5000
[A] 6300
Number of poles 4 4 4
Rated service voltage Ue [V ~] 690 690 690
220/230/380/400/415 V ~ [kA] 80 100 100
440 V ~ [kA] 80 100 100
500/525 V ~ [kA] 75 100 100
660/690 V ~ [kA] 75 100 100
Rated service breaking capacity under short-circuit Ics
220/230/380/400/415 V ~ [kA] 80 100 100
440 V ~ [kA] 80 100 100
500/525 V ~ [kA] 75 100 100
660/690 V ~ [kA] 75 100 100
Rated short-time withstand current Icw
(1s) [kA] 75 85 100
(3s) [kA] 75 75 85
Rated making capacity under short-circuit (peak value) Icm
220/230/380/400/415 V ~ [kA] 176 220 220
440 V ~ [kA] 176 220 220
500/525 V ~ [kA] 165 220 220
660/690 V ~ [kA] 165 220 220
Utilisation category (according to CEI EN 60947-2) B B B
Behavior on isolation (according to CEI EN 60947-2) ■ ■ ■
Overall dimensions
Fixed: H = 418 mm - D = 302 mm L [mm] 746 746 1034
Withdrawable: H = 461 - D = 396.5 mm L [mm] 774 774 1062
Weights (circuit-breaker complete with releases and CS, excluding accessories)
Fixed [kg] 120 120 165
Withdrawable [kg] 170 170 250
2/4 ABB SACE

Switch-disconnectors
The switch-disconnectors are derived from the corresponding circuit-breakers, of which they
maintain the overall dimensions and the possibility of mounting accessories.
This version only differs from the circuit-breakers in the absence of overcurrent releases.
1SDC200060F0001
The circuit-breaker is available in both fixed and withdrawable, three-pole and four-pole ver-
sions. The switch-disconnectors, identified by the letters “/MS”, can be used according to cat-
egory of use AC-23A (switching motor loads or other highly inductive loads) in accordance with
the IEC 60947-3 Standard. The electrical specifications of the switch-disconnectors are listed in
the table below.
E1B/MS E1N/MS E2B/MS E2N/MS E2S/MS E3N/MS E3S/MS E3V/MS E4S/MS E4H/fMS E4H/MS E6H/MS E6H/f MS
Rated uninterrupted current [A] 800 800 1600 1000 1000 2500 1000 800 4000 3200 3200 4000 4000
(at 40 °C) Iu [A] 1000 1000 2000 1250 1250 3200 1250 1250 4000 4000 5000 5000
[A] 1250 1250 1600 1600 1600 1600 6300 6300
[A] 1600 1600 2000 2000 2000 2000
[A] 2500 2500
[A] 3200 3200
Rated service voltage Ue
[V ~] 690 690 690 690 690 690 690 690 690 690 690 690 690
[V –] 250 250 250 250 250 250 250 250 250 250 250 250 250
Rated insulation voltage Ui
[V ~] 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
Rated impulse withstand
voltage Uimp [kV] 12 12 12 12 12 12 12 12 12 12 12 12 12
Rated short-time
withstand current Icw (1s) [kA] 42 50 (1) 42 55 65 65 75 85 75 85 100 (2) 100 100
(3s) [kA] 36 36 42 42 42 65 65 65 75 75 75 85 85
Rated making capacity under
short-circuit (peak value) Icm
220/230/380/400/415/440 V ~ [kA] 88.2 105 88.2 143 187 143 165 286 165 220 220 220 220
500/660/690 V ~ [kA] 75.6 75.6 88.2 121 143 143 165 220 165 220 187 220 220
Note: the breaking capacity Icu, at the maximum rated use voltage, by means of external protection relay, with 500 ms maximum timing, is
equal to the value of Icw (1s), except:
(1) Icu (1s) = 36kA @ 690V
(2) Icu (1s) = 85kA @ 690V
ABB SACE 2/5

Automatic circuit-breakers for applications
up to 1150V AC
SACE Emax circuit-breakers can be supplied in a special version for rated service voltages up
to 1150 V in AC.
Circuit-breakers in this version are identified by the letters of the standard range (rated service
1SDC200061F0001
voltage up to 690 V AC) plus “/E”, and are derived from the corresponding standard SACE Emax
circuit-breakers. They offer the same versions and accessories as the latter. The SACE Emax
range of circuit-breakers for applications up to 1150V in AC can be either fixed and withdraw-
able, in both three-pole and four-pole versions. SACE Emax/E circuit-breakers are especially
suitable for installation in mines, oil and chemical plants, and for traction. This range of Emax
was tested at a voltage of 1250VAC.
The table below shows the electrical specifications of the range.
E2B/E E2N/E E3H/E E4H/E E6H/E
Rated uninterrupted
current (at 40 °C) Iu [A] 1600 2000 1250 1600 2000 1250 1600 2000 2500 3200 3200 4000 5000 6300
Rated service voltage Ue [V~] 1150 1150 1150 1150 1150 1150 1150 1150 1150 1150 1150 1150 1150 1150
Rated insulation voltage Ui [V~] 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250 1250
Rated ultimate breaking capacity
under short-circuit Icu
1000 V [kA] 20 20 30 30 30 50 50 50 50 50 65 65 65 65
1150 V [kA] 20 20 30 30 30 30 30 30 30 30 65 65 65 65
Rated service breaking capacity
under short-circuit Ics
1000 V [kA] 20 20 30 30 30 50 50 50 50 50 65 65 65 65
1150 V [kA] 20 20 30 30 30 30 30 30 30 30 65 65 65 65
Rated short-time withstand
(*) (*) (*) (*) (*)
current Icw (1s) [kA] 20 20 30 30 30 50 50 50 50 50 65 65 65 65
Rated making capacity under
short-circuit (peak value) Icm
1000 V [kA] 40 40 63 63 63 105 105 105 105 105 143 143 143 143
1150 V [kA] 40 40 63 63 63 63 63 63 63 63 143 143 143 143
(*) 30 kA @ 1150 V
2/6 ABB SACE

Switch-disconnectors for applications
up to 1150V AC
The switch-disconnectors complete the range of apparatus for applications at 1150V in alter-
nating current (AC). These circuit-breakers conform with the IEC 60947-3 Standards.
Circuit-breakers in this version are identified by the letters of the standard range, where the
1SDC200061F0001
rated service voltage is up to 690 V AC, plus “/E”, thus becoming SACE Emax/E MS. They are
derived from the corresponding standard SACE Emax switch-disconnectors.
They are available in the three-pole and four-pole, fixed and withdrawable versions in the same
sizes, with accessory options and installations as per the corresponding standard circuit-break-
ers. All the accessories available for the SACE Emax range can be used. Standard fixed parts
may also be used for circuit-breakers in the withdrawable version. As per the corresponding
automatic version, this range of Emax was tested at a voltage of 1250VAC.
E2B/E MS E2N/E MS E3H/E MS E4H/E MS E6H/E MS
Rated current (at 40 °C) Iu [A] 1600 1250 1250 3200 5000
[A] 2000 1600 1600 4000 6300
[A] 2000 2000
[A] 2500
[A] 3200
Poles 3/4 3/4 3/4 3/4 3/4
Rated service voltage Ue [V] 1150 1150 1150 1150 1150
Rated insulation voltage Ui [V] 1250 1250 1250 1250 1250
Rated impulse withstand voltage Uimp [kV] 12 12 12 12 12
Rated short-time withstand current Icw (1s) [kA] 20 30 30(1) 65 65
Rated making capacity Icm 1150V AC (peak value) [kA] 40 63 63(2) 143 143
Note: The breaking capacity Icu, by means of external protection relay, with 500 ms maximum timing, is equal to the value of Icw (1s).
(1) The performance at 1000V is 50 kA.
(2) The performance at 1000V is 105 kA.
ABB SACE 2/7

Switch-disconnectors for applications
up to 1000V DC
ABB SACE has developed the SACE Emax/E MS range of switch-disconnectors for applications
in direct current up to 1000V in compliance with the international IEC 60947-3 Standard. These
non-automatic circuit-breakers are especially suitable for use as bus ties or main isolators in
1SDC200061F0001
direct current systems, such as in applications involving electric traction.

The range covers all installation needs up to 1000V DC / 6300A.
They are available in fixed and withdrawable, three-pole and four-pole versions.
By connecting three breaking poles in series, it is possible to achieve a rated insulation voltage
of 750V DC, while with four poles in series the limit rises to 1000V DC.
The switch-disconnectors of the SACE Emax/E MS range maintain the overall dimensions and
fixing points of the standard range circuit-breakers. They can be fitted with the various terminal
kits and all the accessories common to the SACE Emax range. They cannot, of course, be
associated with the electronic releases, CSs and accessories for determining currents and for
AC applications.
2 The withdrawable circuit-breakers should be used together with the special version fixed parts
for applications at 750/1000V DC.
E1B/E MS E2N/E MS E3H/E MS E4H/E MS E6H/E MS
[A] 1250 1600 1600 4000 6300
[A] 2000 2000
[A] 2500
[A] 3200
Poles 3 4 3 4 3 4 3 4 3 4
Rated service voltage Ue [V] 750 1000 750 1000 750 1000 750 1000 750 1000
Rated insulation voltage Ui [V] 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
Rated impulse withstand voltage Uimp [kV] 12 12 12 12 12 12 12 12 12 12
(1)
Rated short-time withstand current Icw (1s) [kA] 20 20 25 25(1) 40 40 (1)
65 65 65 65
Rated making capacity Icm 750V DC [kA] 20 20 25 25 40 40 65 65 65 65
1000V DC – 20 – 25 – 40 – 65 – 65
Note: The breaking capacity Icu, by means of external protection relay, with 500 ms maximum timing, is equal to the value of Icw (1s).
(1) The performances at 750 V are:
for E1B/E MS Icw = 25 kA,
for E2N/E MS Icw = 40 kA and
for E3H/E MS Icw = 50 kA.
2/8 ABB SACE

Sectionalizing truck
Sectionalizing truck - CS
This version is derived from the corresponding withdrawable circuit-breaker, with replacement
of all the breaking parts and the operating mechanism with simple connections between the top
and bottom isolating contacts.
It is used as a no load isolator where this is required by the system.
2
1SDC200064F0001
1SDC200065F0001
ABB SACE 2/9

Earthing switch with making capacity
Earthing switch with making capacity - MTP

This version is based on the moving part of the corresponding withdrawable circuit-breaker
(without overcurrent releases) and the top or bottom isolating contacts, which are replaced with
connections that short circuit the phases to earth through the circuit-breaker. The earthing switch
is available with top or bottom isolating contacts.
The earthing circuit is dimensioned for a short-time withstand current equal to 60% of the maxi-
mum lcw of the circuit-breaker from which it is derived (IEC 60439-1).
The earthing switch is inserted in the fixed part of a withdrawable circuit-breaker to earth the top
or bottom terminals before carrying out inspection or maintenance operations in safe conditions
on the external circuit. It should be used in cases where residual or recovery voltages can occur
2 in the installations to be earthed.
1SDC200067F0001
1SDC200068F0001
1SDC200069F0001
1SDC200070F0001
2/10 ABB SACE

Earthing truck
Other versions
Earthing truck- MT
This version is similar to the sectionalizing truck, but with the bottom or top isolating contacts
replaced by short-circuited, earthed connections. The earthing truck is available with bottom or
top isolating contacts, suitable for the fixed part of the size.
The earthing circuit is dimensioned for a short-time withstand current equal to 60% of the maxi-
mum lcw of the circuit-breaker from which it is derived (IEC 60439-1).
The truck is temporarily racked into the fixed part of a withdrawable circuit-breaker to earth the
top or bottom terminals before carrying out maintenance operations on the external circuit when
no residual voltages are expected to occur.
2
1SDC200072F0001
1SDC200073F0001
1SDC200074F0001
1SDC200075F0001
Other versions
On request, SACE Emax circuit-breakers can be built in special versions designed for particu-
larly aggressive environments (SO2/H2S), for seismic installations or with the neutral pole on the
right side.
ABB SACE 2/11

Installations
Contents
Installation in switchgear
Modular design ..................................................................................................................... 3/2
Choosing the type of circuit-breaker ................................................................................... 3/3
Current-carrying capacity in switchgear .............................................................................. 3/6
Changing the rated uninterrupted current in relation to the temperature 3

Temperature derating ........................................................................................................... 3/7
Derating at different altitudes .......................................................................................... 3/12
Current-limiting and specific let-through energy curves

for E2L and E3L circuit-breakers ..................................................................................... 3/13
ABB SACE 3/1

Modular design
The circuit-breakers in the SACE Emax series have been built

according to modular design criteria for easier installation and
integration in low voltage electrical switchgear, thanks to their
having the same depth and height for all the sizes, as well as a
significant reduction in their overall installation dimensions.
The front shield of the circuit-breaker is also identical for the
entire series. This simplifies construction of the switchgear doors
since only one type of drilling is required and makes the front of
the switchgear the same for all sizes.
SACE Emax circuit-breakers are suitable for Power Center
switchgear and make it easy to comply with the segregation
requirements of the IEC 60439-1 Standards.
1SDC200082F0001
3/2 ABB SACE

Choosing the type of circuit-breaker
Number of poles
The choice of the number of poles for circuit-breakers that si-
multaneously provide switching, protection and isolation func-
tions in three-phase installations depends on the type of elec-
trical system (TT, TN-S, TN-C, IT) and the type of user or, more
generally, whether it features a distributed or non-distributed
neutral.
Three-pole circuit breakers Four-pole circuit breakers Three-pole circuit breakers

with external neutral
For TN-C systems (the neutral For users that do not use the In all other instances, with Current transformers can be
cannot be interrupted because it neutral (e.g.: asynchronous motors) exceptions for the IT system installed on the external neutral
also acts as the protection and, for systems with undistributed (see CEI 64-8/473.3.2.2 of five-wire systems (TN-S) with
conductor). neutral in general. Standards). 3-pole circuit-breakers.
Fixed or withdrawable version

The fixed version of the circuit-breaker is more compact in size than the withdrawable version. It
is recommended for installations that can tolerate service interruptions in the event of faults or
programmed maintenance.
The withdrawable version of the circuit-breaker is recommended for:
– applications that can only tolerate brief interruptions due to faults or programmed mainte-
nance;
– dual lines, one of which is a standby for the other, with a single circuit-breaker for each pair.
1SDC200083F0001
ABB SACE 3/3

Choosing the type of circuit-breaker
Connecting the main circuit-breaker

circuits
When designing switchgear, one must always bear in mind the
problem of making the most rational connections between the
circuit-breaker and main busbar system and from the busbars
to the users. The SACE Emax series offers switchgear manu-
facturers a range of options to satisfy different circuit-breaker
connection requirements.
The figures below give some indications for terminal selection.
Horizontal rear terminals Vertical rear terminals Front terminals Flat rear terminals
For switchgear with access from For switchgear with access from For wall-mounted switchgear, (withdrawable version only) For
the rear the rear with access from the front only switchgear with access from the
rear
Degrees of protection
A number of solutions have been adopted on SACE Emax cir-
cuit-breakers to achieve IP22 degree of protection for fixed or
withdrawable circuit-breakers, excluding the terminals, and IP30
for their front parts using a flange. Automatic shutters have been
designed for the fixed parts of withdrawable circuit-breakers
which can be locked using padlock devices to allow mainte-
nance on the load side or on the power-supply side of the fixed
part.
A transparent protective cover is also available on request, to
completely segregate the front of the circuit-breaker, reaching
IP54 degree of protection. In any case, the front panel and pro-
1SDC200089F0001
tection release with the relative indications remain completely

visible.
IP22 Fixed or withdrawable version circuit-breaker, exclud-
ing the terminals.
IP30 Front parts of the circuit-breakers (using a flange).
IP54 Fixed or withdrawable version circuit-breaker, fitted with
transparent protective cover to be fixed onto the front
of the switchgear (on request).
3/4 ABB SACE

Power losses
Power losses Circuit breaker Iu Fixed Poles Withdrawable
The IEC 439-1 and CEI EN 3/4 Poles 3/4 Poles
[A] [W] [W]
60439-1 Standards prescribe
calculations for determining E1 B-N 800 65 95
1000 96 147.2
the heat dissipation of ANS 1250 150 230
type switchgear (non-stand- 1600 253 378
ard), for which the following E2 B-N-S 800 29 53
1000 44.8 83.2
must be taken into considera-
1250 70 130
tion: 1600 115 215
– the overall dimensions 2000 180 330
– the rated current of the bus- E2 L 1250 105 165
1600 170 265
bars and connections and
E3 N-S-H-V 800 22 36
the relative dissipation 1000 38.4 57.6
– the dissipated power of the 1250 60 90
apparatus mounted in the 1600 85 150
2000 130 225
switchgear.
For this point, the table beside
2500
3200
205
330
350
570
3
provides information on the cir- E3 L 2000 215 330
2500 335 515
cuit-breakers. For other appa-
E4 S-H-V 3200 235 425
ratus, please consult the cata- 4000 360 660
logues of the relative manufac- E6 H-V 3200 170 290
turers. 4000 265 445
5000 415 700
6300 650 1100
Note
The table values refer to balanced loads, a current flow of Iu, and automatic circuit-
breakers.
1SDC200090F0001
Note
The same standards prescribe type tests
for AS switchboards (standard factory-
manufactured switchgear), including those
for maximum temperature rise.
ABB SACE 3/5

Current-carrying capacity in switchgear
As an example, the following table shows the continuous

current carrying capacity for circuit-breakers installed in a
switchgear with the dimensions indicated below.
These values refer to withdrawable version circuit-breaker
installed in non-segregated switchgear with a degree of
protection up to IP31, and the following dimensions:
2300x800x900 (HxLxD) for E1 - E2 - E3;
2300x1400x1500 (HxLxD) for E4 - E6. Note:
The values refer to a maximum temperature at the terminals of The tables should be used solely as a
general guideline for selecting products.
120°C. Due to the extensive variety of switchgear
For withdrawable circuit-breakers with a rated current of 6300A, construction shapes and conditions that
can affect the behavior of the apparatus,
the use of vertical rear terminals is recommended. the solution used must always be verified.
Vertical terminals Horizontal and front terminals

Type Iu Continuous capacity Busbars section Continuous capacity Busbars section
[A] [A] [mm2] [A] [mm2]
3 E1B/N 08 800
35°C
800
45°C
800
55°C
800 1x(60x10)
35°C
800
45°C
800
55°C
800 1x(60x10)
E1B/N 10 1000 1000 1000 1000 1x(80x10) 1000 1000 1000 2x(60x8)
E1B/N 12 1250 1250 1250 1250 1x(80x10) 1250 1250 1200 2x(60x8)
E1B/N 16 1600 1600 1600 1500 2x(60x10) 1550 1450 1350 2x(60x10)
E2S 08 800 800 800 800 1x(60x10) 800 800 800 1x(60x10)
E2N/S 10 1000 1000 1000 1000 1x(60x10) 1000 1000 1000 1x(60x10)
E2N/S 12 1250 1250 1250 1250 1x(60x10) 1250 1250 1250 1x(60x10)
E2B/N/S 16 1600 1600 1600 1600 2x(60x10) 1600 1600 1530 2x(60x10)
E2B/N/S 20 2000 2000 2000 1800 3x(60x10) 2000 2000 1750 3x(60x10)
E2L 12 1250 1250 1250 1250 1x(60x10) 1250 1250 1250 1x(60x10)
E2L 16 1600 1600 1600 1500 2x(60x10) 1600 1500 1400 2x(60x10)
E3H/V 08 800 800 800 800 1x(60x10) 800 800 800 1x(60x10)
E3S/H 10 1000 1000 1000 1000 1x(60x10) 1000 1000 1000 1x(60x10)
E3S/H/V 12 1250 1250 1250 1250 1x(60x10) 1250 1250 1250 1x(60x10)
E3S/H/V 16 1600 1600 1600 1600 1x(100x10) 1600 1600 1600 1x(100x10)
E3S/H/V 20 2000 2000 2000 2000 2x(100x10) 2000 2000 2000 2x(100x10)
E3N/S/H/V 25 2500 2500 2500 2500 2x(100x10) 2500 2450 2400 2x(100x10)
E3N/S/H/V 32 3200 3200 3100 2800 3x(100x10) 3000 2880 2650 3x(100x10)
E3L 20 2000 2000 2000 2000 2x(100x10) 2000 2000 1970 2x(100x10)
E3L 25 2500 2500 2390 2250 2x(100x10) 2375 2270 2100 2x(100x10)
E4H/V 32 3200 3200 3200 3200 3x(100x10) 3200 3150 3000 3x(100x10)
E4S/H/V 40 4000 4000 3980 3500 4x(100x10) 3600 3510 3150 6x(60x10)
E6V 32 3200 3200 3200 3200 3x(100x10) 3200 3200 3200 3x(100x10)
E6H/V 40 4000 4000 4000 4000 4x(100x10) 4000 4000 4000 4x(100x10)
E6H/V 50 5000 5000 4850 4600 6x(100x10) 4850 4510 4250 6x(100x10)
E6H/V 63 6300 6000 5700 5250 7x(100x10) - - - -
3/6 ABB SACE

Changing the rated uninterrupted current
in relation to the temperature
Temperature derating
The circuit-breakers can operate at higher temperatures than

their reference temperature (40 °C) under certain installation
conditions. In these cases the current-carrying capacity of the
switchgear should be reduced.
The SACE Emax series of air circuit-breakers uses electronic
releases which offer the benefit of great operating stability when
subjected to temperature changes.
The tables below show the current-carrying capacities of the
circuit breakers (as absolute values and percentage values) in
relation to their rated values at T = 40 °C.
SACE Emax E1
Temperature E1 800 E1 1000 E1 1250 E1 1600
[°C] % [A] % [A] % [A] % [A]
10 100 800 100 1000 100 1250 100 1600
20
30
100
100
800
800
100
100
1000
1000
100
100
1250
1250
100
100
1600
1600 3
40 100 800 100 1000 100 1250 100 1600
45 100 800 100 1000 100 1250 98 1570
50 100 800 100 1000 100 1250 96 1530
55 100 800 100 1000 100 1250 94 1500
60 100 800 100 1000 100 1250 92 1470
65 100 800 100 1000 99 1240 89 1430
70 100 800 100 1000 98 1230 87 1400
Iu [A]
1800
1600 E1 1600
1400
E1 1250
1200
1000 E1 1000
800 E1 800
600
400
200
0
10 20 30 35 40 45 50 55 60 65 70
T [°C]
ABB SACE 3/7

SACE Emax E2
Temperature E2 800 E2 1000 E2 1250 E2 1600 E2 2000
[°C] % [A] % [A] % [A] % [A] % [A]
10 100 800 100 1000 100 1250 100 1600 100 2000
20 100 800 100 1000 100 1250 100 1600 100 2000
30 100 800 100 1000 100 1250 100 1600 100 2000
40 100 800 100 1000 100 1250 100 1600 100 2000
45 100 800 100 1000 100 1250 100 1600 100 2000
50 100 800 100 1000 100 1250 100 1600 97 1945
55 100 800 100 1000 100 1250 100 1600 94 1885
60 100 800 100 1000 100 1250 98 1570 91 1825
65 100 800 100 1000 100 1250 96 1538 88 1765
70 100 800 100 1000 100 1250 94 1510 85 1705
Iu [A]
3500
3 3000
2500
2000 E2 2000
E2 1600
1500
E2 1250
1000 E2 1000
E2 800
500
0
10 20 30 35 40 45 50 55 60 65 70
T [°C]
3/8 ABB SACE

SACE Emax E3
Temperature E3 800 E3 1000 E3 1250 E3 1600 E3 2000 E3 2500 E3 3200

[C°] % [A] % [A] % [A] % [A] % [A] % [A] % [A]
10 100 800 100 1000 100 1250 100 1600 100 2000 100 2500 100 3200
20 100 800 100 1000 100 1250 100 1600 100 2000 100 2500 100 3200
30 100 800 100 1000 100 1250 100 1600 100 2000 100 2500 100 3200
40 100 800 100 1000 100 1250 100 1600 100 2000 100 2500 100 3200
45 100 800 100 1000 100 1250 100 1600 100 2000 100 2500 100 3200
50 100 800 100 1000 100 1250 100 1600 100 2000 100 2500 97 3090
55 100 800 100 1000 100 1250 100 1600 100 2000 100 2500 93 2975
60 100 800 100 1000 100 1250 100 1600 100 2000 100 2500 89 2860
65 100 800 100 1000 100 1250 100 1600 100 2000 97 2425 86 2745
70 100 800 100 1000 100 1250 100 1600 100 2000 94 2350 82 2630
Iu [A]
3500
E3 3200
3000
3
2500 E3 2500
2000 E3 2000
1500 E3 1600
E3 1250
1000 E3 1000
E3 800
500
0
10 20 30 35 40 45 50 55 60 65 70
T [°C]
ABB SACE 3/9

SACE Emax E4
Temperature E4 3200 E4 4000
[°C] % [A] % [A]
10 100 3200 100 4000
20 100 3200 100 4000
30 100 3200 100 4000
40 100 3200 100 4000
45 100 3200 100 4000
50 100 3200 98 3900
55 100 3200 95 3790
60 100 3200 92 3680
65 98 3120 89 3570
70 95 3040 87 3460
Iu [A]
7000
3 6000
5000
4000 E4 4000
E4 3200
3000
2000
1000
0
10 20 30 35 40 45 50 55 60 65 70
T [°C]
3/10 ABB SACE

SACE Emax E6
Temperature E6 3200 E6 4000 E6 5000 E6 6300

[°C] % [A] % [A] % [A] % [A]
10 100 3200 100 4000 100 5000 100 6300
20 100 3200 100 4000 100 5000 100 6300
30 100 3200 100 4000 100 5000 100 6300
40 100 3200 100 4000 100 5000 100 6300
45 100 3200 100 4000 100 5000 100 6300
50 100 3200 100 4000 100 5000 100 6300
55 100 3200 100 4000 100 5000 98 6190
60 100 3200 100 4000 98 4910 96 6070
65 100 3200 100 4000 96 4815 94 5850
70 100 3200 100 4000 94 4720 92 5600
Iu [A]
7000
E6 6300
6000
3
5000 E6 5000
4000 E6 4000
E6 3200
3000
2000
1000
0
10 20 30 35 40 45 50 55 60 65 70
T [°C]
ABB SACE 3/11

Derating at different altitudes
SACE Emax air circuit-breakers do not undergo any changes

in their rated performance up to an altitude of 2000 meters.
As the altitude increases the atmospheric properties alter in
terms of composition, dielectric capacity, cooling power and
pressure.
The performance of the circuit-breakers therefore undergoes
derating which can be measured through the variation in sig-
nificant parameters such as the maximum operating voltage
and the rated uninterrupted current.
The table below shows these values in relation to altitude.
Altitude H [m] <2000 3000 4000 5000

Rated service voltage Ue [V] 690 600 500 440
Rated current In [A] In 0.98xIn 0.93xIn 0.90xIn
3/12 ABB SACE

Current-limiting and specific let-through energy
curves for E2L and E3L circuit-breakers
The current-limiting capacity of a current-limiting circuit-breaker

indicates its greater or lesser capacity, under short-circuit con-
ditions, to let through or make a current lower than the pro-
spective fault current. This characteristic is shown by two dif-
ferent curves which indicate the following, respectively:
– the value of the specific energy “I2t” (in A2s) let through by
the circuit-breaker in relation to the uninterrupted symmetri-
cal short-circuit current.
– the peak value (in kA) of the limited current in relation to the
uninterrupted symmetrical short-circuit current.
The graph shown at the side

schematically indicates the Ik
trend of the uninterrupted cur-
rent, with the relative estab-
lished peak (curve B), and the
trend of the limited current with
the lowest peak value (curve
A). 3
Comparing the areas beneath
the two curves shows how the
specific let-through energy is
reduced as a result of the lim-
iting effects of the circuit
breaker.
1SDC200091F0001
A peak limited Ik
B prospective Ik (peak value)
ABB SACE 3/13

Current-limiting and specific let-through energy
curves for E2L and E3L circuit-breakers
E2L
Current-limiting curves
690
380/415
1SDC200092F0001
E2L
Specific let-through
energy curves
690
380/415
lrms prospective symmetrical

short-circuit current
1SDC200093F0001
lp peak current
l2t specific let-through energy
at the voltages indicated
3/14 ABB SACE

E3L
Current-limiting curves
690
380/415
1SDC200094F0001
E3L
Specific let-through
energy curves
690
380/415
lrms prospective symmetrical

short-circuit current
1SDC200095F0001
lp peak current
l2t specific let-through energy
at the voltages indicated
ABB SACE 3/15

Overcurrent releases and
related accessories
Contents
Protection releases and trip curves
PR121/P ............................................................................................................................... 4/2
PR122/P ............................................................................................................................... 4/9
PR123/P ............................................................................................................................... 4/23
Accessories for protection releases
PR120/K Internal Module ..................................................................................................... 4/34
PR120/V Measurement Module ........................................................................................... 4/34
PR120/D-M Communication Module .................................................................................... 4/35

4
PR120/D-BT Wireless Communication Module ................................................................... 4/35
BT030 Communication unit .................................................................................................. 4/35
PR030/B power supply unit ................................................................................................. 4/35
Interface from front of HMI030 panel .................................................................................. 4/35
SACE PR010/T configuration test unit ................................................................................. 4/36
SACE PR021/K signalling unit ............................................................................................. 4/37
Communication devices and systems
Industrial networking and ABB SACE Emax ........................................................................ 4/38
PR120/D-M ........................................................................................................................... 4/40
BT030 ................................................................................................................................... 4/40
EP010 – FBP ........................................................................................................................ 4/40
SD-View 2000 ....................................................................................................................... 4/42
SD-Pocket ............................................................................................................................. 4/44
TestBus2 ............................................................................................................................... 4/45
ABB SACE 4/1

PR121/P
Characteristics
PR121/P is the new basic and complete release for the Emax series. The complete range of
protection functions together with the wide combination of thresholds and trip times offered
make it suitable for protecting a wide range of alternating current installation. In addition to
protection functions the unit is provided with multifunction LED indicators. Furthermore, PR121/P
allows connection to external devices enhancing its advanced characteristics like remote signal-
ling and monitoring, or remote supervision display.
16 17 8 6 5 7 1 2 10 11 20 21 26 24 15
1SDC200105F0001
19 18 9 4 3 12 22 13 23 14 25
Legend
1 LED signalling Alarm for 9 DIP switches for setting current 17 Indication of the DIP switch 24 Trip cause indication and trip test
protection function L threshold l4 positions for the various current pushbutton
2 LED signalling Alarm for 10 DIP switches for setting trip time threshold values l2 25 Test connector for connecting or
protection function S t1 (type of curve) 18 Indication of the DIP switch testing the release through an
3 LED signalling Alarm for 11 DIP switches for setting trip time positions for the various current external device (PR030/B battery
protection function I t2 (type of curve) threshold values l3 unit, BT030 wireless communica-
19 Indication of the DIP switch tion unit and SACE PR010/T unit)
4 LED signalling Alarm for 12 DIP switches for setting trip time
protection function G t4 (type of curve) positions for the various current 26 Serial number of protection
threshold values l4 release
5 DIP switches for fine setting 13 Indication of the DIP switch
current threshold l1 position for network frequency 20 Indication of DIP switch positions
for the various time settings t1
6 DIP switches for main setting 14 Indication of the DIP switch
current threshold l1 position for Neutral protection 21 Indication of DIP switch positions
setting for the various time settings t2
7 DIP switches for setting current
threshold I2 15 Rating plug 22 Indication of DIP switch positions
for the various time settings t4
8 DIP switches for setting current 16 Indication of the DIP switch
threshold l3 positions for the various current 23 DIP switch for setting network
thresholds values l1 frequency and neutral protection
setting
4/2 ABB SACE

Operation and protection functions
Protection functions 15 current thresholds and 8 4 curves. Each curve is iden-
The PR121 release offers the curves are available, allowing tified by the time t4 in relation
following protection functions: a fine setting. Each curve is to current I4. As per S protec-
• overload (L) identified as follows: tion the trip time can be cho-
• selective short-circuit (S) – for curves t = k by the trip sen independent of the cur-
• instantaneous short-circuit (I) time for l > I2 rent (t = k) or with a constant
• earth fault (G). – for curves t = k/l2 by the trip specific let-through energy
time for l = 10xln (ln = rated (t = k/l2).
Overload (L) current of the circuit-
Note: the function G is re-
breaker).
The inverse long time-delay pressed for fault current values
The function can be excluded
trip overload protection L is higher than the values shown
by setting the DIP switches to
type l2t = k; 25 current thresh- in table below.
the combination labelled
olds and 8 curves are avail-
“OFF”.
able. Each curve is identified
by the trip time in relation to the
Adjustable instantaneous
current l = 3 x l1 (l1 = set
short-circuit (l)
threshold).
The protection I offers 15 trip
Selective short-circuit (S) thresholds and can be ex-
cluded (dip switches in “OFF”
The selective short-circuit pro-
tection S can be set with two
position). 4
different types of curves with
Earth fault (G)
a trip time independent of the
current (t = k) or with a con- The earth fault protection G
stant specific let-through en- (which can be excluded) of-
ergy (t = k/l2). fers 7 current thresholds and
I4 threshold Repression threshold

I4 < 0.5 In 4 In
0.5 In ≤ I4 < 0,8 In 6 In
I4 ≥ 0.8 In 8 In
In = rated current of the rating plug
t t
k k
t= t=
I2 I2
t=k
t=k
1SDC200116F0001
1SDC200117F0001
I I
ABB SACE 4/3

PR121/P
User interface
The user communicates directly with the release in the trip parameter preparation stage by
means of the dip switches.
Up to four LEDs (according to the version) are also available for signalling.
These LEDs (one for each protection) are active when:
• a protection is timing. For protection L the prealarm status is also shown;
• a protection has tripped (the corresponding LED is activated by pressing the “Info/Test”
pushbutton);
• a failure in connection of a current sensor or in the opening solenoid is detected. The indication
is active when the unit is powered (through current sensors or an auxiliary power supply)
• wrong rating plug for the circuit-breaker.
The protection tripped indication works even with the circuit-breaker open, without the need for any
internal or external auxiliary power supply. This information is available for 48 hours of inactivity after
the trip and is still available after reclosing. If the query is made more than 48 hours later it is
sufficient to connect a PR030/B battery unit, PR010/T, or a BT030 wireless communication unit.
Communication
By means of the BT030 wireless communication unit, PR121/P can be connected to a pocket PC
(PDA) or to a personal computer, extending the range of information available for the user. In
fact, by means of ABB SACE’s SD-Pocket communication software, It is possible to read the
values of the currents flowing through the circuit-breaker, the value of the last 20 interrupted
currents, and the protection settings.
PR121 can also be connected to the optional external PR021/K signalling unit, for the remote
signalling of protections alarms and trips, and to HMI030, for the remote user interfacing.
4 Setting the neutral
Protection of the neutral can be set at 50%, 100% or 200% of the phase currents. Settings above
50% can be selected for E1-E2-E3-E4/f and E6/f. In particular, setting the neutral at 200% of
phase current requires protection L to be set at 0.5In in order to respect the current-carrying
capacity of the circuit-breaker. The user can also switch the neutral protection OFF. When three-
poles circuit-breakers with external neutral current sensor are used, a setting above 100% for
the neutral does not require any reduction in the L setting.
Test Function
The Test function is carried out by means of the info/Test pushbutton and the PR030/B battery
unit (or BT030) fitted with a polarized connector housed on the bottom of the box, which allows
the device to be connected to the test connector on the front of PR121/P releases.
The PR121/P electronic release can be tested by using the SACE PR010/T test and configuration
unit by connecting it to the TEST connector.
4/4 ABB SACE

Versions available
The following versions are available:
1SDC200106F0001
PR121/P LI
1SDC200107F0001
PR121/P LSI
1SDC200105F0001
PR121/P LSIG
ABB SACE 4/5

PR121/P
Protection functions and setting values - PR121

Function Trip threshold Trip time Poss. excl. Relation t=f(I)
Overload I1= 0,4 - 0.425 - 0.45 - 0.475 - 0.5 - With current I = 3 x I1 – t=k/I 2
(1)
protection 0.525 - 0.55 - 0.575 - 0.6 - 0.625 - t1 = 3 - 12 - 24 - 36 - 48 - 72 - 108 - 144 s
0.65 - 0.675 - 0.7 - 0.725 - 0.75 -
0.775 - 0.8 - 0.825 - 0.85 - 0.875
0.9 - 0.925 - 0.95 - 0.975 - 1 x In
Tolerance (2)
Release between 1.05 and 1.2 x I1 ± 10% Ig ≤ 4 x In
± 20% Ig > 4 x In
Selective short-circuit I2= 1 - 1.5 - 2 - 2.5 - 3 - 3.5 - 4 - 5 With current I > I2 ■ t=k
protection 6 - 7 - 8 - 8.5 - 9 - 9.5 - 10 x In t2 = 0.1 - 0.2 - 0.3 - 0.4 - 0.5 - 0.6 - 0.7 - 0.8 s
Tolerance (2)
± 7% Ig ≤ 4 x In The better of the two figures:
± 10% Ig > 4 x In ± 10% or ± 40 ms
I2= 1 - 1.5 - 2 - 2.5 - 3 - 3.5 - 4 - 5 With current I = 10 x In ■ t=k/I2
6 - 7 - 8 - 8.5 - 9 - 9.5 - 10 x In t2 = 0.1 - 0.2 - 0.3 - 0.4 - 0.5 - 0.6 - 0.7 - 0.8 s
Tolerance (2)
± 7% Ig ≤ 4 x In ± 15% Ig ≤ 4 x In
± 10% Ig > 4 x In ± 20% Ig > 4 x In
Instantaneous I3= 1.5 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - Instantaneous ■ t=k
short-circuit protection 9 - 10 - 11 - 12 - 13 - 14 - 15 x In
Tolerance (2)
± 10% ≤ 30 ms
Earth fault I4= 0.2 - 0.3 - 0.4 - 0.6 - With current I = 4 x In ■ t=k/I2
protection 0.8 - 0.9 - 1 x In t4 = 0.1 - 0.2 - 0.4 - 0.8 s
(2)
Tolerance ± 7% ± 15%
I4= 0.2 - 0.3 - 0.4 - 0.6 - With current I > I4 ■ t=k
0.8 - 0.9 - 1 x In t4 = 0.1 - 0.2 - 0.4 - 0.8 s
(2)
Tolerance ± 7% The better of the two figures: ± 10% or ± 40 ms
4
(1) The minimum trip time is 1 s, regardless of the type of curve set (self-protection)
(2) These tolerances are valid in the following conditions:
- self-supplied release at full power (without start-up)
- two- or three-phase power supply
- trip time set ≥ 100 ms
The following tolerance values apply in all cases not covered by the above:
Trip threshold Trip time

L Release between 1.05 and 1.25 x I1 ± 20%
S ± 10% ± 20%
I ± 15% ≤ 60ms
G ± 15% ± 20%
Power supply
The unit does not require an external power supply either for protection functions or for alarm
signalling functions. It is self-supplied by means of the current sensors installed on the circuit-
breaker. For it to operate, it is sufficient for at least one phase to be loaded at 100A. An external
power supply can be connected in order to activate additional features, and in particular for
connection to external devices: HMI030, and PR021/K.
PR121/P
Auxiliary power 24 V DC ± 20%
supply (galvanically insulated)
Maximum ripple 5%
Inrush current @ 24V ~10 A for 5 ms
Rated power @ 24V ~2 W
4/6 ABB SACE

Functions L-I
1SDC200100F0001
4
Functions L-S-I
k
t=
I2
1SDC200101F0001
Threshold and trip times

tolerances ........................ page 4/6
ABB SACE 4/7

PR121/P
Functions L-S-I
t=k
1SDC200102F0001
4
Function G
k
t=
I2
t=k
1SDC200103F0001

tolerances ........................ page 4/6
4/8 ABB SACE

PR122/P
Characteristics
The SACE PR122 release is a sophisticated and flexible protection system based on a state-of-
the art microprocessor and DSP technology. Fitted with the optional internal PR120/D-M dia-
logue unit, PR122/P turns into an intelligent protection, measurement and communication de-
vice, based on the Modbus® protocol. By means of the PR120/D-M, PR122/P can also be con-
nected to the ABB EP010 Fieldbus plug adapter, which makes it possible to choose among
several different networks, such as Profibus and DeviceNet.
The new PR122/P is the result of ABB SACE’s experience in designing protection releases.
The exhaustive range of settings makes this protection unit ideal for general use in any type of
installation, from distribution to the protection of motors, transformers, drives and generators.
Access to information and programming using a keyboard and graphic liquid crystal display is
extremely simple and intuitive. The interface is now common to PR122/P and PR123/P in order to
give to the user maximum ease of use.
An integrated ammeter and many other additional features are provided over and above the
protection functions. These additional functions can be further increased with addition on board
of the dialogue, signalling, measurement, and wireless communication units.
Functions S and G can operate with a time delay independent of the current (t = k) or with an
inverse time delay (constant specific let-through energy: I2t = k), as required.
Protection against earth faults can also be obtained by connecting the PR122 release to an
external toroid located on the conductor that connects the transformer star centre to earth (ho-
mopolar toroid).
4
All the thresholds and trip curve delays of the protection functions are stored in special memo-
ries which retain the information even when no power is supplied.
1 2 3 10 9
1SDC200108F0001
8 4 5 7 6
Legend
1 LED Warning indicator 6 Test connector for connecting or 8 Button to exit submenus or cancel
2 Alarm LED testing the release by means of an operations (ESC)
external device (PR030/B battery 9 Rating plug
3 Rear-lit graphic display unit, BT030 wireless communica-
4 Cursor UP button tion unit and SACE PR010/T unit) 10 Serial number of protection
release
5 Cursor DOWN button 7 ENTER button to confirm data or
change pages
ABB SACE 4/9

PR122/P
Operation, protection functions and self-test

Basic Protection functions sion. The neutral protection avoids untimely tripping
The PR122 release offers the can be excluded or set to caused by the high inrush cur-
following protection functions 100% for E1, E2, E3, E4/f and rents of certain loads (motors,
(according to the version): E6/f. In installations where very transformers, lamps).
• overload (L) high harmonics occur, the re- The start-up phase lasts from 100
• selective short-circuit (S) sulting current at the neutral ms to 1.5 s, in steps of 0.05 s. It
• instantaneous short-circuit (I) can be higher than that of the is automatically recognized by
• earth fault (G) phases. Therefore it is possible the PR122 release as follows:
• phase unbalance (U) to set the neutral protection at – when the circuit-breaker
• self-protection against over- 150% or 200% of the value set closes with the release self-
temperature (OT) for the phases. In this case it supplied;
• thermal memory for func- is necessary to reduce the set- – when the peak value of the
tions L and S ting of protection L accord- maximum current exceeds
• zone selectivity for functions ingly(1). 0.1 x In. A new start-up be-
S and G The table below lists the neu- comes possible after the
• residual current (Rc) with tral settings for the various pos- current has fallen below the
external toroid sible combinations between threshold of 0.1 x In, if the
• source ground return with type of circuit-breaker and the release is supplied from an
external toroid threshold I1 setting. external source.
4 Setting the neutral Start-up function

In PR122/P, and PR123/P as The start-up function allows
well, the neutral protection is protections S, I and G to oper-
50% of the value set for phase ate with higher trip thresholds
protection in the standard ver- during the start-up phase. This

I4 < 0.5 In 4 In
0.5 In ≤ I4 < 0,8 In 6 In
I4 ≥ 0.8 In 8 In
In = rated current of the rating plug
Adjustable neutral protection settings

Threshold I1 settings (overload protection)
Circuit-breaker model 0.4 ≤ I1 ≤ 0.5 0.5 < I1 ≤ 0.66 0.66 < I1 ≤ 1(*)
E1B-N 0-50-100-150-200% 0-50-100-150% 0-50-100%
E2B-N-S-L 0-50-100-150-200% 0-50-100-150% 0-50-100%
E3N-S-H-V-L 0-50-100-150-200% 0-50-100-150% 0-50-100%
E4S-H-V 0-50-100% 0-50% 0-50%
E4S/f-H/f 0-50-100-150-200% 0-50-100-150% 0-50-100%
E6H-V 0-50-100% 0-50% 0-50%
E6H/f 50-100-150-200% 0-50-100-150% 0-50-100%
(*) The setting I1 =1 indicates the maximum overload protection setting. The actual maximum setting allowable must take into account any
derating based on temperature, the terminals used and the altitude (see the “Installations” chapter)
(1) When three-pole circuit-breakers with external neutral current sensor are used, a setting above 100% for the neutral does not require any
reduction in the L setting up to Iu N.
4/10 ABB SACE

Phase unbalance protection U
Protection function U against phase unbalance is used in those situations requiring particularly
precise control over missing and/or unbalanced phase currents, only givin the pre-alarm sig-
nal. This function can be excluded.
Protection against overtemperature

The range of SACE PR122 releases allows the presence of abnormal temperatures, which could
cause temporary or continuous malfunctions of the microprocessor, to be signalled to the user.
The user has the following signals or commands available:
– lighting up of the “Warning” LED when the temperature is higher than 70 °C (temperature at
which the microprocessor is still able to operate correctly)
– lighting up of the “Alarm” LED when the temperature is higher than 85 °C (temperature above
which the microprocessor can no longer guarantee correct operation) and, when decided
during the unit configuration stage, simultaneous opening of the circuit-breaker with indica-
tion of the trip directly on the display, as for the other protections.
Zone selectivity for protections S and G

Zone selectivity is one of the most advanced methods for making co-ordination of the protec-
tions: by using this protection philosophy, it is possible to reduce the trip times of the protection
closest to the fault in relation to the times foreseen by time selectivity, of which zone selectivity
is an evolution.
Zone selectivity is applicable to protection functions S and G,
even contemporarily and is available as standard on the PR122. 4
The word zone is used to refer to the part of an installation
between two circuit-breakers in series (see picture beside).
Protection is provided by connecting all of the zone selectiv-
Zone 1
ity outputs of the releases belonging to the same zone to-

gether and taking this signal to the zone selectivity input of the
release immediately to the supply side.
Each circuit-breaker that detects a fault communicates this to
the circuit-breaker on the supply side using a simple connec-
Zone 2
tion wire. Therefore the fault zone is the zone immediately to

the load side of the circuit-breaker that detects the fault, but
does not receive any communication from those on the load
side. This circuit-breaker opens without waiting for the set
Zone 3
time-delay.
ABB SACE provides important calculation tools to facilitate
1SDC200186F0001
the work of designers in coordinating protection devices, in-

cluding the Slide rule kits, DOCWin and CAT software pack-
ages and updated coordination charts.
The zone selectivity function S and G can be activated or
deactivated using the keyboard.
ABB SACE 4/11

PR122/P
Self-diagnosis
The PR122 range of releases contains an electronic circuit which periodically checks the conti-
nuity of internal connections (opening solenoid or each current sensor, including the Source
Ground Return when present).
In the case of a malfunction an alarm message appears directly on the display. The Alarm is
highlighted by the Alarm LED as well.
Residual Current
Different solutions are available for integrated residual current protection. The basic choice is
PR122/P-LSIRc, which has all the characteristics of PR122/P-LSI and residual current protection
as well. When additional features are required, the solution is PR122/P LSIG with an additional
PR120/V module (see next paragraph). Using this configuration, residual current protection is
added to a powerful unit, having the features of PR122/P-LSI and all the add-ons described for
the PR120/V module, such as voltage protection and advanced measurement functions.
Residual current protection acts by measuring the current from the external dedicated toroid.
Test Functions
Once enabled from the menu, the “info/Test” pushbutton on the front of the release allows correct
operation of the chain consisting of the microprocessor, opening solenoid and circuit-breaker
tripping mechanism to be checked.
The control menu also includes the option of testing correct operation of the display, signalling
LEDs, and electrical contacts of the PR120/K release.
By means of the front multi-pin connector it is possible to apply a SACE PR010/T Test unit which
allows the functions of the PR121, PR122 and PR123 ranges of releases to be tested and checked.
4
User interface
The human-machine interface (HMI) of the device is made up of a wide graphic display, LEDs,
and browsing pushbuttons. The interface is designed to provide maximum simplicity.
The language can be selected from among five available options: Italian, English, German, French
and Spanish.
As in the previous generation of releases, a password system is used to manage the “Read” or
“Edit” modes. The default password, 0001, can be modified by the user.
The protection parameters (curves and trip thresholds) can be set directly via the HMI of the
device. The parameters can only be changed when the release is operating in “Edit” mode, but
the information available and the parameter settings can be checked at any time in “Read”
mode.
When a communication device (internal PR120/D-M and PR120/D-BT modules or external BT030
device) is connected, it is possible to set parameters simply by downloading them into the unit
(over the network for PR120/D-M, by using the SD-Pocket software and a PDA or a notebook for
PR120/D-BT and BT030). Parameterisation can then be carried out quickly and automatically in
an error-free way by transferring data directly from DocWin.
Indicator LEDs
LEDs on the front panel of the release are used to indicate all the pre-alarms (“WARNING”) and
alarms (“ALARM”). A message on the display always explicitly indicates the type of event
concerned.
Example of events indicated by the “WARNING” LED:
– unbalance between phases;
– pre-alarm for overload (L1>90%);
– first temperature threshold exceeded (70 °C);
– contact wear beyond 80%;
– phase rotation reversed (with optional PR120/V)
4/12 ABB SACE

Example of events indicated by the “ALARM” LED:
– overload (may begin from 1.05xl1<I<1.3xl1, in accordance with the standard IEC 60947-2);
– timing of function L;
– timing of function S;
– timing of function G;
– second temperature threshold exceeded (85 °C);
– contact wear 100%;
– timing of Reverse Power flow protection (with optional PR120/V);
Data logger
By default PR122/P, as well as PR123/P, is provided with the Data Logger function, that automati-
cally records in a wide memory buffer the instantaneous values of all the currents and voltages.
Data can be easily downloaded from the unit by means of SD-Pocket or TestBus2 applications
using a Bluetooth port and can be transferred to any personal computer for elaboration. The
function freezes the recording whenever a trip occurs, so that a detailed analysis of faults can
be easily performed. SD-Pocket and TestBus2 allow also reading and downloading of all the
others trip information.
• Number of channels: 8
• Maximum sampling rate: 4800 Hz
• Maximum sampling time: 27 s (@ sampling rate 600 Hz)
• 64 events tracking
Trip information and opening data

In case a trip occurs PR122/P and PR123/P store all the needed information:
4
• Protection tripped
• Opening data (current)
• Time stamp (guaranteed with auxiliary supply or self-supply with power failure no longer than
48h)
By pushing the “info/Test” pushbutton the release shows all these data directly on display.
No auxiliary power supply is needed. The information is available to user for 48 hours with the
circuit breaker open or without current flowing.
The information of the latest 20 trips are stored in memory.
If the information can be furthermore retrieved more than 48 hours later, it is sufficient to connect
a PR030/B battery unit or a BT030 wireless communication unit.
Load control
Load control makes it possible to engage/disengage individual loads on the load side before
the overload protection L is tripped, thereby avoiding unnecessary trips of the circuit-breaker
on the supply side. This is done by means of contactors or switch-disconnectors (externally
wired to the release), controlled by the PR122/P by PR120/K internal contacts, or by PR021/K
unit.
Two different Load Control schemes can be implemented:
– disconnection of two separate loads, with different current thresholds
– connection and disconnection of a load, with hysteresis
Current thresholds and trip times are smaller than those available for selection with protection
L, so that load control can be used to prevent overload tripping.
Internal PR120/K or external PR021/K accessory unit is required for Load Control. The function
is only active when an auxiliary power supply is present.
ABB SACE 4/13

PR122/P
PR120/V Measurement Module

This optional internal module, installed in PR122 (standard in PR123), allows the release to mea-
sure the phase and neutral voltages and to process them in order to achieve a series of features,
in terms of protection and measurement.
PR120/V does not normally require any external connection or Voltage Transformer, since it is
connected internally to the lower terminals of Emax. When necessary, the connection of voltage
pick-ups can be moved to any other points (i.e. upper terminals), by using the alternative con-
nection located in the terminal box. The module is provided with a sealable switch-disconnector
for the dielectric test. PR120/V is able to energize the PR122 while line voltage input is above
1SDC200114F0001
85V. The use of Voltage Transformers is mandatory for rated voltages higher than 690V.
Voltage transformers shall have burdens equal to 10VA and accuracy class 0.5 or better.
Additional Protections with PR120/V:

– UnderVoltage (UV) protection
– Overvoltage (OV) protection
– Residual voltage (RV) protection
– Reverse power (RP) protection
– Underfrequency (UF) protection
– Overfrequency (OF) protection
– Phase sequence (alarm only)
All the above indicated protections can be excluded, although it is possible to leave only the
alarm active when required.
With the circuit-breaker closed, these protections also operate when the release is self-sup-
4 plied. With the circuit-breaker open, they operate when the auxiliary power supply (24V DC or
PR120/V) is present: in this case the release will indicate the “ALARM” status.
Voltage protections UV, OV, RV

With the PR120/V module, the PR122/P release is able to provide the undervoltage and overvolt-
age protection (UV, OV) and the residual voltage protection (RV). The residual voltage protection
RV identifies interruptions of the neutral (or of the earthing conductor in systems with earthed
neutral) and faults that shift the star centre in systems with insulated neutral (e.g. large earth
faults). The star centre shift is calculated as a vectorial sum of the phase voltages.
Reverse power protection RP

Reverse power protection is especially suitable for protecting large machines such as motors
and generators. The PR122 with the PR120/V module can analyse the direction of the active
power and open the circuit-breaker if the direction is opposite to that of normal operation. The
reverse power threshold and the trip time are adjustable.
Frequency protections UF, OF

The frequency protections detect the variation of network frequency above adjustable thresh-
olds, generating an alarm or opening the circuit-breaker. It is a protection typically needed in an
isolated network, i.e. powered by a genset.
4/14 ABB SACE

Measurement function
The current measurement function (ammeter) is present on all versions of the SACE PR122 unit.
The display shows histograms showing the currents of the three phases and neutral on the main
page. Furthermore, the most loaded phase current is indicated in numerical format. Earth fault
current, where applicable, is shown on a dedicated page.
The latter current value takes on two different meanings depending on whether the external
toroidal transformer for the “Source Ground Return” function or the internal transformer (residual
type) is connected.
The ammeter can operate either with self-supply or with an auxiliary power supply voltage. In the
latter case the display is rear-lit and the ammeter is active even at current levels lower than 160A.
Accuracy of the ammeter measurement chain (current sensor plus ammeter) is no more than
1.5% in the 30% - 120% current interval of In.
– Currents:: three phases (L1, L2, L3), neutral (Ne) and earth fault;
– Instantaneous values of currents during a period of time (data logger);
– Maintenance: number of operations, percentage of contact wear, opening data storage (last
20 trips and 20 events).
When the optional PR120/V is connected the following additional measurement function are
present:
– Voltage: phase-phase, phase-neutral and residual voltage
– Instantaneous values of voltages during a period of time (data logger);
– Power: active, reactive and apparent
– Power factor
4
– Frequency and peak factor
– Energy: active, reactive, apparent, counter
Versions available
The following versions are available:
1SDC200113F0001
PR122/P LI-LSI-LSIG-LSIRc
ABB SACE 4/15

PR122/P

Function Trip Threshold Trip Time Poss. Relation Thermal Zone
threshold steps Time Step excl. t=f(I) memory selectivity
Overload I1= 0.4….1 x In 0.01 x In With current I = 3 x I1 3s (1)
– t=k/I2 ■ –
protection t1= 3 s....144 s
Tolerance (2) Release between ± 10% Ig ≤ 4 x In
1.05 and 1.2 x I1 ± 20% Ig > 4 x In
Selective short- With current I > I2
circuit protection I2= 0.6….10 x In 0.1 x In t2= 0.05 s….0.8 s (2) 0.01 s ■ t=k – ■
Tolerance (2) ± 7% Ig ≤ 4 x In The better of the two figures:
± 10% Ig > 4 x In ± 10% or ± 40 ms
With current I = 10 x In
I2= 0.6….10 x In 0.1 x In t2= 0.05 s….0.8 s 0.01 s ■ t=k/I2 ■ –
Tolerance (2) ± 7% Ig ≤ 4 x In ± 15% Ig ≤ 4 x In
± 10% Ig > 4 x In ± 20% Ig > 4 x In
Instantaneous
short-circuit
protection I3= 1.5….15 x In 0.1 x In Instantaneous – ■ t=k – –
Tolerance (2) ± 10% ≤ 30 ms
Earth fault With current I > I4
protection I4= 0.2….1 x In 0.02 x In t4= 0.1 s…..1 s 0.05 s ■ t=k – ■
Tolerance (2) ± 7% The better of the two figures:
± 10% or ± 40 ms
I4= 0.2….1 x In 0.02 x In t4= 0.1 s…..1 s (with I=4xIn) 0.05 s ■ t=k/I2 – ■
Tolerance (2) ± 7% ± 15%
Residual Current
Rc protection Id= 0.3-0.5-0.7-1-2- td= 0.06-0.1-0.2-0.3-0.4- ■ t=k – –
3-5-7-10-20-30 A 0.5-0.8-1-3-4-4.8 s (3)
4
(2)
Tolerance ± 10%
OT Protection against
overtemperature may not be set – Instantaneous – – temp=k – –
U Phase unbalance
protection I6= 5%….90% 5% t4= 0.5 s…..60 s 0.5 s ■ t=k – –
Tolerance (2) ± 10% The better of the two figures:
± 20% or ± 100 ms
(1) The minimum trip value is 1 s, regardless of the type of curve set (self-protection)
- self-supplied release at full power and/or auxiliary power supply (without start-up)
(3) Non intervention time

S ± 10% ± 20%
I ± 15% ≤ 60ms
G ± 15% ± 20%
Others ± 20%
4/16 ABB SACE

Additional Protection functions and setting values - PR122 with PR120/V
UV Undervoltage I8= 0.5….0.95 x Un 0.01 x Un With current U < U8 0.1 s ■ t=k – ■

protection t8= 0.1 s....5 s
Tolerance (1) The better of the two figures:
± 5% ± 20% or ± 100 ms
OV Overvoltage I9= 1.05….1.2 x Un 0.01 x Un With current U > U9 0.1 s ■ t=k – –

± 5% ± 20% or ± 100 ms
RV Residual voltage I10= 0.1….0.4 x Un 0.05 x Un With current U0 > U10 0.5 s ■ t=k – –
± 5% ± 10% or ± 100 ms
RP Reverse power P11= -0.3….-0.1 x Pn 0.02 x Pn With current P < P11 0.1 s ■ t=k – –
± 5% ± 10% or ± 100 ms
UF Underfrequency f12= 0.90….0.99 x fn 0.01 x fn With current f < f12 0.1 s ■ t=k – –
± 5% ± 10% or ± 100 ms
OF
Overfrequency f13= 1.01….1.10 x fn 0.01 x fn With current f > f13 0.1 s ■ t=k – –
± 5% ± 10% or ± 100 ms

- self-supplied release at full power and/or auxiliary power supply (without start-up)
4
Power supply
The PR122 release does not normally require any external power supplies, being self-supplied
from the current sensors (CS): to activate the protection and ammeter functions, it is sufficient for
at least one phase to have a current load higher than 100 A.
For the display to come on, at least one phase must have a current load higher than 160 A.
The unit ensures fully self-supplied operation. When an auxiliary power supply is present, it is
also possible to use the unit with the circuit-breaker either open or closed with very low current
flowing through.
It is also possible to use an auxiliary power supply provided by the PR030/B portable battery unit
(always supplied), which allows the protection functions to be set when the release is not self-
supplied.
PR122/P stores and shows all the information needed after a trip (protection tripped, trip current,
time, date). No auxiliary supply is required for this functionality.
PR122/P PR120/D-M PR120/K PR120/D-BT

Auxiliary power supply 24 V DC ± 20% from PR122/PR123 from PR122/PR123 from PR122/PR123
(galvanically insulated)
Maximum ripple 5%
Rated power @ 24V ~3 W +1 W +1 W +1 W
(*) PR120/V can give power supply to the release when at least one line voltage is equal or higher to 85V RMS.
ABB SACE 4/17

PR122/P
Functions L-I
1SDC200109F0001
4
Functions L-S-I
k
t=
I2
1SDC200110F0001

tolerances ...................... page 4/16
4/18 ABB SACE

Functions L-S-I
t=k
1SDC200111F0001
4
Function G
k
t=
I2
t=k
1SDC200112F0001

tolerances ...................... page 4/16
ABB SACE 4/19

PR122/P
Function U
1SDC200122F0001
4
Function UV
UV
1SDC200123F0001

tolerances ...................... page 4/16
4/20 ABB SACE

Function OV
OV
1SDC200124F0001
4
Function RV
RV
1SDC200125F0001

tolerances ...................... page 4/16
ABB SACE 4/21

PR122/P
Function RP
RP
1SDC200126F0001
4

tolerances ...................... page 4/16
4/22 ABB SACE

PR123/P
Characteristics
The PR123 protection release completes the range of releases
available for the Emax family of circuit-breakers.
It is a high-performance and extraordinarily versatile release,
capable of offering a complete set of functions for protection,
measurement, signalling, data storage and control of the cir-
cuit-breaker, and it represents the benchmark in low voltage
protection units for circuit-breakers.
The front interface of the unit, common to PR122/P, is extremely
simple thanks to the aid of the liquid crystal graphics display. It
can show diagrams, bar graphs, measurements and sine curves
for the various electrical values.
PR123 integrates all the features offered by PR122/P plus a series
of evolute functionalities. As well as PR122 it can be integrated
with the additional features provided by internal modules and
external accessories.
12 11 1 2 3 10 9
4
1SDC200115F0001
8 4 5 7 6
Legend
1 LED Warning indicator 6 Test connector for connecting or 8 Button to exit submenus or cancel
2 Alarm LED testing the release by means of an operations (ESC)
external device (PR030/B battery 9 Rating plug
3 Rear-lit graphic display unit, BT030 wireless communica-
4 Cursor UP button tion unit and SACE PR010/T unit) 10 Serial number of protection release
5 Cursor DOWN button 7 ENTER button to confirm data or 11 Power LED

change pages 12 Voltage uptake switch-disconnector
ABB SACE 4/23

PR123/P
Protection functions
The PR123 release offers the following protection functions:
– overload (L) (1),
– selective short-circuit (S),
– instantaneous short-circuit (I),
– earth fault with adjustable delay (G),
– directional short-circuit with adjustable delay (D),
– phase unbalance (U),
– protection against overtemperature (OT),
– load control (K),
– undervoltage (UV),
– overvoltage (OV),
– residual voltage (RV),
– reverse power (RP),
– underfrequency (UF),
– overfrequency (OF),
Note (1): In accordance with IEC 60255-3.. – phase sequence (alarm only).

I4 < 0.5 In 4 In
0.5 In ≤ I4 < 0,8 In 6 In
I4 ≥ 0.8 In 8 In
4 In = rated current of the rating plug
In addition to PR122/P features, the following improvements are available:

Overload protection L
With the PR123 unit, the overload protection L includes the option to adjust the slope of the
protection curve. This adjustment allows perfect coordination with fuses or with medium-voltage
protection systems.
Double selective short-circuit protection S

In addition to the standard S protection, PR123/P makes contemporarily available a second
time-constant S protection (excludible) that allows two thresholds to be set independently achieving
an accurate selectivity even under highly critical conditions.
Double earth fault protection G

While in PR121/P and PR122/P the user must choose among the implementation of G protection
through internal current sensors (calculating the vectorial sum of currents) or external toroid
(direct earth fault current measuring), PR123/P offers the exclusive feature of the contemporane-
ous management of both the configuration, by means of two independent earth fault protections
curves. The main application of this characteristic is simultaneous activation of restricted and
unrestricted earth fault protection. See chapter 6 for details.
Directional short-circuit protection with adjustable delay D

The protection works in a similar way to the fixed-time protection “S”, with the added ability to
recognize the direction of the phases current during the fault period.
The current direction makes it possible to determine whether the fault is on the supply or load
side of the circuit-breaker. Particularly in ring distribution systems, this makes it possible to iden-
tify and disconnect the distribution segment where the fault has occurred, whilst keeping the rest
of the installation running. If multiple PR122 or PR123 releases are used, this protection can be
associated with zone selectivity.
4/24 ABB SACE

Dual setting of protections
PR123/P can store an alternative set of all the protection parameters. This second set (set B) can
replace, when needed, the default set (set A) by means of an external command. The command
can be given typically when network configuration is modified, like when a parallel of incoming
lines is closed or when an emergency source is present in the system, changing load capability
and short-circuit levels.
The set B can be activated by:

Notes: – digital input provided with PR120/K module. For example It can be connected to an auxiliary
The directional short-circuit protection can be contact of a bus-tie
disabled for an adjustable set time (t = k), and
can either be self-supplied or use the auxiliary – communication network, through PR120/D-M (i.e. when the changeover is scheduled);
power supply. – directly from user interface of PR123/P
Directional protection is not available on 400A
rating. – an adjustable time internal after closing of the circuit-breaker.
Zone selectivity function

The zone selectivity function allows the fault area to be insulated by segregating the system very
rapidly only at the level closest to the fault, whilst leaving the rest of the installation running.
This is done by connecting the releases together: the release nearest the fault is tripped in-
stantly, sending a block signal to the other releases affected by the same fault
The zone selectivity function can be enabled if the fixed-time curve has been selected and an
auxiliary power supply is present.
Zone selectivity can be applied with protections S and G or, alternatively, with protection D.
4
Measurement functions
The PR123 release provides a complete set of measurements:
– Currents:: three phases (L1, L2, L3), neutral (Ne) and earth fault
– Voltage: phase-phase, phase-neutral and residual voltage
– Power: active, reactive and apparent
– Power factor
Ip
– Frequency and peak factor,
Irms
– Energy: active, reactive, apparent, counter
– Harmonics calculation: up to the 40th harmonic (waveform and module of the harmonics dis-
played); up to the 35th for frequency f = 60Hz
– Maintenance: number of operations, percentage of contact wear, opening data storage.
The PR123 unit is able to provide the pattern of measurements for some values over an adjust-
able period of time P, such as: mean active power, maximum active power, maximum current,
maximum voltage and minimum voltage. The last 24 P periods (adjustable from 5 to 120 min.)
are stored in a non-volatile memory and displayed in a bar graph.
Other Functions
PR123/P integrates all the features (in terms of protection, measurement, signaling and commu-
nication) described for PR122/P equipped with PR120/V.
ABB SACE 4/25

PR123/P

Function Trip Threshold Trip Time Can be Relation Thermal Zone
threshold steps Time Step excluded t=f(I) memory selectivity
Overload With current I = 3xI1
protection I1= 0.4….1 x In 0.01 x In t1= 3 s....144 s 3s (1)
– t=k/I2 ■ –
Tolerance (2) Release between ± 10% Ig ≤ 4 x In
1.05 and 1.2 x I1 ± 20% Ig > 4 x In
I1= 0.4….1 x In 0.01 x In With current I = 3xIn(4); t1= 3 s....144 s 3s –
Tolerance 1.05 ... 1.2 x I1 ± 20% Ig > 5 x I1
(in accordance with IEC 60255-3) ± 30% 2xI1≤ Ig ≤ 5 x I1 In
Selective short-circuit With current I > I2
protection I2= 0.6….10 x In 0.1 x In t2= 0.05 s….0.8 s 0.01s ■ t=k – ■
± 10% Ig > 4 x In ± 10% or ± 40 ms
I2= 0.6….10 x In 0.1 x In With current I = 10xIn; t2= 0,05 s…0,8 s 0.01s ■ t=k/I2 ■ –
± 10% Ig > 4 x In ± 20% Ig > 4 x In
protection I2= 0.6….10 x In 0.1 x In t2= 0.05 s….0.8 s 0.01s ■ t=k – ■
± 10% Ig > 4 x In ± 10% or ± 40 ms
I2= 0.6….10 x In 0.1 x In With I = 10xIn; t2= 0,05 s…0,8 s 0.01s ■ t=k/I2 ■ –
± 10% Ig > 4 x In ± 20% Ig > 4 x In
Instantaneous
short-circuit
± 7% ± 10% or ± 40 ms
4 Tolerance (2)
I4= 0.2….1 x In
± 7%
0.02 x In t4= 0.1 s…..1 s (with I=4xIn)
± 15%
0.05 s ■ t=k/I2 – –
Residual Current
Rc protection Id= 0.3-0.5-0.6-1- td= 0.06-0.1-0.2-0.3- 0.4- ■ t=k – –
3-5-7-10-20-30 A 0.5-0.8-1-3-4-4.8 s (3)
Tolerance (2) ± 10%
D Directional With current I > I7
short-circuit I7= 0.6….10 x In 0.1 x In t7= 0.20 s…..0.8 s 0.01 s ■ t=k – ■
protection The better of the two figures:
Tolerance (2) ± 10% ± 10% or ± 40 ms
U Phase unbalance I6= 5%….90% 5% t6= 0.5 s…..60 s 0.5 s ■ t=k – –
Tolerance (2) ± 10% ± 20% or ± 100 ms
overtemperature cannot be set – Instantaneous – – temp=k – –
UV Undervoltage I8= 0.5….0.95 x Un 0.01 x In With current U < U8; t8= 0,1 s….5 s 0.1 s ■ t=k – –
Tolerance (2) ± 5% ± 20% or ± 40 ms
OV Overvoltage I9= 1.05….1.2 x Un 0.01 x In With current U > U9; t9= 0,1 s….5 s 0.1 s ■ t=k – –
Tolerance (2) ± 5% ± 20% or ± 40 ms
RV Residual voltage I10= 0.1….0.4 x Un 0.05 Un With current U0 > U10; t10= 0,5 s….30 s 0.5 s ■ t=k – –
Tolerance (2) ± 5% ± 10% or ± 100 ms
RP Reverse With current P < P11
power P11= -0.3….-0.1 x Pn 0.02 Pn t11= 0.5 s…..25 s 0.1 s ■ t=k – –
Tolerance (2) ± 10% ± 10% or ± 100 ms
UF Underfrequency f12 = 0.90….0.99 x fn 0.01 fn With current f < f12; t9= 0.5 s….3 s 0.1 s ■ t=k – –
Tolerance (2) ± 5% ± 10% or ± 100 ms
OF Overfrequency f13 = 1.01….1.10 x fn 0.01 fn With current f > f13; t10= 0.5 s….3 s 0.1 s ■ t=k – –
Tolerance (2) ± 5% ± 10% or ± 100 ms
(1) The minimum trip value is 1 s, regardless of the type of curve set (self-protection) The following tolerance values apply in all cases not covered by the above:
(2) These tolerances hold in the following conditions:
- self-powered relay at full power and/or auxiliary power supply (without start-up) Trip threshold Trip time
- trip time set ≥ 100 ms L Release between 1.05 and 1.25 x I1 ± 20%
(3) Non intervention time S ± 10% ± 20%
I ± 15% ≤ 60ms
G ± 15% ± 20%
Others ± 20%
4/26 ABB SACE

Power supply
The PR123 release does not normally require any external power supplies, being self-supplied
from the current sensors (CS): to activate the protection and ammeter functions, it is sufficient for
at least one phase to have a current load higher than 100 A. For the display to come on, at least
one phase must have a current load higher than 160 A.
The unit ensures fully self-supplied operation. When an auxiliary power supply is present, it is
also possible to use the unit with the circuit-breaker either open or closed with very low current
flowing through.
It is also possible to use an auxiliary power supply provided by the PR030/B portable battery unit
(always supplied), which allows the protection functions to be set when the release is not self-
supplied.
PR123/P stores and shows all the information needed after a trip (protection tripped, trip current,
time, date). No auxiliary supply is required for this functionality.
PR123/P PR120/D-M PR120/K PR120/D-BT

Auxiliary power supply 24 V DC ± 20% from PR122/PR123 from PR122/PR123 from PR122/PR123
Maximum ripple 5%
Rated power @ 24V ~3 W +1 W +1 W +1 W
PR120/V can give power supply to the release when at least one line voltage is equal or higher to 85V.
ABB SACE 4/27

PR123/P
Functions L-S-I
k
t=
I2
1SDC200110F0001
4
Functions L-S-I
t=k
1SDC200111F0001

tolerances ...................... page 4/26
4/28 ABB SACE

Function G
k
t=
I2
t=k
1SDC200112F0001
4
Function L
According to IEC 60225-3
k = 0,14
α = 0,02
1SDC200118F0001

tolerances ...................... page 4/26
ABB SACE 4/29

PR123/P
Function L
k = 13,5
α=1
1SDC200119F0001
4
Function L
k = 80
α=2
1SDC200120F0001

tolerances ...................... page 4/26
4/30 ABB SACE

Function D
1SDC200121F0001
4
Function U
1SDC200122F0001

tolerances ...................... page 4/26
ABB SACE 4/31

PR123/P
Function UV
UV
1SDC200123F0001
4
Function OV
OV
1SDC200124F0001

tolerances ...................... page 4/26
4/32 ABB SACE

Function RV
RV
1SDC200125F0001
4
Function RP
RP
1SDC200126F0001

tolerances ...................... page 4/26
ABB SACE 4/33

Optional modules
PR122 and PR123 can be enriched with additional internal modules, increasing the capacity of
the release and making these units highly versatile.
Electrical signalling contacts: PR120/K Internal Module

This unit, internally connected to PR122/P and PR123/P, allows the remote signalling of alarms
and trips of the circuit breaker.
Four independent power relays provided on the PR120/K release enable electrical signalling of
the following:
1SDC200300F0001
– timing for protections L, S, G (and UV, OV, RV, RP, D, U, OF, UF where applicable);
– protections L, S, I, G, OT, (and UV, OV, RV, RP, D, U, OF, UF where applicable) tripped and
other events;
– in addition, by using an external device (PR010/T, BT030, PR120/D-BT), the contacts can be
freely configured in association with any possible event or alarm.
PR120/K can also be used as actuator for the Load control function.
In addition the unit can be provided with a digital input signal, enabling the following functions:
– activation of alternative set of parameter (PR123/P only);
– external trip command
– trip reset of the release
– reset of PR120/K power relays
When the digital input is required the power relays have a common connection (see circuit
4 diagrams Chapter 8).
This latest kind of connection must be specified in the order when required together with the
circuit breaker. When PR120/K is ordered as loose accessory both of the configurations are
possible.
The auxiliary 24VDC power supply is needed for the unit (shown by a green Power LED). Four
yellow LEDs show the status of each output relay.
The use of Voltage Transformers is mandatory for rated voltages higher than 690V.
Specifications of the signalling relays

Type Monostable STDP
Maximum switching power
(resistive load) 100 W/1250 VA
Maximum switching voltage 130 V DC/250 V AC
Maximum switching current 5A
Breaking capacity (resistive load)
@ 30V DC 3.3 A
@ 250V AC 5A
Contact/coil insulation 2000 V eff (1 min@ 50 Hz)
PR120/V Measurement Module

This optional internal module can be added to PR122, and it is supplied as standard in PR123. It
measures and processes the phase and neutral voltages, are transferring these values to the
protection release by means of its internal bus in order to achieve a series of protection and
measurement features.
It can be connected at any time to PR122/P, which recognizes it automatically without the need
1SDC200114F0001
of any configuration.
PR122 does not normally require any external connection or Voltage Transformer, since it is
connected internally to the lower terminals of Emax. When necessary, the connection of voltage
pick-ups can be moved to any other points (i.e. upper terminals), by using the alternative con-
nection located in the terminal box.
When ordered as a loose accessory, PR122 is provided with all the possible connections, inter-
nal or through the terminal box.
The module is provided with a Power LED and a sealable switch-disconnector for the dielectric test.
4/34 ABB SACE

PR120/D-M Communication Module
PR120/D-M communication module is the solution for connecting Emax to a Modbus network,
allowing the remote supervision and control of the circuit-breaker.
It is suitable for PR122/P and PR123/P releases. As for PR120/V this module can be added at
any time to the protection release and its presence is automatically recognized. When ordered
1SDC200301F0001
separately from the circuit-breakers it is supplied complete of all the accessories needed for its
installation, such as precabled auxiliary switches and cables for signalling the curcuit-breaker
status (springs, position inserted). Refer to circuit diagram page 8/8 for details about connec-
tions.
The list of available functions can be found on page 4/41.
It is provided with three LEDS on the front side:
– Power LED
– Rx/Tx LEDs
PR120/D-BT Wireless Communication Module

PR120/D-BT is the innovative wireless communication module, based on Bluetooth standard. It
allows the communication among the PR122/P and PR123/P Protection releases and a PDA or a
Notebook with a Bluetooth port. This device is dedicated to the use with SD-Pocket application
(see in the following the features of this application).
The module can be powered by means of te 24V DC auxiliary supply or by means of PR130/B
1SDC200302F0001
battery unit.
It is provided with four LEDS on the front side:
– Power LED
– Rx/Tx LEDs 4
– Bluetooth LED, showing the activity of Bluetooth communication
PR120/D-BT can be connected at any time to the protection release.
BT030 Communication unit

BT030 is a device to be connected on Test connector of PR121/P, PR122/P and PR123/P. It
allows Bluetooth communication among the Protection release and a PDA or a Notebook with a
Bluetooth port. BT030 can also be used with Tmax circuit breakers equipped with PR222DS/PD.
This device is dedicated to the use with SD-Pocket application.
BT030 can provide the power supply needed to energize itself and the protection release by
means of a Li-ion rechargeable battery.
PR030/B power supply unit

This accessory, always supplied with the PR122 and PR123 range of releases, makes it
possible to read and configure the parameters of the unit whatever the status of the circuit-
breaker (open-closed, in test isolated or racked-in position, with/without auxiliary power supply).
PR030/B is also needed for reading trip data if the trip occurred more than 48 hours earlier and
the release was no longer powered.
An internal electronic circuit supplies the unit for approximately 3 consecutive hours for the
sole purpose of reading and configuring data.
In relation to the amount of use, battery life decreases if the SACE PR030/B accessory is also
used to perform the Trip test & Auto test.
Interface from front of HMI030 panel

This accessory, suitable for all protection releases, is designed for the installation on the front
side of the switchboard. It consists of a graphic display where all the measurements and
alarms/events of the release are shown. The user can browse the measurements by using the
navigation pushbuttons, similarly to PR122/P and PR123/P. Thanks to the high precision level,
the same of the protection releases, the device can replace the traditional instrumentation,
without the need for current/voltage transformers. The unit requires only a 24 V DC power
supply. In fact HMI030 is connected directly to the protection release via a serial line.
ABB SACE 4/35

SACE PR010/T configuration test unit

The SACE PR010/T unit is an instrument capable of performing the functions of testing, program-
ming and reading parameters for the protection units equipping SACE Emax low-voltage air
circuit-breakers.
In particular, the test function involves the following units:
– PR121 (all versions)
whereas the parameter programming and reading functions regard the range of PR122 and
PR123 releases.
All of the functions mentioned can be carried out “on board” by connecting the SACE PR010/T
unit to the front multi-pin connector on the various protection units. Special interfacing cables
supplied with the unit must be used for this connection.
1SDC200129F0001
The human-machine interface takes the form of a touchpad and multi-line alphanumeric display.
The unit also has two LEDs to indicate, respectively:
– POWER-ON and STAND BY
– battery charge state.
Two different types of test are available: automatic (for PR121, PR122 and PR123) and manual.
By connection to a PC (using the floppy-disc supplied by ABB SACE), it is also possible to
upgrade the software of the SACE PR010/T unit and adapt the test unit to the development of
new products.
It is also possible to store the most important test results in the unit itself, and to send a report to
the personal computer with the following information:
– type of protection tested
– threshold selected
4 – curve selected
– phase tested
– test current
– estimated trip time
– measured trip time
– test results.
At least 5 complete tests can be stored in the memory. The report downloaded onto a PC allows
creation of an archive of tests carried out on the installation.
In automatic mode, the SACE PR010/T unit is capable of testing the following with the PR122
range:
– protection functions L, S, I,
– G protection function with internal transformer,
– G protection function with toroid on the transformer star centre,
– monitoring of correct microprocessor operation.
The unit can also test the following protections of PR122 equipped with PR120/V:
– overvoltage protection function OV,
– undervoltage protection function UV,
– residual voltage protection function RV,
– phase unbalance protection function U.
The SACE PR010/T unit is portable and runs on rechargeable batteries and/or with an external
power supply (always supplied) with a rated voltage of 100-240V AC/12V DC.
The standard version of the SACE PR010/T unit includes:

– SACE PR010/T test unit complete with rechargeable batteries
– SACE TT1 test unit
– 100 - 240V AC/12V DC external power supply with cord
– cables to connect the unit and connector
– cable to connect the unit and computer (RS232 serial)
– user manual and floppy-disc containing application software
– plastic bag.
4/36 ABB SACE

SACE PR021/K signalling unit
The SACE PR021/K signalling unit can convert the digital signals supplied by the PR121, PR122
and PR123 protection unit into electrical signals, via normally open electrical contacts (potential
free).
The unit is connected to the protection release by means of a dedicated serial line through which
all of the information about the activation status of the protection functions flows. The corre-
sponding power contacts are closed based on this information.
The following signals/contacts are available:
– overload pre-alarm L (the alarm signal remains active throughout the overload, until the re-
lease is tripped)
– timing and tripping of any protections (the trip signals of the protections remain active during
the timing phase, and after the release has tripped)
– protection I tripped
– timing and overtemperature threshold exceeded (T>85 °C)
– two load control contacts (connection and disconnection of a load, or disconnection of two
loads)
– release tripped
– dialogue fault on a serial line (connecting the protection and signalling units)
– phase unbalance.
Setting a dip-switch allows up to seven signal contacts to be freely configured in PR122-PR123,

including: directional protection D tripped, under- and overvoltage UV and OV tripped, reverse
power RP tripped, and others.
4
Two contacts available on the SACE PR021/K unit (load control) can pilot a circuit-breaker shunt
opening or closing release. These contacts allow various applications, including load control,
alarms, signals and electrical locks.
Pressing the Reset pushbutton resets the status of all signals.
The unit also contains ten LEDs to visually signal the following information:
– “Power ON”: auxiliary power supply present
– “TX (Int Bus)”: flashing synchronized with dialogue with the Internal Bus
– eight LEDs associated with the signalling contacts.
The table below lists the characteristics of the signalling contacts available in the SACE PR021/K
unit.
Auxiliary power supply 24 V DC ± 20%

Maximum ripple 5%
Rated power @ 24 V 4.4 W
Specifications of the signalling relays

Type Monostable STDP
Maximum switching power
(resistive load) 100 W/1250 VA
Maximum switching voltage 130 V DC/250 V AC
Maximum switching current 5A
Breaking capacity (resistive load)
@ 30V DC 3.3 A
@ 250V AC 5A
Contact/coil insulation 2000 V eff (1 min@ 50 Hz)
ABB SACE 4/37

Industrial networking and ABB SACE Emax

In addition to providing flexible and safe protection of power
installations, ABB SACE Emax electronic releases have an ex-
tended range of communication features, which opens the way
for connection of circuit-breakers to the world of industrial com-
munication.
PR122 and PR123 electronic releases can be fitted with com-
munication modules, which make it possible to exchange data
and information with other industrial electronic devices by means
of a network.
The basic communication protocol implemented is Modbus RTU,
a well-known standard of widespread use in industrial automa-
tion and power distribution equipment. A Modbus RTU commu-
nication interface can be connected immediately and exchange
data with the wide range of industrial devices featuring the same
protocol.
ABB products featuring the Modbus RTU protocol include:
1SDC200303F0001
• low voltage circuit breakers such as Emax,
• Medium Voltage protection devices
• sensors,
• automation I/O systems,
• power meters and other measurement devices,
4 • intelligent devices such as PLCs,
• operator interfaces
• supervision and control systems.
And if other communication protocols are required, the ABB Fieldbus Plug system is also avail-
able: intelligent field bus protocols such as Profibus-DP and DeviceNet thus become immedi-
ately available.
The power of industrial networking

The communication network can be used to read all information available in the protection re-
lease, from any location connected to the bus and in real time:
• circuit-breaker status: closed, open, opened by protection release trip
• all values measured by the protection release: RMS currents, voltages, power, power factor
and so on
• alarms and prealarms from protection release, e.g., overload protection alarm (timing to trip or
prealarm warning)
• fault currents in case of circuit-breaker opening on a protection trip
• number of operations performed by the circuit-breaker, with indication of the number of trips
per protection type (short-circuit, overload, etc.)
• complete settings of the protection release
• estimate of the residual life of circuit-breaker contacts, calculated on the basis of interrupted
currents
Remote control of circuit-breakers is possible: commands to open, close and reset alarms can
be issued to the circuit-breaker and protection release. Close commands are executed only after
a security check (e.g., that there are no diagnostic alarms active on the release).
It is also possible to change the settings of the protection release remotely by means of the
communication bus.
All remote commands can be disabled by a “local” configuration feature, for safety of operators
and installation.
4/38 ABB SACE

Circuit-breakers with communication can easily be integrated with automation and supervision
systems. Typical applications include:
– supervision of the installation with continuous data logging (values of currents, voltage, power)
and event logging (alarms, faults, trip logs). Supervision can be limited to low voltage devices
or include medium voltage and possibly other kinds of industrial apparatus
– predictive maintenance, based on number of operations of each circuit-breaker, interrupted
currents and estimate of residual equipment life
– load shedding and demand side management under control of PLC, DCS or computers.
Communication products for ABB SACE Emax

ABB SACE has developed a complete series of accessories for the Emax family of electronic
releases:
– PR120/D-M communication module
– EP010 – FBP.
Furthermore, a new generation of software dedicated to installation, configuration, supervision
and control of protection releases and circuit-breakers is now available:
– SDView 2000
– SD-Pocket
– TestBus2.
System architecture for plant supervision and control
M.V. protection
Emax with PR122/123
Moulded case breakers

with communication
Meter with communication

1SDC200310F0001
(e.g., remote power measurement)
ABB SACE 4/39

PR120/D-M
PR120/D-M is the new communication module for PR122/P and PR123/P protection releases.
1SDC200304F0001
It is designed to allow easy integration of the Emax circuit-breakers in a Modbus network.

The Modbus RTU protocol is of widespread use in the power as well as the automation industry.
It is based on a master/slave architecture, with a bandwidth of up to 19200 Kbytes/sec. A
standard Modbus network is easily wired up and configured by means of an RS485 physical
layer. ABB SACE releases work as slaves in the field bus network.
All information required for simple integration of PR120/D-M in an industrial communication sys-
tem are available on the ABB Web page.
BT030
BT030 is a device to be connected to the Test connector of PR121/P, PR122/P and PR123/P. It
allows Bluetooth communication between the Protection release and a PDA or a Notebook with
a Bluetooth port.
BT030 can also be used with Tmax circuit-breakers equipped with PR222DS/PD. This device is
dedicated to use with the Sd-Pocket application.
It can provide the auxiliary supply needed to energize the protection release by means of re-
chargeable batteries.
4
EP 010 - FBP
EP 010 – FBP is the Fieldbus Plug interface between the Emax protection releases and the ABB
Fieldbus Plug system, allowing connection of Emax Circuit-breakers to a Profibus, DeviceNet, or
AS-I field bus network.
EP 010 – FBP can be connected to the new Emax PR122 and PR123 protection releases (the
PR120/D dialogue module is required).
The ABB Fieldbus Plug concept is the latest development in industrial communication systems.
1SDC200305F0001
All devices feature a standard connection socket, to which a set of interchangeable “smart”
connectors can be plugged. Each connector is fitted with advanced electronics implementing
the communication interface towards the selected field bus. Selecting a communication system
is made as easy as selecting and connecting a plug. Communication systems currently avail-
able are Profibus-DP, DeviceNet and AS-i. More are being developed.
4/40 ABB SACE

Measurement, signalling and available data functions
Details about functions available on PR122/P, PR123/P releases with PR120/D-M and EP010 – FBP are listed in the table below:
PR122/P PR123/P PR122/P-PR123/P

+ PR120/D-M + PR120/D-M + PR120/D-M
and EP 010
Communication functions
Protocol Modbus RTU Modbus RTU FBP
Physical layer RS-485 RS-485 Profibus-DP or
DeviceNet cable
Maximum baudrate 19200 bps 19200 bps 115 kbps
Measuring functions
Phase currents ■ ■ ■
Neutral current ■ ■ ■
Ground current ■ ■ ■
Voltage (phase-phase, phase-neutral, residual) opt. (1) ■ on demand (2)
Power (active, reactive, apparent) opt. (1) ■ on demand (2)
Power factor opt. (1) ■ on demand (2)
Frequency and peak factor opt. (1) ■ on demand (2)
Energy (active, reactive, apparent) opt. (1) ■ on demand (2)
Harmonic analisys up to the 40th harmonic ■ on demand (2)
Signalling functions
LED: auxiliary power supply, warning, alarm ■ ■ ■
Temperature ■ ■ ■
Indication for L, S, I, G and other protection opt. (1) ■ ■
Available data
Circuit-breaker status (open, closed) ■ ■ ■ 4
Circuit-breaker position (racked-in, racked-out) ■ ■ ■
Mode (local, remote) ■ ■ ■
Protection parameters set ■ ■ ■
Load control parameters ■ ■ ■
Alarms
Protection L ■ ■ ■
Protection S ■ ■ ■
Protection I ■ ■ ■
Protection G ■ ■ ■
Fault release mechanism failure ■ ■ ■
Undervoltage, overvoltage and residual voltage
(timing and trip) protection opt. (1) ■ on demand (2)
Reverse power protection (timing and trip) opt. (1) ■ on demand (2)
Directional protection (timing and trip) ■ ■ PR123 only
Underfrequency/overfrequency protection (timing and trip) opt. (1) ■ on demand (2)
Phases rotation ■ on demand (2)
Maintenance
Total number of operations ■ ■ ■
Total number of trips ■ ■ ■
Number of trip tests ■ ■ ■
Number of manual operations ■ ■ ■
Number of separate trips for each protection function ■ ■ ■
Contact wear (%) ■ ■ ■
Record data of last trip ■ ■ ■
Operating mechanisms
Circuit-breaker openi/close ■ ■ ■
Reset alarms ■ ■ ■
Setting of curves and protection thresholds ■ ■ ■
Synchronize system time ■ ■ ■
Events
Status changes in circuit-breaker, protections and all alarms ■ ■ ■
(1) with PR120/V

(2) please ask ABB for further details
ABB SACE 4/41

SD-View 2000
SD-View 2000 is a “ready-to-use” system, consisting of software for personal computers, in stan-
dard configuration, which allows complete control of the low voltage electrical installation.
Putting the SD-View 2000 system into operation is quick and easy. In fact, the software itself
guides the user in recognising and configuring the protection units.
The user only needs knowledge of the installation (such as how many circuit-breakers are in-
stalled and how they are connected to each other). No engineering work on the supervision
system is required, since all the pages displayed are already configured in the system, ready to
be used.
Usage of the software is intuitive and easy to learn for the operator: SD-View 2000 has graphic
pages based on Internet Explorer, which make the system as simple to manage as surfing on the
Internet.
System architecture
System architecture is based on the latest developments in personal computer and industrial
communication network technology.
The ABB SACE devices are connected to the serial bus RS485 Modbus. A maximum of 31
devices can be connected to a bus. A maximum of 4 serial bus can lines be connected to a
personal computer which works as data server, reading and storing the data received from the
devices. The server is also used as the operator station, from where the data can be displayed
4 and printed, commands can be sent to the devices, and all the operations needed to manage
the installation can be carried out.
The server can be connected to a local network together with other personal computers which
work as additional operator stations (clients). In this way, installation supervision and control can
be carried out with total reliability from any station connected to the network on which SD-View
2000 is installed.
Modbus RTU on RS-485
Converter
RS232-RS485
Tmax T1-T3 Tmax T4-T5 Isomax S4-S7 Emax E1-E6

1SDC200306F0001
+ AC31 + PR222DS/PD + PR212/PD + PR122 or PR123

+ PR120/D-M
4/42 ABB SACE

Complete control of the installation
SD-View 2000 is the ideal tool available to managers, in order to have the situation of the instal-
lations under control at all times and to be able to control all the functions easily and in real time.
1SDC200307F0001
The SD-View 2000 operator station (personal computer) allows information from the installation to
be received and to control the circuit-breakers and relative releases. In particular, it is possible to:
– Send opening and closing commands to the circuit-breakers
– Read the electrical installation values (current, voltage, power factor, etc.)
– Read and modify the trip characteristics of the protection units
4
– Determine the status of the apparatus (open, closed, number of operations, trip for fault, etc.)
– Determine abnormal operating situations (e.g. Overload) and, in the case of the releases trip-
ping, the type of fault (short-circuit, earth fault, value of the uninterrupted currents, etc.)
– Log the history of the installation (energy consumption, most highly loaded phase, any warn-
ings of anomalies or faults, etc.)
– Show the temporal evolution of the installation by means of graphs.
Access to the various system functions can be enabled by means of se-
cret codes or passwords with different levels of authorisation.
Usage of the system is really simple thanks to the user interface based on
Internet explorer. The graphic pages relative to each circuit-breaker are
particularly intuitive and easy to use.
Devices which can be connected

The circuit-breakers with electronic releases which can be interfaced with
SD-View 2000 are:
1SDC200308F0001
• Emax LV air circuit-breakers from E1 to E6 fitted with PR122/P or PR123/P

releases with Modbus RTU PR120/D-M communication unit
• Emax LV air circuit-breakers from E1 to E6 fitted with PR112/PD or
PR113/PD Modbus releases
• Tmax LV moulded-case circuit-breakers T4 and T5 fitted with PR222/PD
release
• Isomax LV circuit-breakers from S4 to S7 fitted with PR212/P release with
Modbus RTU PR212/D-M communication unit.
In addition, SD-View 2000 can acquire current, voltage and power measure-
ments in real time from the MTME-485 multimeters with Modbus communi-
cation
Furthermore, it is possible to interface any air or moulded-case circuit-breaker
or switch-disconnector, not fitted with electronics, with SD-View 2000 by
using a PLC AC31 unit as the communication module. For the circuit-break-
1SDC200309F0001
ers or switch-disconnectors connected in this way, SD-View 2000 shows the

conditions of the apparatus (open, closed, tripped, racked-in or racked-out)
in real time and allows it to be operated remotely.
ABB SACE 4/43

All the characteristics of the devices listed are preconfigured in the SD-View 2000 system. The
user does not therefore have to carry out any detailed configuration (i.e. insert tables with data to
be displayed for each release, or draft ad hoc graphic pages): simply enter the list of devices
connected into the system.
Technical characteristics
Up to 4 serial ports
Up to 31 ABB SACE devices for each serial port
9600 or 19200 baud
Modbus® RTU Protocol
Personal computer requirements

Pentium 1 GHz, 256 MB RAM (512 MB recommended), 20 GB hard disk, Windows 2000, Internet
Explorer 6, Ethernet card, Printer (optional)
SD-Pocket
4 SD-Pocket is an application designed to connect the new protection releases to a PDA or to a
personal computer. This means it is now possible to use wireless communication to:
– configure the protection threshold function
– monitor measurement functions, including reading of data recorded in data logger (PR122/
PR123)
– verify the status of the circuit-breaker (i.e. number of operations, trip data, according to the
release connected).
SD-Pocket application scenarios include:
• during start-up of switchgear, with rapid and error-free transfer of the protection parameters to
the releases (also using the dedicated exchange file directly from Docwin);
• during normal installation service, gathering information on the circuit-breaker and load condi-
tions (last trip information, runtime currents, and other information).
To use all these functions, it is sufficient to have a PDA with MS Windows Mobile 2003 and BT
interface or a personal computer with MS Windows2000 OS and new PR120/D-BT or BT030
Bluetooth interface devices.
SD-Pocket is freeware and it can be downloaded from the BOL website (http://bol.it.abb.com).
Its use does not require the presence of dialogue units for the releases.
4/44 ABB SACE

TestBus2
TestBus2 is the ABB SACE commissioning and diagnostic software for all Modbus RTU devices.
It can be used during system startup, or to troubleshoot an installed network.
TestBus2 automatically scans the RS-485 bus, detects all connected devices and checks their
communication settings. All possible combination of device address, parity and baud rate are
checked.
A click on “scan” is enough to spot devices which are not responding, wrong addresses,
misconfigured parity bits, and so on. This function is not limited to ABB SACE devices: all stan-
dard Modbus RTU devices are detected and their configuration is displayed.
After the scan, the software displays warning messages about potential problems and configu-
ration errors, allowing com-
1SDC200311F0001
plete diagnosis of a field bus
network.
When ABB SACE circuit break-
ers are detected, additional
functions can be used to
check wirings, send open/
close/reset commands, and
retrieve diagnostic information.
This user-friendly tool makes
commissioning of Modbus net-
works a breeze. TestBus2 is
freeware and can be down-
4
loaded from the BOL website
(http://bol.it.abb.com).
ABB SACE 4/45

Accessories
Contents
Functions of the accessories ....................................................................................... 5/2
Accessories supplied as standard .............................................................................. 5/3
Accessories supplied on request ..................................................................................... 5/4
Shunt opening and closing releases ............................................................................... 5/6
Undervoltage release ......................................................................................................... 5/8
Geared motor for the automatic charging of closing springs .................................. 5/10
Signalling of overcurrent releases tripped ...................................................................... 5/11
Auxiliary contacts ............................................................................................................... 5/12
Transformers and operation counters ............................................................................. 5/15

5
Mechanical safety locks .................................................................................................... 5/16
Transparent protective covers .......................................................................................... 5/18
Interlock between circuit-breakers ................................................................................... 5/19
Automatic transfer switch - ATS010 ................................................................................. 5/22
Spare parts and Retrofitting .............................................................................................. 5/25
ABB SACE 5/1

Functions of the accessories
The table below lists a few functions that can be obtained by

selecting the appropriate accessories from among those pro-
vided. Several of the functions listed may be needed at the same
time, depending on how the circuit-breaker is used. See the
relative section for a detailed description of the individual ac-
cessories.
Components
Function
• Opening release
Remote control • Closing release
• Geared motor for automatic charging of the closing springs
• Circuit-breaker open-closed auxiliary contacts

• Circuit-breaker racked-in, test isolated, racked-out auxiliary
Remote signalling or actuation of automatic functions contacts (withdrawable circuit-breaker only)
depending on the state (open-closed-tripped) or position • Contact for electrical signalling of overcurrent releases tripped
(racked-in, test isolated, racked-out) of the circuit-breaker.
• Contact for signalling undervoltage release de-energized
• Contact for signalling springs charged
Remote opening for various needs, including:

– manual emergency control
– opening dependent on tripping of other interruption • Opening or undervoltage release
devices or system automation needs (1).
5 Automatic opening of the circuit-breaker for undervoltage • Instantaneous or time delay undervoltage release (2)
(for example, when operating asynchronous motors) • Contact for signalling undervoltage release energized
Increased degree of protection • IP54 door protection
• Key lock in open position

Mechanical safety locks for maintenance or functional • Padlock device in open position
requirements for interlocking two or more circuit-breakers • Key lock and padlocks in racked-in, test isolated, racked-out
position
• Mechanical interlock between two or three circuit-breakers

Automatic switching of power supplies
• Automatic transfer switch - ATS010
(1) Examples: (2) The time-delay device is recommended when unwanted operation due to temporary
– circuit-breakers on Low Voltage side of parallel transformers that must open voltage drops, is to be avoided (for functional or safety reasons).
automatically when the Medium Voltage side device opens.
– automatic opening for control by external relay (undervoltage, residual current, etc.).
5/2 ABB SACE

Accessories supplied as standard
The following standard accessories are supplied depending on

the circuit-breaker version:
Fixed circuit-breaker:
– flange for switchgear compartment door (IP30)
– support for service releases
– four auxiliary contacts for electrical signalling of circuit-breaker
open/closed (for automatic circuit-breakers only)
– terminal box for connecting outgoing auxiliaries
– mechanical signalling of overcurrent release tripped (*)
Note:
(*) Not supplied with the switch discon-
– horizontal rear terminals
nector. – lifting plate
Withdrawable circuit-breaker:
– flange for switchgear compartment door
– support for service releases
– four auxiliary contacts for electrical signalling of circuit-breaker
5
open/closed (for automatic circuit-breakers only)
– sliding contacts for connecting outgoing auxiliaries
– mechanical signalling of overcurrent release tripped (*)
– horizontal rear terminals
– anti-insertion lock for circuit-breakers with different rated cur-
rents
Note:
(*) Not supplied with the switch discon-
– racking-out crank handle
nector. – lifting plate
ABB SACE 5/3

Accessories supplied on request
The ranges Automatic circuit-breakers

Circuit-breakers with
full-size neutral
Circuit-breakers for
applications up to 1150V AC
Circuit-breaker version Fixed Withdrawable
1a) Shunt opening/closing release (YO/YC)
and second opening release (YO2) ■ ■
1b) SOR test unit ■ ■
2a) Undervoltage release (YU) ■ ■
2b) Time-delay device for undervoltage release (D) ■ ■
3) Geared motor for the automatic charging of the closing springs (M) ■ ■
4a) Electrical signalling of electronic releases tripped ■ ■
4b) Electrical signalling of electronic releases tripped with remote reset command ■ ■
5a) Electrical signalling of circuit-breaker open/closed (1) ■ ■
5b) External supplementary electrical signalling of circuit-breaker open/closed ■ ■
5c) Electrical signalling of circuit-breaker racked-in/test isolated/racked-out ■
5d) Contact signalling closing springs charged ■ ■
5e) Contact signalling undervoltage release
de-energized (C. Aux YU) ■ ■
6a) Current transformer for neutral conductor outside circuit-breaker ■ ■
6b) Homopolar toroid for the main power supply earthing
conductor (star center of the transformer) ■ ■
6c) Homopolar toroid for residual current protection ■ ■
7) Mechanical operation counter ■ ■
8a) Lock in open position: key ■ ■
8b) Lock in open position: padlocks ■ ■
5 8c) Circuit-breaker lock in racked-in/racked-out/test isolated position ■
8d) Accessories for lock in racked-out/test isolated position ■
8e) Accessory for shutter padlock device ■
8f) Mechanical lock for compartment door ■ ■
9a) Protection for opening and closing pushbuttons ■ ■
9b) IP54 door protection ■ ■
10) Interlock between circuit-breakers (2) ■ ■
11) Automatic transfer switch - ATS010 (3) ■ ■
CAPTION
■ Accessory on request for fixed circuit-breaker or moving part
■ Accessory on request for fixed part
■ Accessory on request for moving part
5/4 ABB SACE

Switch-disconnectors Sectionalizing Earthing switch Earthing
for applications up to 1150V AC truck with making capacity truck
(CS) (MPT) (MT)
for applications up to 1000V DC
Fixed Withdrawable Withdrawable Withdrawable Withdrawable
■ ■ ■ (YC)
■ ■
■ ■
■ ■
■ ■ ■
■ ■ ■
■ ■ ■
■ ■ ■ ■
■ ■ ■
■ ■
■ ■ ■
■ ■ ■
■ ■ ■
■ ■ ■ ■ 5
■ ■ ■ ■
■ ■ ■ ■
■ ■ ■
■ ■ ■
■ ■ ■
■ ■
■ ■
(1) For automatic circuit-breakers, four auxiliary contacts to electrically signal circuit-breaker open/closed are included in the supply as standard.
(2) Incompatible with the E6/f versions with full-size neutral
(3) Incompatible with the range of circuit-breakers for applications up to 1150V AC
ABB SACE 5/5

Shunt opening and closing releases
1a) Shunt opening and closing release (YO/YC)

and second opening release (YO2)
(1) The minimum impulse current du- Allows remote control opening or closing of the apparatus, depending on the installation position
ration time in instantaneous service and connection of the releases on the support. The release can, in fact, be used for either of
must be 100 ms
these two applications. Given the characteristics of the circuit-breaker operating mechanism,
(2) If the opening release is perma- opening (with the circuit-breaker closed) is always possible, whereas closing is only possible
nently connected to the power supply,
wait at least 30 ms before sending the when the closing springs are charged. The release can operate with direct current or alternating
command to the shunt closing release. current. This release provides instantaneous operation (1), but can be powered permanently (2).
Some installations require very high safety in controlling circuit-breaker opening remotely. In
particular, the control and opening release circuits must be duplicated. To meet these needs,
SACE Emax circuit-breakers can be equipped with a second shunt opening release, fitted with a
special support to hold it, that can house the standard shunt closing and opening releases.
The seat of the second shunt opening release is that of the undervoltage release, which is there-
fore incompatible with this type of installation. The special support, including the second shunt
opening release, is installed in place of the standard support.
The technical specifications of the second shunt opening release remain identical to those of the
standard shunt opening release.
When used as a permanently powered closing release, it is necessary to momentarily de-ener-
gize the shunt closing release in order to close the circuit-breaker again after opening (the cir-
cuit-breaker operating mechanism has an anti-pumping device).
1SDC200131F0001
Reference figure in electrical circuit diagrams: YO (4) - YC (2) - YO2 (8)
5
1SDC200132F0001
1SDC200133F0001
1SDC200134F0001
Characteristics
Power supply (Un): 24 V DC 120-127 V AC/DC
30 V AC/DC 220-240 V AC/DC
48 V AC/DC 240-250 V AC/DC
60 V AC/DC 380-400 V AC
110-120 V AC/DC 440 AC
Operating limits: (YO-YO2): 70% ... 110% Un
(IEC EN 60947-2 Standards) (YC): 85% ... 110% Un
Inrush power (Ps): DC = 200 W
Inrush time ~100 ms AC = 200 VA
Continuous power (Pc): DC = 5 W
AC = 5 VA
Opening time (YO- YO2): (max) 60 ms
Closing time (YC): (max) 80 ms
Insulation voltage: 2500 V 50 Hz (for 1 min)
5/6 ABB SACE

1b) SOR Test Unit
The SOR control and monitoring Test Unit helps ensure that the
various versions of SACE Emax opening releases are running
smoothly, to guarantee a high level of reliability in controlling
circuit-breaker opening.
Under particularly severe operating conditions or simply for re-
mote control of the circuit-breaker, the opening release is widely
used as an accessory for the SACE Emax series of air circuit-
breakers.
1SDC200135F0001
Keeping all the functions of this accessory is a necessary con-

dition to guarantee a high level of safety in the installation: it is
therefore necessary to have a device available which cyclically
checks correct operation of the release, signalling any malfunc-
tions.
The SOR control and monitoring Test Unit ensures the continu-
ity of opening releases with a rated operating voltage between
24 V and 250 V (AC and DC), as well as the functions of the
opening coil electronic circuit are verified.
Continuity is checked cyclically with an interval of 20s between
tests.
The unit has optic signals via LEDs on the front, which provide
the following information in particular:
– POWER ON: power supply present
– YO TESTING: test in progress
– TEST FAILED: signal following a failed test or lack of auxiliary
power supply
– ALARM: signal given following three failed tests.
Two relays with one change-over are also available on board
the unit, which allow remote signalling of the following two events:
5
– failure of a test - resetting takes place automatically when the
alarm stops )
– failure of three tests - resetting occurs only by pressing the
manual RESET on the front of the unit)
There is also a manual RESET button on the front of the unit.
Reference figure in electrical circuit diagrams: AY(61)
Characteristics
Auxiliary power supply 24 V ... 250 V AC/DC
Maximum interrupted current 6A
Maximum interrupted voltage 250V AC
ABB SACE 5/7

Undervoltage release
2a) Undervoltage release (YU)

The undervoltage release opens the circuit-breaker when there
is a significant voltage drop or power failure. It can be used for
remote release (using normally-closed pushbuttons), for a lock
on closing or for monitoring the voltage in the primary and sec-
ondary circuits. The power supply for the release is therefore
obtained on the supply side of the circuit-breaker or from an
independent source. The circuit-breaker can only be closed
when the release is powered (closing is mechanically locked).
The release can operate with direct current or alternating cur-
1SDC200136F0001
rent.
The circuit-breaker is opened with release power supply voltages
of 35-70% Un.
The circuit-breaker can be closed with a release power supply
voltage of 85-110% Un.
It can be fitted with a contact to signal when the undervoltage
release is energized (C. aux YU) (see accessory 5e).
Reference figure in electrical circuit diagrams: YU (6)
Characteristics
Power supply (Un): 24 V DC 120-127 V AC/DC
30 V AC/DC 220-240 V AC/DC
48 V AC/DC 240-250 V AC
60 V AC/DC 380-400 V AC
5 Operating limits:
110-120 V AC/DC 440 V AC
CEI EN 60947-2 Standards
AC = 200 VA
AC = 5 VA
Opening time (YU): 30 ms
1SDC200137F0001
5/8 ABB SACE

2b) Time-delay device for undervoltage
release (D)
The undervoltage release can be combined with an electronic
time-delay device for installation outside the circuit-breaker, al-
lowing delayed release tripping with adjustable preset times.
Use of the delayed undervoltage release is recommended to
prevent tripping when the power supply network for the release
is subject to brief voltage drops or power supply failures.
1SDC200138F0001
Circuit-breaker closing is inhibited when it is not powered.

The time-delay device must be used with an undervoltage re-
lease with the same voltage.
Reference figure in electrical circuit diagrams: YU +D (7)
Characteristics
Power supply (D): 24-30 V DC
48 V AC/DC
60 V AC/DC
110-127 V AC/DC
220-250 V AC/DC
Adjustable opening time (YU+D): 0.5-1-1.5-2-3 s
ABB SACE 5/9

Geared motor for the automatic charging of
the closing springs
3) Geared motor for the automatic charging

of the closing springs (M)
This automatically charges the closing springs of the circuit-
breaker operating mechanism. After circuit-breaker closing,
the geared motor immediately recharges the closing springs.
The closing springs can, however, be charged manually (using
the relative operating mechanism lever) in the event of a power
supply failure or during maintenance work.
It is always supplied with a limit contact and microswitch for
signalling that the closing springs are charged (see accessory
5d).
1SDC200139F0001
Reference figure in electrical circuit diagrams: M (1)
Characteristics
Power supply 24-30 V AC/DC
48-60 V AC/DC
100-130 V AC/DC
220-250 V AC/DC
Operating limits: 85%...110% Un (CEI EN 60947-2 Standards)
AC = 500 VA
Rated power (Pn): DC = 200 W
AC = 200 VA
Inrush time 0.2 s
5 Charging time: 4-5 s
1SDC200140F0001
5/10 ABB SACE

Signal for overcurrent releases tripped
4) Electrical signalling of electronic

releases tripped
The following signals are available after the electronic release
has tripped:
4a) Electrical signalling of electronic releases tripped

This allows visual signalling on the operating mechanism
(mechanical) and remote signalling (electrical using switch) that
the circuit-breaker is open following operation of the overcurrent
releases. The mechanical signalling pushbutton must be
rearmed to reset the circuit-breaker.
Reference figure in electrical circuit diagrams: S51 (13)

1SDC200141F0001
Available reset coils

4b) Electrical signalling of electronic releases tripped with
24-30 V AC/DC
remote reset command 220-240 V AC/DC 5
This allows visual signalling on the operating mechanism (me- 110-130 V AC/DC
chanical) and remote signalling (electrical using switch) that
the circuit-breaker is open following operation of the overcurrent
releases. With this accessory, it is possible to reset the mechani-
cal signalling pushbutton via an electrical coil from a remote
command, which also allows the circuit-breaker to be reset.
Reference figure in electrical circuit diagrams: S51 (14)

1SDC200144F0001
ABB SACE 5/11

Auxiliary Contacts
5) Auxiliary contacts
Auxiliary contacts are available installed on the circuit-breaker,
which enable signalling of the circuit-breaker status. The auxil-
iary contacts are also available in a special version for applica-
tion with rated voltages Un < 24 V (digital signals).
Characteristics
Un In max T
125 V DC 0.3 A 10 ms
250 V DC 0.15 A
Un In max ϕ
cosϕ
250 V AC 15 A 0,3
The versions available are as follows:
5a-5b) Electrical signalling of circuit-breaker open/closed

It is possible to have electrical signalling of the status (open/
closed) of the circuit-breaker using 4, 10 or 15 auxiliary con-
tacts.
The auxiliary contacts have the following configurations:
– 4 open/closed contacts for PR121 (2 normally open + 2 nor-
mally closed)
1SDC200145F0001
– 4 open/closed contacts for PR122/PR123 (2 normally open +

2 normally closed + 2 dedicated to release)
– 10 open/closed contacts for PR121 (5 normally open + 5 nor-
5 mally closed)
– 10 open/closed contacts for PR122/PR123 (5 normally open
+ 5 normally closed + 2 dedicated to release)
– 15 supplementary open/closed contacts for installation out-
side the circuit-breaker.
The basic configuration described above can be modified by
the user for normally open or normally closed indication by re-
positioning the faston connector on the microswitch.
When 10 open/closed contacts for PR122/PR123 are required,
the zone selectivity and PR120/K unit are not available.
Reference figure in electrical circuit diagrams: Q/1÷10 (21-22)

1SDC200146F0001
5/12 ABB SACE

5c) Electrical signalling of circuit-breaker racked-in/test
isolated/racked out
In addition to mechanical signalling of the circuit-breaker posi-
tion, it is also possible to obtain electrical signalling using 5 or
10 auxiliary contacts which are installed on the fixed part.
1SDC200147F0001
It is only available for withdrawable circuit-breakers, for instal-

lation on the fixed part.
The auxiliary contacts take on the following configurations:
– 5 contacts; set comprising 2 contacts for racked-in signal, 2
contacts for racked-out signal, and 1 contact to signal the
test isolated position (main pliers isolated, but sliding con-
tacts connected).
– 10 contacts; set comprising 4 contacts for racked-in signal, 4
contacts for racked-out signal, and 2 contacts to signal the
test isolated position (main pliers isolated, but sliding con-
tacts connected).
Reference figure in electrical circuit diagrams:

S75I (31-32)
S75T (31-32)
S75E (31-32)
5
1SDC200148F0001
ABB SACE 5/13

Auxiliary Contacts
5d) Contact for signalling closing springs charged

This is made up of a microswitch which allows remote signal-
ling of the state of the circuit-breaker operating mechanism clos-
ing springs (always supplied with the spring charging geared
motor).
1SDC200149F0001
Reference figure in electrical circuit diagrams: S33 M/2 (11)
1SDC200150F0001
5 5e) Contact signalling undervoltage release de-energized

(C.aux YU)
The undervoltage releases can be fitted with a contact (nor-
mally closed or open, as preferred) for signalling undervoltage
release energized, to remotely signal the state of the
undervoltage release.
1SDC200151F0001
Reference figure in electrical circuit diagrams: (12)

1SDC200152F0001
5/14 ABB SACE

Transformers and operation counters
6a) Current sensor for neutral conductor

outside circuit-breaker
For three-pole circuit-breakers only, this allows protection of
the neutral by connecting it to the overcurrent release. Sup-
plied on request.
Reference figure in electrical circuit diagrams: UI/N (page 8/8)

1SDC200153F0001
6b) Homopolar toroid for the main power

supply earthing conductor (star centre
of the transformer)
SACE PR122 and PR123 electronic releases can be used in
combination with an external toroid located on the conductor,
which connects the star centre of the MV/LV transformer (ho-
mopolar transformer) to earth. In this case, the earth protection
is defined as Source Ground Return. Through two different com-
binations of connection of its terminals (see chapter 8), the In of
the same toroid can be set at 100 A, 250 A, 400 A, 800 A.
1SDC200154F0001
Characteristics
6c) Homopolar toroid for residual current Rated current 0.3 - 30A 5
protection
SACE PR122/P LSIRc, PR122/P LSIG (with PR120/V) and PR123/P
may be also used in combination with this accessory, enabling re-
sidual current protection. The toroid is provided with a dip-switch mul-
tiplier selector to be set according to the desired sensitivity (up to 3A
or up to 30A). This accessory is designed to be mounted on the
busbar and is available in different sizes: up to 3200A for 3/4 poles
circuit-breakers, up to 4000A for 3 poles circuit-breakers.
7) Mechanical operation counter

This is connected to the operating mechanism by means of a
simple lever mechanism, and indicates the number of mechani-
cal operations carried out by the circuit-breaker.
The count is shown on the front of the circuit-breaker.
1SDC200155F0001
1SDC200156F0001
ABB SACE 5/15

Mechanical safety locks
8) Mechanical safety locks

8a-8b) Lock in open position
Several different mechanisms are available which allow the cir-
cuit-breaker to be locked in the open position.
These devices can be controlled by:
1SDC200157F0001
– Key (8a): a special circular lock with different keys (for a sin-
gle circuit-breaker) or the same keys (for several circuit-break-
ers). In the latter case, up to four different key numbers are
available.
– Padlocks (8b): up to 3 padlocks (not supplied): ø 4 mm.
1SDC200158F0001
1SDC200159F0001
8c) Circuit-breaker lock in racked-in/test isolated/racked-

out position
This device can be controlled by a special circular key lock with
1SDC200160F0001
different keys (for a single circuit-breaker) or the same keys (for

several circuit-breakers - up to four different key numbers avail-
5 able) and padlocks (up to 3 padlocks, not supplied - Ø 4 mm).
It is only available for withdrawable circuit-breakers, to be in-
stalled on the moving part.
1SDC200161F0001
8d) Accessories for lock in test isolated/racked-out position

In addition to the circuit-breaker lock in the racked-in/test iso-
lated/racked-out position, this only allows the circuit-breaker to
be locked in the racked-out or test isolated positions.
1SDC200162F0001

stalled on the moving part.
5/16 ABB SACE

8e) Accessory for shutter padlock device
This allows the shutters (installed on the fixed part) to be pad-
locked in their closed position.
1SDC200163F0001
stalled on the fixed part.
1SDC200164F0001
8f) Mechanical lock for compartment door

This stops the compartment door from being opened when the 5
circuit-breaker is closed (and circuit-breaker racked in for with-
drawable circuit-breakers) and prevents the circuit-breaker from
being closed when the compartment door is open.
1SDC200165F0001
ABB SACE 5/17

Transparent protective covers
9) Transparent protective covers

9a) Protective cover for opening and closing pushbuttons
These protections are fitted over the opening and closing
pushbuttons, preventing the relative circuit-breaker operations
1SDC200166F0001
unless a special tool is used.
1SDC200167F0001
9b) IP54 door protection

This is a transparent plastic protective cover which completely
protects the front panel of the circuit-breaker, with a protection
rating of IP54. Mounted on hinges, it is fitted with a key lock.
5
1SDC200168F0001
1SDC200169F0001
5/18 ABB SACE

Interlock between circuit-breakers
10) Mechanical interlock

This mechanism creates a mechanical interlock between two
or three circuit-breakers (even different models and different
versions, fixed/withdrawable) using a flexible cable. The circuit
diagram for electrical switching using a relay (to be installed by
the customer) is supplied with the mechanical interlock. The
1SDC200170F0001
circuit-breakers can be installed vertically or horizontally.
Four types of mechanical interlocks are available:
Type A: between 2 circuit-breakers (power supply + emergency power supply)

Type B: between 3 circuit-breakers (2 power supplies + emergency power supply)
Note:
Type C: between 3 circuit-breakers (2 power supplies + bus-tie) See the “Overall dimensions” and “Electrical
Type D: between 3 circuit-breakers (3 power supplies / one single closed CB) circuit diagrams” chapters for information
about dimensions (fixed and withdrawable
versions) and settings.
1SDC200172F0001
1SDC200171F0001
Vertical interlock Horizontal interlock
ABB SACE 5/19

The mechanical interlocks possible are shown below, depend-

ing on whether 2 or 3 circuit-breakers (any model and in any
version) are used in the switching system.
Type of interlock Typical circuit Possible interlocks

Type A
Between two circuit-breakers Circuit-breaker 1 can
One normal power supply and one emergency only be closed if 2 is
1 2
G
power supply open, and vice-versa. O O
I O
1 2
O I
O = Circuit-breaker open
I = Circuit-breaker closed
Type B
Between three circuit-breakers Circuit-breakers 1 and
Two normal power supplies and one emergency 3 can only be closed if
1 2 3
G
power supply. 2 is open. O O O
Circuit-breaker 2 can
only be closed if 1 and I O O
1 2 3 3 are open.
O O I
I O I
O = Circuit-breaker open O I O
5 Type C
Between three circuit-breakers One or two circuit-
The two half-busbars can be powered by a breakers out of three
1 2 3
single transformer (bus-tie closed) or by can be closed at the O O O
both at the same time (bus-tie open) same time.
I O O
1 2 3
O I O
O O I
O = Circuit-breaker open O I I
I = Circuit-breaker closed I I O
I O I
Type D
Between three circuit-breakers Only one of three
Three power supplies (generators or transform- circuit-breakers can be
1 2 3
ers) on the same busbar, so parallel operation is G closed. O O O
not allowed
I O O
1 2 3 O I O
O O I
O = Circuit-breaker open
5/20 ABB SACE

The emergency power supply is usually provided to take over
from the normal power supply in two instances:
– to power health and safety services (e.g. hospital installa-
tions);
– to power parts of installations which are essential for require-
ments other than safety (e.g. continuous cycle industrial
plants).
The range of accessories for SACE Emax circuit-breakers in-
cludes solutions for a wide variety of different plant engineering
requirements.
See the specific regulations regarding protections against
overcurrents, direct and indirect contacts, and provisions
to improve the reliability and safety of emergency circuits.
Switching from the normal to the emergency power supply can
either be carried out manually (locally or by remote control) or
automatically.
To this end, the circuit-breakers used for switching must be fit-
ted with the accessories required to allow electric remote con-
trol and provide the electrical and mechanical interlocks required
by the switching logic.
These include:
– the shunt opening release
– the shunt closing release
– the motor operator
– the auxiliary contacts.
Switching can be automated by means of a special electroni-
cally-controlled relay circuit, installed by the customer (diagrams
provided by ABB SACE).
Mechanical interlocks between two or three circuit-breakers are
made by using cables which can be used both for circuit-break-
5
ers side by side or superimposed.
ABB SACE 5/21

Automatic transfer switch - ATS010
11) Automatic transfer switch - ATS010

The ATS010 switching unit (Automatic transfer switch) is the new network-generator switching
device offered by ABB SACE. It is based on electronic technology conforming with the major
electromagnetic compatibility and environmental Standards (EN 50178, EN 50081-2, EN 50082-
2, IEC 68-2-1, IEC 68-2-2, IEC 68-2-3).
The device is able to manage the entire switching procedure between the normal and emer-
gency line circuit-breakers automatically, allowing great flexibility of adjustment.
In case of an anomaly in the normal line voltage, in accordance with the delays set, the normal
1SDC200177F0001
line circuit-breaker is opened, the generator started and the emergency line circuit-breaker closed.
Similarly, when the normal line returns, the reverse switching procedure is automatically control-
led.
It is especially suitable for use in all emergency power supply systems requiring a solution that is
ready to install, easy to use and reliable.
Some of the main applications include: power supply for UPS (Uninterrupted Power Supply)
units, operating rooms and primary hospital services, emergency power supply for civilian build-
ings, airports, hotels, data banks and telecommunications systems and power supply of indus-
trial lines for continuous processes.
The switching system consists of the ATS010 unit connected to two motor-driven and mechani-
cally interlocked circuit-breakers. All the circuit-breakers in the SACE Emax series can be used.
The network sensor built into the SACE ATS010 device makes it possible to detect errors in the
network voltage. The three inputs can be directly connected to the three phases of the normal
power supply line for networks with rated voltage up to 500V AC. Networks with a higher voltage
require insertion of voltage transformers (TV), setting a rated voltage for the device that matches
their secondary voltage (typically 100V).
Two changeover contacts for each circuit-breaker allow direct connection to the shunt opening
and closing releases. The circuit-breaker connection is completed by wiring the status contacts:
Open/Closed, Release tripped, Racked-in (for withdrawable/plug-in circuit-breakers).
5 That is why the following are included on every circuit-breaker connected to the ATS010 unit, in
addition to the mechanical interlock accessories:
– spring charging motor,
– opening and closing coil,
– open/closed contact,
– racked-in contact (for withdrawable versions),
– signal and mechanical lock for protection release tripped.
The ATS010 device is designed to ensure extremely high reliability for the system it controls. It
contains various safety systems intrinsically related to software and hardware operation.
For software safety, a special logic prevents unwarranted operations, while a constantly opera-
tional watchdog system signals any microprocessor malfunctions via a LED on the front of the
device.
Hardware safety allows integration of an electrical interlock via a power relay, so that there is no
need to use an external electrical interlock system. The manual selector on the front of the device
can also control the entire switching procedure, even in the event of a microprocessor fault, by
working electromechanically on the control releases.
5/22 ABB SACE

General specifications
Rated supply voltage 24V DC ± 20% 48V DC ± 10%
(galvanically insulated from earth) (maximum ripple ± 5%)
Maximum power consumption 5W at 24V DC 10W at 48V DC
Rated power (network present
and circuit-breakers not controlled) 1.8W a 24V DC 4.5W at 48V DC
Operating temperature -25 °C…+70 °C
Maximum humidity 90% without condensation
Storage temperature -25 °C…+80 °C
Degree of protection IP54 (front panel)
Dimensions [mm] 144 x 144 x 85
Weight [kg] 0.8
Setting range for thresholds and times

Minimum voltage Un Min -5%…-30% Un
Maximum voltage Un Max +5%…+30% Un
Fixed frequency thresholds 10%…+10% fn
t1: opening delay of the normal line circuit-breaker
due to network anomaly (CB-N) 0…32s
t2: generator start-up delay due to network anomaly 0…32s
t3: stopping delay of the generator 0…254s
t4: switching delay due to network re-entry 0…254s
t5: closing delay of the emergency line circuit-breaker
after detecting the generator voltage (CB-E) 0…32s
Rated voltages settings available 100, 115, 120, 208, 220, 230, 240, 277,
347, 380, 400, 415, 440, 480, 500 V 5
Operating sequence
VN
t1
CB-N
t2 t3
GE
VE
CoCo
Caption
VN Network voltage t5 t4
CB-N Normal line circuit-breaker closed CB-E
GE Generator
VE Emergency line voltage
CoCo Enabling switching to emergency line LOAD
CB-E Emergency line circuit-breaker
closed
LOAD Disconnection of lower priority loads
ABB SACE 5/23

Automatic transfer switch - ATS010
Front panel
2
1
5
3
7
4
6 Caption
1 Status of the ATS010 unit and logic
2 Operating mode selector
1SDC200178F0001
3 Normal line check
4 Normal line circuit-breaker status
5 Voltage present on the emergency line
6 Emergency line circuit-breaker status
7 Generator status
5 Side panel settings
Caption
1 Selectors to adjust the undervoltage and
overvoltage thresholds
2 Dip-switches for adjustment:
1SDC200179F0001
– rated voltage
– normal single-phase or three-phase line
– network frequency
– switching strategy
3 Switching delay time settings for t1... t5
5/24 ABB SACE

Spare parts and retrofitting
Spare parts
The following spare parts are available:
– front metal shields and escutcheon plate
– opening solenoid for PR121, PR122 and PR123 overcurrent release
– arcing chamber
– closing springs
– jaw-type isolating contact for the fixed part of the withdrawable circuit-breaker
– earthing sliding contact (for withdrawable version)
– shutters for fixed part
– complete pole
– operating mechanism
– connection cables for releases and current sensors
– transparent protective cover for releases
– SACE PR030/B power supply unit
– toolbox
– battery for SACE PR030/B power supply unit
– front escutcheon plate for Ronis key lock
For further details, please request a copy of the ABB SACE spare parts catalogue.
Retrofitting Kits
5
Special kits have been prepared to replace old SACE Otomax and SACE Novomax G30 circuit-
breakers. The kits include SACE Emax circuit-breakers that take advantage of all the compo-
nents of the existing switchgear. Installing a new circuit-breaker in old switchgear, offers definite
technical and economic benefits, and is extremely rapid as there is no need to redo the main
switchgear connections.
ABB SACE 5/25

Applications of the
circuit-breaker
Contents
Primary and secondary distribution
Selective protection .............................................................................................................. 6/2
Back-up protection ................................................................................................................ 6/13
Directional protection ........................................................................................................ 6/14
Earth fault protection ......................................................................................................... 6/20
Switching and protection of transformers ...................................................................... 6/26
Line protection .................................................................................................................... 6/30
Switching and protection of generators .......................................................................... 6/32
Switching and protection of asynchronous motors ....................................................... 6/35
Switching and protection of capacitors ........................................................................... 6/41
ABB SACE 6/1

Selective protection
Selectivity is normally actuated for tripping overcurrent pro- Circuit diagram with selective
tection devices in civil and industrial installations to isolate the coordination of protections
part affected by a fault from the system, causing only the cir-
cuit-breaker immediately on the supply side of the fault to trip.
The example in the figure highlights the need to coordinate
tripping between the two circuit-breakers A and B so that only
circuit-breaker B is tripped in the event of a fault in C, ensuring
continuity of service for the rest of the system supplied by
circuit-breaker A.
Whereas natural selectivity within the overload current range is
normally found due to the difference between the rated currents
of the load protection circuit-breaker and the main circuit-breaker
1SDC200181F0001
on the supply side, selectivity can be obtained in the short-
circuit current range by differentiating the current values and, if
necessary, the trip times.
Selectivity can be total or partial:

– total selectivity: only circuit-breaker B opens for all current
values lesser than or equal to the maximum short-circuit cur-
rent in C;
– partial selectivity: only circuit-breaker B opens for fault cur-
rents below a certain value; A and B are both tripped for
greater or equal values.
In principle, the following types of selectivity are possible:

Current selectivity, obtained
by setting the instantaneous
trip currents of the circuit-
breaker chain to different
values (higher settings for the
circuit-breakers on the supply
side). This often results in
partial selectivity.
6
1SDC200182F0001
Example of current-type selectivity
Time selectivity, obtained by

intentionally incorporating in-
creasing time-delays in the trip
times of the circuit-breakers fur-
thest to the supply side in the
chain.
1SDC200183F0001
Example of time-type selectivity
6/2 ABB SACE

To guarantee selectivity for Emax circuit-breakers, equipped with
electronic PR121, PR122 and PR123 type releases, the follow-
ing conditions must be verified:
– that there is no intersection between the time-current curves
of the two circuit-breakers, tolerances included
– the minimum difference between the trip time t2 of the cir-
cuit-breaker on the supply side and the time t2 of the circuit-
breaker on the load side, whenever it is an Emax circuit-
breaker, must be:
- t2 supply side > t2 load side + 100 ms* t = cost
- t2 supply side > t2 load side + 100 ms i²t = cost (<400 ms)
- t2 supply side > t2 load side + 200 ms i²t = cost (>400 ms)
* in auxiliary power supply or in self-supply at full power, it is reduced to 70ms.
When the above conditions are met:

– if function I is active (I3=on), the maximum short-circuit current
guaranteeing selectivity is equal to the setting value I3 (minus
the tolerances)
– if function I is disabled (I3=off), the maximum short-circuit
current for which selectivity is guaranteed must be equal to:
- the value indicated in the table on page 6/12, if the circuit-
breaker on the load side is a moulded-case circuit-breaker
(MCCB)
- the minimum value between the Icw of the circuit-breaker
on the supply side and the Icu of the circuit-breaker on the
load side, when both the circuit-breakers are Emax type.
ABB SACE 6/3

Here is an example of total Ik = 70kA@415V

selectivity between three Emax
Circuit-breaker A
circuit-breakers in series in a E6H 6300 PR122-LSI In 6300
system with 415 V rated volt-
age and 70 kA prospective
short-circuit current.
Circuit-breaker B
E3S 3200 PR122-LSI In 3200
Circuit-breaker C
1SDC200312F0001
E2S 1250 PR122-LSI In 1250
Circuit-breakers L S (t=cost) I
Name Type Icu@415V Icw I1 t1 I2 t2 I3
A E6H 63 100 kA 100 kA 1 108 10 0,25 off
B E3S 32 75 kA 75 kA 1 108 10 0,15 off
C E2S 12 85 kA 65 kA 1 108 10 0,05 off
As shown in the figure below, with the above-mentioned setting

there is no intersection between the time-current curves of the
different circuit-breakers and the minimum delay of 70 ms de-
fined for the trip thresholds of protection S. Furthermore, exclu-
sion of protection I (I3=off) guarantees selectivity as follows:
– up to 75 kA between A and B
– up to 75 kA between B and C.
So, since the maximum prospective short-circuit current of the
system is 70 kA, it is possible to talk of total selectivity.
Time-Current Curve
6
1SDC200185F0001
6/4 ABB SACE

Double S
Thanks to the new PR123 release, which allows two thresholds
of protection function S to be set independently and be acti-
vated simultaneously, selectivity can also be achieved under
highly critical conditions.
Here is an example of how, by using the new release, it is pos-
sible to obtain a better selectivity level compared with the use
of a release without “double S”.
This is the wiring diagram of the system under examination; in
particular, attention must be focussed on:
– the presence, on the supply side, of a MV circuit-breaker,
which, for selectivity reasons, imposes low setting values for
the Emax circuit-breaker on the LV side
– the presence of a LV/LV transformer which, due to the inrush
currents, imposes high setting values for the circuit-breakers
on its primary side.
MV CB
MV/LV Transformer
Ik=22.6kA
LV/LV Transformer
1SDC200313F0001
ABB SACE 6/5

Solution with a release without “double S”
LV/LV Trans. 315kVA
1SDC200314F0001
Time-Current Curve @ 400V
MV CB (PR521)
50 (I>): 50 A t=0.5s
51 (I>>): 500 A t=0s
E2N 1250 PR122 T5V 630 PR222DS/P

LSIG R1250 LSIG R630
L Setting 0.8 0.74
Curve 108s 12s
6 S t=constant Setting
Curve
3.5
0.5s
4.2
0.25s
I Setting OFF 7
In the case of a short-circuit, the Emax E2 circuit-breaker and

the MV circuit-breaker will open simultaneously with this solu-
tion. Attention must be paid to the fact that, owing to the value
Ik, function I of the E2 circuit-breaker has to be disabled (I3=OFF)
so that selectivity with the T5 on the load side is granted.
6/6 ABB SACE

Solution with the PR123 release with “double S”
LV/LV Trans. 315kVA
1SDC200315F0001
Time-Current Curve @ 400V
MV CB (PR521)
50 (I>): 50 A t=0.5s
51 (I>>): 500 A t=0s
E2N 1250 PR123 T5V 630 PR222DS/P

LSIG R1250 LSIG R630
L Setting 0.8 0.74
Curve 108s 12s
S t=constant Setting
Curve
-
-
4.2
0.25s
6
S1 t=constant Setting 3.5 -
Curve 0.5s -
S2 t=constant Setting 5 -
Curve 0.05s -
I Setting OFF 7
As is evident, by means of the “double S” function, selectivity

can be achieved both with the T5 circuit-breaker on the load
side as well as with the MV circuit-breaker on the supply side.
A further advantage obtained by using the “double S” function
is the reduction in the time of permanence of high current val-
ues under short-circuit conditions, which results in lower ther-
mal and dynamic stresses on the busbars and on the other in-
stallation components.
ABB SACE 6/7

Dual Setting
Thanks to the new PR123 re- In the system described be- Under normal service condi-
lease, it is also possible to pro- low, in the case of a loss of the tions of the installation, the cir-
gram two different sets of pa- normal supply on the network cuit-breakers C are set in or-
rameters and, through an ex- side, by means of the ABB der to be selective with both
ternal command, to switch SACE ATS010 automatic circuit-breaker A, on the sup-
from one set to the other. transfer switch, it is possible ply side, as well as with circuit-
This function is useful when to switch the supply from the breakers D on the load side.
there is an emergency source network to the emergency By switching from the network
(generator) in the system, only power unit and to disconnect to the emergency power unit,
supplying voltage in the case the non-primary loads by circuit-breaker B becomes the
of a power loss on the network opening the QS1 switch- reference circuit-breaker on
side. disconnector. the supply side of circuit-
breakers C. This circuit-
breaker, being the protection
of a generator, must be set to
trip times shorter than A and
therefore the setting values of
the circuit-breakers on the load
side might not guarantee the
selectivity with B.
By means of the “dual setting”
function of the PR123 release,
it is possible to switch circuit-
breakers C from a parameter
set which guarantees selectiv-
ity with A, to another set which
make them selective with B.
However, these new settings
could make the combination
between circuit-breakers C
non-priority loads and the circuit-breakers on the
load side non-selective.
6
1SDC200316F0001
6/8 ABB SACE

The figure at the side shows
the time-current curves of the
installation under normal ser-
vice conditions.
The values set allow no inter-
section of the curves.
1SDC200317F0001
Time current curves
The figure at the side shows

the situation in which, after
switching, the power is sup-
plied by the power unit through
circuit-breaker B. If the settings
of circuit-breakers C are not
modified, there will be no se-
lectivity with the main circuit-
breaker B. 1SDC200318F0001
Time current curves
This last figure shows how it is

possible to switch to a set of 6
parameters which guarantees
selectivity of circuit-breakers C
with B by means of the “dual
setting” function.
1SDC200319F0001
Time current curves
ABB SACE 6/9

Zone selectivity
The zone selectivity, which is applicable to protection func-
tions S and G, can be enabled in the case where the curve with
fixed time is selected and the auxiliary power supply is present.
This type of selectivity allows shorter trip times for the circuit-
breaker closest to the fault than in the case of time-selectivity.
It is a type of selectivity suitable for radial nets.
The word zone is used to refer to the part of an installation be-
tween two circuit-breakers in series. The fault zone is the zone
immediately on the load side of the circuit-breaker that detects
the fault. Each circuit-breaker that detects a fault communicates
this to the circuit-breaker on the supply side by using a simple
communication wire. The circuit-breaker that does not receive
any communication from those on the load side will launch the
opening command within the set selectivity time (40÷200ms).
We have to consider that the circuit-breakers receiving a signal

from another release will operate according to the set time t2.
If, for any reason, after the selectivity time, the circuit-breaker
due to trip has not opened yet, it lets the “block signal” fall on
the other circuit-breaker, which will trip.
To realize correctly the zone selectivity the following settings are

suggested:
S t2 ≥ selectivity time + t opening *

I I3 = OFF
G t4 ≥ selectivity time + t opening *
Selectivity time same setting for each circuit-breaker
* Trip duration for I < Icw (max) = 70 ms.
6/10 ABB SACE

To carry out the cabling, a shielded twisted pair cable (not sup-
plied; ask ABB for information) can be used. The shield should
only be earthed on the release of the circuit-breaker on the sup-
ply side.
The maximum length of the cabling for zone selectivity, between
two units, is 300 meters.
The maximum number of the circuit-breakers which can be con-
nected to the outputs (Z out) of a release is 3.
The maximum numbers of the circuit-breakers which can be
connected to the inputs (Z in) of a release is 20.
Note
All Emax circuit-breakers in versions B-N-S-H-V fitted with PR122 With regard to selectivity in the case of
earth faults with circuit-breakers in series,
and PR123 releases allow zone selectivity to be realised. see page 6/20.
Zone 1
Zone 2
Zone 3
1SDC200186F0001
ABB SACE 6/11

Selectivity tables
Emax air circuit-breakers with moulded-case circuit-breakers

Supply-side E1 E2 E3 E4 E6
Version B N B N S L* N S H V L* S H V H V
Release EL EL EL EL EL
Load-side Version Release Iu [A] 800 800 1600 1000 800 1250 2500 1000 800 800 2000 4000 3200 3200 4000 3200
1000 1000 2000 1250 1000 1600 3200 1250 1000 1250 2500 4000 4000 5000 4000
1250 1250 1600 1250 1600 1250 1600 6300 5000
1600 1600 2000 1600 2000 1600 2000 6300
2000 2500 2000 2500
3200 2500 3200
3200
B T T T T T T T T T T T T T T T T
T1 C TM 160 T T T T T T T T T T T T T T T T
N T T T T T T T T T T T T T T T T
S 36 T T T T T T T T T T T T T T T
T2 TM, EL 160
H 36 T T 55 65 T T T T T T T T T T T
L 36 T T 55 65 T T T 75 T T T T T T T
T3 N T T T T T T T T T T T T T T T T
TM 250
250
T4 H TM, EL 36 T T 55 65 T T T T T T T T T T T
320
L 36 T T 55 65 100 T T 75 85 100 T T 100 T 100
V 36 T T 55 65 100 T T 75 85 100 T T 100 T 100
400
T5 H TM, EL 36 T T 55 65 T T T T T T T T T T T
630
L 36 T T 55 65 100 T T 75 85 100 T T 100 T 100
V 36 T T 55 65 100 T T 75 85 100 T T 100 T 100
S6 TM, EL 800
H 36 T T 55 T T T T T T T T T T T T
L 36 T T 55 65 T T T 75 85 T T T T T T
S – – T T T – T T T T T T T T T T
1250
S7 H EL – – T 55 T – T T T T T T T T T T
1600
L – – T 55 65 – T T 75 85 T T T T T T
6 General prescriptions:
– Function I of the electronic PR121, PR122 and PR123 releases of the supply-side circuit-breakers must be excluded (I3 in OFF).
– Selectivity is expressed in kA at the supply voltage of 380-415 V AC in accordance with IEC 60947-2 Standards.
– T = total selectivity (the selectivity value is the lowest one between the breaking capacities (Icu) of both the circuit-breaker on the load-
side as well of the circuit-breaker on the supply side)
– It is of fundamental importance to verify that the settings chosen by the user for the releases placed both on the supply as well as on the
load side do not result in intersections of the time-current curves for protection against overload (function L) and for protection against
short-circuit with time-delayed trip (function S).
* Emax L circuit-breakers with PR122/P and PR123/P releases only.
6/12 ABB SACE

Back-up protection
Back-up protection is required by the IEC 60364-4-43 Standards

and Annex A of the IEC 60947-2 Standard, which allow the use
of a protection device with breaking capacity lower than the
prospective short-circuit current at the points where it is installed,
provided that there is another protection device on the supply
side with the necessary breaking capacity. In this case, the
characteristics of the two devices must be coordinated in such
a way that the specific energy let through by the combination is
not higher than that which can be withstood without damage by
the device on the load side, and by the protected conductors.
1SDC200187F0001
In the diagram in the figure, circuit-breaker B, located on the
load side of circuit-breaker A, can have a lower breaking ca-
pacity than the prospective short-circuit current in the event of
a fault in “C”, if circuit-breaker A is able to satisfy both of the
following conditions:
– it has a suitable breaking capacity (higher than or equal to
the prospective short-circuit current at its point of installation
and obviously higher than the short-circuit current in “C”)
– in the event of a fault in “C” with short-circuit values higher
than the breaking capacity of circuit-breaker B, circuit-
breaker A must provide a specific let-through energy limit-
ing function, limiting it to a value that can be withstood by
circuit-breaker B and by the protected conductors.
A fault in “C” can therefore cause a double interruption, how-
ever the back-up protection must ensure that B always trips
within the limits of its breaking capacity.
1SDC200188F0001
It is necessary to choose switchgear combinations that have
been verified by laboratory tests for this type of protection. The
possible combinations are specified in ABB SACE documents
and PC programs (Slide rule kits, DOCWin, etc.) and shown
here for SACE Emax circuit-breakers. Note
Back-up protection can also be implemen-
Back-up protection is used in electrical installations in which ted on more than two levels: the figure
there is no essential need for continuous operation: when the above shows an example of coordination on
three levels. In this case, the choices are
supply-side circuit-breaker opens, it also excludes loads that correct if at least one of the two situations
below is satisfied:
are not affected by the fault. Furthermore, the use of this type of – the circuit-breaker furthest on the supply
coordination limits the size of the installation and consequently side A is coordinated with both circuit-
breakers B and C (coordination between
reduces costs. circuit-breakers B and C is not
necessary);
6
– each circuit-breaker is coordinated with
the circuit-breaker immediately to the load
side of it, i.e. the circuit-breaker furthest
to the supply side A is coordinated with
the next one B, which is in turn
coordinated with circuit-breaker C.
Table showing coordination for back-up protection

Supply-side circuit-breaker Breaking capacity
E2L - E3L 130 [kA] (at 380/415 V)
Load-side circuit-breaker Back-up value

T4N 65 [kA
T4S - T5N - S6N - E1B - E2B 85 [kA]
T4H - T5S/H - S6S/H - S7S/H - E1N - E2N 100 [kA]
T4L - T5L 130 [kA]
ABB SACE 6/13

Directional protection
Directional protection is based on the ability to correlate the circuit-breaker’s behavior with the
direction of the fault current.
Two different trip times can be set on the PR123 release depending on the current direction:
– a time (t7Fw) for a direction of current concordant (Fw) with the reference direction set;
– a time (t7Bw) for a direction of current discordant (Bw) with the reference direction set.
A current threshold only (I7) can be set on the PR123 release.
If the fault current is discordant (Bw) with the reference direction, the protection shall intervene
when the threshold I7 is reached within the set time t7Bw (provided that the functions S and I
have not been set as to intervene before function D).
If the fault current is concordant (Fw) with the reference direction, the protection shall intervene
when the threshold I7 is reached within the set time t7Fw (provided that the functions S and I
have not been set as to intervene before function D).
Moreover, if function I is active and the short-circuit current exceeds the set value I3, the circuit-
breaker will trip instantaneously independently of the direction of the current.
The reference direction set by ABB is from the top of the circuit-breaker (the zone where the
release is located) towards the bottom.
G1 G2
Release Release
Reference Reference Reference
direction direction direction
set by inverted set by
ABB through ABB
1SDC200189F0001
software
The figure above shows the actual configuration the circuit-breakers have in the system. The red
arrow shows the reference direction set by default on the circuit-breaker.
If the power supply direction of the circuit-breaker is from top to bottom (supply from G2), the
reference direction must remain the one set by ABB.
If the power supply direction of the circuit-breaker is from bottom to top (supply from G1), the
new PR123 release allows the default setting to be inverted by operating on its software.
6
In this way, all the quantities measured by the PR123 release can be evaluated as they actually
flow through the installation. Furthermore, in the wiring diagram of the system, the reference
direction to carry out a selec-
Contribution to the tivity study and consider the
G1 short-circuit by each generator: G2
10 kA
tripping directions Bw or Fw
QF1 with QF2 with
correctly still remains from top
A B
PR123 PR123 to bottom.
In the following wiring dia-
Reference Reference gram the reference directions
direction I> direction I>
are shown in red. By consid-
ering the circuit-breakers sup-
C plied as in the figure above, it
QF3 with QF4 can be seen that for QF2 this
PR222
D E is the default direction,
I> I> whereas for QF1 the direction
has been inverted by means
1SDC200190F0001
Contribution of the
Other
passive M motor to the of the software.
loads short-circuit: 5 kA
6/14 ABB SACE

By assuming some numerical values for the short-circuit cur-
rents, and considering some fault points, the following is the
result.
For circuit breaker QF1, if a fault occurs at point B, the current
will flow in direction A-B concordant to the reference direction
or similarly, for a fault in A, the current direction will be B-A in
discordance with the reference direction.
The different configurations can be resumed in the following
table:
Circuit-breaker Location of fault Measured current [kA] Direction Tripping time

A 15 Discordant t7Bw
QF1
B, C, D, E 10 Concordant t7Fw
B 15 Discordant t7Bw
QF2
A, C, D, E 10 Concordant t7Fw
This installation aims at selectivity between QF1, QF2, QF3 and

QF4.
On examining the table, we see that the only instance in which
the fault current direction is discordant with that set for the cir-
cuit-breaker QF1 occurs in case of a fault in point A. The circuit-
breaker QF1 must trip more quickly than the other circuit-break-
ers, since it is the one nearest to the fault. To this purpose, the
trip time t7Bw of QF1 must be set at:
– a value below the time t7Fw of the circuit-breaker QF2, since
the fault current is concordant with QF2 reference direction
– a value lower than the time “t2” of protection “S”, if available,
for the release of the moulded-case circuit-breaker QF4. The
instantaneous protection of QF4 shall be set in OFF or shall
have a setting value I3 higher of the contribution given by
the motor to the short-circuit current.
Moreover, the functions S and I of both QF1 and QF2 have been
set so as not to intervene before function D.
Similarly to the process described for circuit-breaker QF1, to

ensure selectivity, circuit-breaker QF2 must trip first in the case
6
of a fault in B, and then with a delayed trip in the case of faults
anywhere else in the system.
The settings available for directional protection D, both for Fw

and Bw, are the following:
I7=0.6...10xIn (tolerance + 10%) step 0.1xIn

t7=0.20s...0.8s (tolerance + 20%) step 0.01s
ABB SACE 6/15

Zone selectivity D (Directional Zone Selectivity)

Thanks to this function, it is also possible to obtain selectivity in meshed and ring networks.
By means of zone selectivity with function D “Zone selectivity D”, which can only be set to [On]
when zone selectivity “S” and “G” are set to [Off] and there is an auxiliary power supply, it is
possible to coordinate the behaviour of the various PR123 devices, by cabling the release buses
in a suitable way.
In fact, each release has 4 signals available:
– two input signals (one in a concordant and one in a discordant direction) by means of which
the release receives the “block” signal from other releases
– two output signals (one in a concordant and one in a discordant direction) by means of which
the release sends a “block” signal to other releases.
The circuit-breakers which do not receive a “block” signal (coordinated in the direction of the
current) will send the opening command within a time equal to “t7sel”.
The circuit-breakers which receive the “block” signal will open within the backward or forward
time according to the direction of the current.
If function I is activated and the short-circuit current exceeds the set value (I3), the circuit-breaker
will open instantaneously and independently of the directions and of the signals received.
For safety reasons, the maximum duration of the “block” signal is 200ms.
If, after this time and for any reason, the circuit-breakers due to trip have not yet opened, the
“block” signal falls on the other circuit-breakers which will command immediate opening. This
operation therefore occurs after a maximum time of 200ms.
A shielded twisted pair cable (not supplied; ask ABB for information) can be used to carry out
the cabling. The shield should only be earthed on the release of the circuit-breaker on the supply
side.
• The maximum length of the cabling for zone direction selectivity, between two units, is 300
metres.
• A maximum number of 3 circuit-breakers can be connected to the outputs (OUT Bw or OUT
Fw) of a release.
• A maximum number of 20 circuit-breakers can be connected to the inputs (IN Bw or IN Fw) of
a release.
The figure below shows the connections necessary to activate the “blocks” between the various
releases. In particular:
1) in the case of a fault in A, circuit-breaker QF1 is passed through by a current from busbar B1;
this current flows in a direction discordant with the one set. The OUT Bw bus of QF1 “blocks”
6 the IN Fw bus of circuit-breaker QF2 and the IN Bw bus of circuit-breaker QF3: in fact, the
current flows through QF2 in
Direction (OUT-IN) Arrow
the same direction as the set-
G1 G2 ting, whereas QF3 is passed
Bw Þ Bw
Bw Þ Fw through by a current discor-
Fw Þ Fw A B dant with the setting (the ac-
tive “block” signals are indi-
Reference Direction cated by wider arrows).
QF1 + QF2 +
PR123 I> PR123 I>
IN IN
Fw Bw Fw Bw
OUT OUT
Fw Bw Fw Bw
C B1
IN
Fw Bw
QF3 + OUT
PR123 I> Fw Bw
1SDC200191F0001
6/16 ABB SACE

2) in the case of a fault in B, circuit-breaker QF2 is passed through by a current from busbar B1;
this current flows in a direction discordant with the one set. The OUT Bw bus of QF2 “blocks”
the IN Fw bus of circuit-breaker QF1 and the IN Bw bus of circuit-breaker QF3: in fact, the
current flows through QF1 in
Direction (OUT-IN) Arrow the same direction as the set-
G1 G2
Bw Þ Bw ting, whereas QF3 is passed
Bw Þ Fw through by a current discor-
Fw Þ Fw A B
dant with the setting (the ac-
Reference Direction tive “block” signals are indi-
QF1 + QF2 + cated by wider arrows).
PR123 I> PR123 I>
IN IN
Fw Bw Fw Bw
OUT OUT
Fw Bw Fw Bw
C B1
IN
Fw Bw
QF3 + OUT
PR123 I> Fw Bw
1SDC200192F0001
D
3) in case of a fault in C, circuit-breakers QF1 and QF2 are passed through by a current flowing
in the same direction as the one set, whereas QF3 is passed through by a current with discor-
dant direction. No circuit-
Direction (OUT-IN) Arrow breaker is “blocked” and con-
G1 G2
Bw Þ Bw sequently all the circuit-break-
Bw Þ Fw ers affected by the fault will
Fw Þ Fw A B
trip according to the time set-
Reference Direction tings of protections “S” and/
QF1 +
PR123 I>
QF2 +
PR123 I>
or “I”. 6
IN IN
Fw Bw Fw Bw
OUT OUT
Fw Bw Fw Bw
C B1
IN
Fw Bw
QF3 + OUT
PR123 I> Fw Bw
1SDC200193F0001
D
M
ABB SACE 6/17

4) in the case of a fault in D, circuit-breaker QF3 is passed through by a current from busbar B1;
this current flows in the same direction as the one set. The OUT Fw bus of QF3 “blocks” the IN
Fw bus of circuit-breakers
Direction (OUT-IN) Arrow QF1 and QF2: in fact, both
G1 G2
Bw Þ Bw circuit-breakers are passed
Bw Þ Fw through by fault currents con-
Fw Þ Fw A B
cordant with the direction set
Reference Direction (the active “block” signals are
QF1 + QF2 + indicated by wider arrows).
PR123 I> PR123 I>
IN IN
Fw Bw Fw Bw
OUT OUT
Fw Bw Fw Bw
C B1
IN
Fw Bw
QF3 + OUT
PR123 I> Fw Bw
1SDC200194F0001
M
The following example analyses a network with a bus-tie and takes the behavior of the protection
devices in the presence of faults into consideration:
1) Fault in B1 with the bus-tie closed: only circuit-breakers QF1 and QF3 must interrupt the fault: in
particular, circuit-breaker QF3 is passed through by a current from busbar B2 (therefore in the
same direction as the one set); the OUT Fw bus sends a “block” signal to the IN Fw bus of circuit-
breaker QF2 (passed through
Direction (OUT-IN) Arrow by a current flowing from trans-
Fw Þ Fw former TM2 and consequently
Fw Þ Bw -TM1 -TM2
Bw Þ Fw
in a direction concordant with
Ik
A QF1 + QF2 +
the one set), and to the IN Bw
Reference Direction IN PR123 IN PR123 IN bus of circuit-breaker QF5
6 Fw Bw
OUT
Fw Bw
Fw Bw
OUT
Fw Bw
Fw Bw
OUT
Fw Bw
(passed through from a current
I> I> flowing from the motor and
-B1 -B2 consequently in a direction dis-
I>
cordant with the one set).
IN IN
Fw Bw QF3 + Fw Bw
OUT OUT
PR123
Fw Bw Fw Bw
QF4 + QF5 +
PR123 PR123
I> I>
1SDC200320F0001
L M
6/18 ABB SACE

2) Fault in the motor: in this case, only circuit-breaker QF5 must interrupt the fault. Circuit-breaker
QF5 is passed through by a current flowing from busbars B1 and B2, in a direction concor-
dant with the one set; therefore, the OUT Fw bus of QF5 “blocks” both the IN Fw bus of QF2
(passed through by a current flowing from TM2 and consequently in a direction concordant
with the one set) as well as the IN Bw bus of QF3 (which is passed through by a current
flowing from TM1 and consequently in a direction discordant with the one set). Similarly,
circuit-breaker QF3 is also
Direction (OUT-IN) Arrow passed through by a current
Fw Þ Fw flowing from TM1 in a direc-
Fw Þ Bw -TM1 -TM2 tion discordant with the one
Bw Þ Bw Ik set: consequently, the OUT
Bw Þ Fw A QF1 + QF2 +
PR123 PR123 Bw bus of QF3 “blocks” the
IN IN IN
Reference Direction Fw Bw Fw Bw Fw Bw
OUT
IN Fw bus of QF1 (passed
OUT OUT
Fw Bw Fw Bw Fw Bw through by a current flowing
I> I>
from TM1 and therefore in a
-B1 -B2
I> direction concordant with the
IN IN
setting).
Fw Bw QF3 + Fw Bw
OUT OUT
PR123
Fw Bw Fw Bw
QF4 + QF5 +
PR123 PR123
I> I>
1SDC200321F0001
L M
3) Fault on the supply side of transformer TM2: in this case, only circuit-breaker QF2 must inter-
rupt the fault. Circuit-breaker QF2 is passed through by a current flowing from TM1 and from
the motor, in a direction discordant with the one set; as a consequence the OUT Bw bus of
QF2 “blocks”:
– the IN Bw bus of QF5 (passed through by a current flowing from the motor and consequently
in a direction discordant with the one set)
– the IN Bw bus of QF3 (passed through by a current flowing from TM1 and consequently in
a direction discordant with the
6
Direction (OUT-IN) Arrow one set).
Fw Þ Fw Similarly, circuit-breaker QF3
Fw Þ Bw -TM1 -TM2 is also passed through by a
Bw Þ Bw Ik current flowing from TM1 in a
Bw Þ Fw A QF1 + QF2 + direction discordant with the
IN PR123 IN PR123 IN
Reference Direction Fw Bw Fw Bw Fw Bw one set; therefore its OUT Bw
OUT OUT OUT
Fw Bw Fw Bw Fw Bw
bus “blocks” the IN Fw bus of
I> I> QF1 (passed through by a
-B1 -B2 current flowing from TM1 and
I>
therefore in a direction con-
IN IN cordant with the one set).
Fw Bw QF3 + Fw Bw
OUT OUT
PR123
Fw Bw Fw Bw
QF4 + QF5 +
PR123 PR123
I> I>
1SDC200322F0001
L M
ABB SACE 6/19

Earth fault protection
Circuit-breakers with protection G

Circuit-breakers fitted with re- Protection function G calcu- regard to the protection de-
leases offering earth fault pro- lates the vectorial sum of the vices installed on the load side.
tection function G are usually currents detected by the cur- Selectivity is therefore ensured
used in MV/LV distribution sub- rent transformers on the regarding the residual-current
stations to protect both the phases and on the neutral con- releases located on the load
transformers and the distribu- ductor. In a sound circuit, this side.
tion lines. sum, which is called residual Function G of the PR121,
current, is equal to zero, PR122 and PR123 releases is
whereas in the presence of an provided with specific let-
earth fault it has a value de- through energy curves (I²t=k)
TT L1 pending on the fault ring in- and with independent time-
L2
L3 volved. current curves (t=k).
N
Function G is effectively used The figure in the following page
in TT, IT, and TN-S electrical shows an example of one pos-
P
sible choice of earth fault pro-
1SDC200195F0001
massa installations and, limited to the

section of the installation with tection devices and their pos-
a neutral conductor (N) sible settings.
branched and separated from Protection functions G of the
the conductor PE, in TN-CS circuit-breakers on the main
systems as well (for the TN-S switchboard A serve to enable
TN-C L1
area only). them to trip selectively, in rela-
L2 Function G is not used in TN- tion to each other and to the
L3
PEN C systems, since these pro- residual-current protection de-
vide the neutral and protection vices located on the loads of the
functions using a single con- distribution switchboard B.
1SDC200196F0001
massa ductor.
The protection device thresh-
olds and trip times can be se-
lected from a wide range, also
making it easy to achieve se-
lectivity for this type of fault with
TN-S L1
6 L2
L3
N
PE
absence of fault fault trip within t4
Id=IL1 + IL2 + IL3 +IN =0 Id=IL1 + IL2 + IL3 +IN ≠ 0 Id ≥ I4
1SDC200197F0001
massa
IT L1
L2
L3
Z
PE
1SDC200198F0001
6/20 ABB SACE

Example of selection of earth fault protection devices and their
relevant settings.
1600 kVA
20 / 0,4 kV
Switchboard A
E3N25 with PR122

In = 2500 A
I4 = 0.25 x In = 625 A
t4 = 0.8 s (t=k)
E1N12 with PR121

In = 1000 A
I4 = 0.2 x In = 200 A
t4 = 0.4 s (t = k)
Switchboard B
T4N320 with RC222 T2N160 with RC221

In = 320 A In = 100 A
IΔn = 5 mA IΔn = 0.1 mA

1SDC200199F0001
tΔn = 0.2 s tΔn = 0 s

6
ABB SACE 6/21

Use of the toroid on the star center of the

transformer
In the case of circuit-breakers
to protect MV/LV transformers,
it is possible to install a toroid
on the conductor connecting
the star centre of the trans-
former to earth (application al-
lowed with the SACE Emax se-
ries fitted with the PR122 and
PR123 electronic releases. This
detects the earth fault current.
The figure beside shows the
PR122 - PR123
operating principle of the tor-
oid installed on the star centre
of the transformer.
1SDC200200F0001
The use of this accessory al-
lows the protection threshold
against earth fault (function G)
to be independent of the size
of the primary current trans-
formers installed on the circuit-breaker phases. For the techni-
cal characteristics of the toroid see the table at page 6/24.
Double G
The Emax type circuit-breakers, equipped with the PR123 elec-
tronic release, allow two independent curves for protection G:
one for the internal protection (function G without external toroid)
and one for the external protection (function G with external
toroid, as described in the above paragraph).
A typical application of function double G consists in simulta-
neous protection both against earth fault of the secondary of
the transformer and of its connection cables to the circuit-breaker
terminals (restricted earth fault protection), as well as against
6 earth faults on the load side of the circuit-breaker (outside the
restricted earth fault protection).
Example
Transformer
Figure 1 shows a fault on the secondary winding
load side of an Emax circuit-
breaker: the fault current flows
Emax
through one phase only and, Internal CTs
if the vectorial sum of the cur-
rents detected by the four cur-
rent transformers (CTs) is to be
higher than the set threshold,
the electronic release activates
function G (and the circuit-
breaker trips).
External
toroid
1SDC200323F0001
Figure 1
6/22 ABB SACE

With the same configuration, a fault on the supply side of the
circuit-breaker (Figure 2) does not cause intervention of func-
tion G since the fault current
does not affect either the CT Transformer
secondary winding
of the phase or that of the neu-
tral.
Emax
Internal CTs
1SDC200324F0001
Figure 2
The use of function “double G” allows installation of an external

toroid, as shown in Figure 3, so that earth faults on the supply
side of Emax CB can be de-
tected as well. In this case, the Transformer
secondary winding
alarm contact of the second G
is exploited in order to trip the
circuit-breaker installed on the Emax
Internal CTs
primary and to ensure fault dis-
connection.
6
External
toroid
1SDC200325F0001
Figure 3
ABB SACE 6/23

If, with the same configuration as Figure 3, the fault occurs on

the load side of the Emax circuit-breaker, the fault current would
affect both the toroid as well as the current transformers on the
phases. To define which circuit-breaker is to trip (MV or LV cir-
cuit-breaker), suitable coordination of the trip times is required:
in particular, it is necessary to set the times so that the LV cir-
cuit-breaker opening due to internal function G is faster than
realization of the alarm signal coming from the external toroid.
Therefore, thanks to the time-current discrimination between the
two G protection functions, before the MV circuit-breaker on the
primary of the transformer receives the trip command, the cir-
cuit-breaker on the LV side is able to eliminate the earth fault.
Obviously, if the fault occurred on the supply side of the LV cir-
cuit-breaker, only the circuit-breaker on the MV side would trip.
The table shows the main characteristics of the range of toroids

(available only in the closed version).
Characteristics of the toroid ranges
Rated current 100 A, 250 A, 400 A, 800 A

Outer dimensions of the toroid
D = 165 mm
H D
W = 160 mm
W H = 35 mm
Internal diameter of the toroid Ø = 112 mm
Residual current protection

Emax air circuit-breakers can be equipped with a toroid fitted
on the back of the circuit-breaker so as to ensure protection
against earth faults.
In particular, the electronic release types able to perform this
function are:
• PR122/P L – S – I - Rc
• PR122/P L – S – I - G - with “Measuring” module
• PR123/P L – S – I – G
which can all be provided for the following types of circuit-
breakers: E2 and E3, both three and four pole versions, and
6 E4 (three pole version).
Thanks to the wide range of settings, the above mentioned elec-
tronic releases with the residual current function are suitable for
applications where a residual current protection system coordi-
nated with the various distribution levels is to be constructed
from the main switchboards to the final load.
It is particularly suitable where low-sensitivity residual current
protection is required, for example in both partial (current-type)
or total (time-type) selectivity chains, and for high-sensitivity
applications to protect people against indirect contact.
These electronic releases with residual current protection are
suitable for use in the presence of:
– alternating earth current (Type AC)
– alternating and/or pulsating current with continuous compo-
nents (Type A)
The table below shows the main technical characteristics of the
residual current protection:
Sensitivity IΔn [A] 0.3-0.5-0.7-1-2-3 (dip in position 0.1)

3-5-7-10-20-30 (dip in position 1)
Tripping time [s] 0.06-0.1-0.2-0.3-0.4-0.5-0.8-1-3-5
Type AC and A
6/24 ABB SACE

Using the SACE RCQ switchboard
electronic residual current relays
The family of SACE Emax circuit-breakers with a rated current
up to 2000A can be combined, if fitted with a shunt opening
release, with the SACE RCQ residual current relay for switch-
board with a separate toroidal transformer (for installation out-
side on the line conductors) thereby enabling earth leakage
currents to be determined for values between 0.03 and 30A.
Thanks to the wide range of settings, the SACE RCQ switchboard
relay is suitable for applications where a residual current protec-
tion system coordinated with the various distribution levels is to
be constructed from the main switchgear to the final load.
It is particularly suitable, for
example, where low-sensitivity SACE RCQ residual current switchboard relay
residual current protection is Power supply voltage AC [V] 80 ... 500
required in both partial (cur- DC [V] 48 ... 125
rent-type) and total (time-type) Tripping threshold setting IΔn
- 1a setting range [A] 0.03 - 0.05 - 0.1 - 0.3 - 0.5
selective chains, and for high-
- 2a setting range [A] 1 - 3 - 5 - 10 - 30
sensitivity applications to pro- Trip time settings 1a range [s] 0 - 0.05 - 0.1 - 0.25
tect people against indirect Trip time settings 2a range [s] 0.5 - 1 - 2.5 - 5
contact. Range of use of closed transformers
- Toroidal transformer ∅ 60mm [A] 0.03 ... 30
When the auxiliary power sup-
ply voltage drops, the opening Range of use of transformers that can be opened
command intervenes after a - Toroidal transformer ∅ 110mm [A] 0.3 ... 30
minimum time of 100ms and - Toroidal transformer ∅180mm [A] 0.1 ... 30
after the time set above
Dimensions (Dx H x W) [mm] 96 x 96 x 131.5
100ms. Drilling for assembly on door [mm] 92 x 92
The SACE RCQ relay is only
suitable for use in the pres-
ence of alternating earth current (Type AC), for alternating and/
or pulsating current with continuous components (Type A), and
is suitable for achieving residual current selectivity.
The SACE RCQ relay acts indirectly, and works on the release
mechanism of the circuit-breaker by means of the circuit-breaker 6
shunt opening release (to be ordered by the customer) to be
housed in the circuit-breaker itself.
The table below shows the main characteristics of the SACE
RCQ relay.
Dimensions of the external toroid for SACE RCQ

Outer dimensions of the toroid Closed Openable
D [mm] 94 165 166 241 297
H W [mm] 118 160 200 236 292
D
W H [mm] 81 40 81 81 81
Internal diameter Ø [mm] 60 110 110 180 230
ABB SACE 6/25

Switching and protection of transformers
General information
When choosing circuit-breakers to protect the LV side of MV/LV
transformers, the following must basically be taken into account::
– the rated current of the protected transformer on the LV side,
on which the circuit-breaker capacity and protection settings
both depend;
– the maximum short-circuit current at the point of installation,
which determines the minimum breaking capacity that must
be offered by the protection device.
MV-LV substation with a single transformer

The rated current of the transformer, LV side, is determined by
the following equation Sn
Sn x 103 U20
In =
3 x U20
where In
Sn = rated power of the transformer, in kVA
U20 = rated secondary voltage (no load) of the transformer, in V
Ik
1SDC200202F0001
ln = rated current of the transformer, LV side, in A (rms value)
The three-phase short-circuit current at full voltage, right at the

LV terminals of the transformer, can be expressed by the follow-
ing equation (assuming infinite short-circuit power at the pri-
mary):
In x 100
Ik =
Uk%
where:
Uk % = short-circuit voltage of the transformer, in %
ln = rated current, LV side, in A (rms value)
6 lk = rated three-phase short-circuit current, LV side, in A
(rms value)
If the circuit-breaker is installed some distance away from the
transformer by using a cable or a bus duct connection, the short-
circuit current decreases, as a function of the impedance of the
connection, in comparison with the values obtained by the equa-
tion above.
In practice, the short-circuit value provided by the transformer
is also affected by the short-circuit power of the Sk network to
which the transformer is connected.
6/26 ABB SACE

MV-LV substation with multiple
transformers in parallel
The rated current of the transformer is calculated following the
same procedure outlined in the previous section.
The minimum breaking capacity of each protection circuit-
breaker on the LV side must be higher than the highest of the
following values (the example is for machine 1 in the figure and
applies to three machines in parallel):
– Ik1 (short-circuit current of transformer 1) in the event of a
fault immediately on the load side of circuit-breaker QF1;
– Ik2 + Ik3 (Ik2 and Ik3 = short-circuit currents of transformers
2 and 3) in the event of a short-circuit on the supply side of
circuit-breaker QF1.
Circuit-breakers QF4 and QF5 on the outgoing feeders must have
a breaking capacity higher than Ik1 + Ik2 + Ik3; the contribution
to the short-circuit current by each transformer obviously depends
on the short-circuit power of the network to which it is connected,
and on the line connecting the transformer and the circuit-breaker
(to be determined on a case-by-case basis).
Circuit-breaker A
Ik2 + Ik3
QF1 Ik1 QF2 QF3

Circuit-breaker B
QF4
Ik1 + Ik2 + Ik3
QF5 6
1SDC200203F0001
ABB SACE 6/27

Switching and protection of transformers
Switching and protection of transformers Sk=750MVA Vn= 400V
Transformer Circuit-breaker A Circuit-breaker B

(LV side) (Feeder circuit-breaker)
Sr Uk Transf Busbar Transf Type Release Busbar
Ir Ib Feeder Ik
Ik
[kVA] % [A] [A] [kA] size [kA] 800 A 1000 A 1250 A 1600 A 2000 A 2500 A 3200 A 4000 A
1x500 4 722 722 17.7 E1B 800 In=800 17.7 E1B08*
1x630 4 909 909 22.3 E1B 1000 In=1000 22.3 E1B08*
1x800 5 1155 1155 22.6 E1B 1250 In=1250 22.6 E1B08*
1x1000 5 1443 1443 28.1 E1B 1600 In=1600 28.1 E1B08* E1B10* E1B12*
1x1250 5 1804 1804 34.9 E2B 2000 In=2000 34.9 E1B08* E1B10* E1B12* E1B16*
1x1600 6.25 2309 2309 35.7 E3N 2500 In=2500 35.7 E1B08* E1B10* E1B12* E1B16* E2B20*
1x2000 6.25 2887 2887 44.3 E3N 3200 In=3200 44.3 E1N08* E1N10* E1N12* E1N16* E2N20* E3N25*
1x2500 6.25 3608 3608 54.8 E4S 4000 In=4000 54.8 E2N10* E2N10* E2N12* E2N16* E2N20* E3N25* E3N32*
1x3125 6.25 4510 4510 67.7 E6H 5000 In=5000 67.7 E2S08* E2S10* E2S12* E2S16* E2S20* E3S25* E3S32* E4S40

Ir Ib Feeder Ik
Ik
2x500 4 722 1444 17.5 E1B 800 In=800 35.9 E1B08*
2x630 4 909 1818 21.8 E1B 1000 In=1000 43.6 E1N08* E1N10* E1N12* E1N16*
2x800 5 1155 2310 22.1 E1B 1250 In=1250 44.3 E1N08* E1N10* E1N12* E1N16* E2N20*
2x1000 5 1443 2886 27.4 E1B 1600 In=1600 54.8 E2N10* E2N10* E2N12* E2N16* E2N20* E3N25*
2x1250 5 1804 3608 33.8 E2B 2000 In=2000 67.7 E2S08* E2S10* E2S12* E2S16* E2S20* E3S25* E3S32*
2x1600 6.25 2309 4618 34.6 E3N 2500 In=2500 69.2 E2S08* E2S10* E2S12* E2S16* E2S20* E3S25* E3S32* E4S40
2x2000 6.25 2887 5774 42.6 E3N 3200 In=3200 85.1 E3H08* E3H10* E3H12* E3H16* E3H20* E3H25* E3H32* E4H40

6 Sr Uk Transf Busbar Transf

Ir Ib Feeder
Type Release Busbar
Ik
Ik
3x630 4 909 2727 42.8 E1N 1000 In=1000 64.2 E2N10* E2N10* E2N12* E2N16* E2N20* E3N25*
3x800 5 1155 3465 43.4 E1N 1250 In=1250 65 E2N10* E2N10* E2N12* E2N16* E2N20* E3N25*
3x1000 5 1443 4329 53.5 E2N 1600 In=1600 80.2 E2S08* E2S10* E2S12* E2S16* E2S20* E3H25* E3H32*
3x1250 5 1804 5412 65.6 E2S 2000 In=2000 98.4 E3H08* E3H10* E3H12* E3H16* E3H20* E3H25* E3H32* E4H40
3x 1600 6,25 2309 6927 67 E3S 2500 In=2500 100.6 E3V08* E3V 12* E3V12* E3V16* E3V20* E3V25* E3V32* E4V40
WARNING!
The table refers to the conditions specified on the previous page. The information for selecting the circuit-breakers is provided only in relation
to the operating current and prospective short-circuit current. To make the correct selection, other factors such as selectivity, back-up
protection, the decision to use current-limiting circuit-breakers, etc. have to be considered. It is therefore essential for designers to carry out
precise verification.
The types of circuit-breakers proposed are all from the SACE Emax series. Positions marked by an asterisk (*) are suitable for other possible
selections from the Tmax or Isomax series of moulded-case circuit-breakers. One also needs to bear in mind that the short-circuit currents
shown in the table have been calculated on the assumption of 750MVA power on the supply side of the transformers and without taking into
account the impedances of the busbars and of the connections to the circuit-breakers.
6/28 ABB SACE

Switching and protection of transformers Sk=750MVA Vn= 690V

Ir Ib Feeder Ik
Ik
[kVA] % [A] [A] [kA] size [kA] 400A 630A 800 A 1000 A 1250 A 1600 A 2000 A 2500 A 3200 A 4000 A
1x500 4 418 418 10.3 E1B 800 In=630 10.3 E1B08*
1x630 4 527 527 12.9 E1B 800 In=630 12.9 E1B08*
1x800 5 669 669 13.1 E1B 800 In=800 13.1 E1B08* E1B08*
1x1000 5 837 837 16.3 E1B 1000 In=1000 16.3 E1B08* E1B08* E1B08*
1x1250 5 1046 1046 20.2 E1B 1250 In=1250 20.2 E1B08* E1B08* E1B08*
1x1600 6.25 1339 1339 20.7 E1B 1600 In=1600 20.7 E1B08* E1B08* E1B08* E1B10* E1B12*
1x2000 6.25 1673 1673 25.7 E2B 2000 In=2000 25.7 E1B08* E1B08* E1B08* E1B10* E1B12* E2B16*
1x2500 6.25 2092 2092 31.8 E3N 2500 In=2500 31.8 E1B08* E1B08* E1B08* E1B10* E1B12* E2B16*
1x3125 6.25 2615 2615 39.2 E3N 3200 In=3200 39.2 E2B16* E2B16* E2B16* E2B16* E2B16* E2B16* E2B20*

Ir Ib Feeder Ik
Ik
2x500 4 418 837 10.1 E1B800 In=630 20.2 E1B08* E1B08*
2x630 4 527 1054 12.6 E1B800 In=630 25.3 E1B08* E1B08* E1B08*
2x800 5 669 1339 12.8 E1B800 In=800 25.7 E1B08* E1B08* E1B08* E1B10*
2x1000 5 837 1673 15.9 E1B1000 In=1000 31.8 E1B08* E1B08* E1B08* E1B10* E1B12*
2x1250 5 1046 2092 19.6 E1B1250 In=1250 39.2 E2B16* E2B16* E2B16* E2B16* E2B16* E2B16*
2x1600 6.25 1339 2678 20.1 E1B1600 In=1600 40.1 E2B16* E2B16* E2B16* E2B16* E2B16* E2B16* E2B20*
2x2000 6.25 1673 3347 24.7 E2B2000 In=2000 49.3 E2N10*E2N10*E2N10*E2N10*E2N12*E2N16*E2N20*E3N25*

Sr Uk Transf Busbar Transf
Ir Ib Feeder
Type Release Busbar
Ik
6
Ik
3x630 4 527 1581 24.8 E1B800 In=630 37.2 E2B16* E2B16* E2B16* E2B16* E2B16*
3x800 5 669 2008 25.2 E1B800 In=800 37.7 E2B16* E2B16* E2B16* E2B16* E2B16* E2B16*
3x1000 5 837 2510 31.0 E1B1000 In=1000 46.5 E2N10*E2N10*E2N10*E2N10*E2N12*E2N16*E2N20*
3x1250 5 1046 3138 38.0 E2B1600 In=1600 57.1 E2S08* E2S08* E2S08 E2S10* E2S12 E2S16 E2S20 E3N25
3x1600 6.25 1339 4016 38.9 E2B1600 In=1600 58.3 E2S08* E2S08* E2S08 E2S10* E2S12 E2S16 E2S20 E3N25 E3N32
3x2000 6.25 1673 5020 47.5 E2N2000 In=2000 71.2 E3S10* E3S10* E3S10* E3S10* E3S12 E3S16 E3S20 E3S25 E3S32 E4S40
WARNING!
The table refers to the conditions specified on the previous page. The information for selecting the circuit-breakers is provided only in relation
to the operating current and prospective short-circuit current. To make the correct selection, other factors such as selectivity, back-up
protection, the decision to use current-limiting circuit-breakers, etc. have to be considered. It is therefore essential for designers to carry out
precise verification.
The types of circuit-breakers proposed are all from the SACE Emax series. Positions marked by an asterisk (*) are suitable for other possible
selections from the Tmax or Isomax series of moulded-case circuit-breakers. One also needs to bear in mind that the short-circuit currents
shown in the table have been calculated on the assumption of 750MVA power on the supply side of the transformers and without taking into
account the impedances of the busbars and of the connections to the circuit-breakers.
ABB SACE 6/29

Line protection
The following main parameters must be known in order to make the correct choice of circuit-
breakers for line operation and protection:
– operating current of the line lb
– permanent current-carrying capacity of the conductor lz
– section S and cable insulation material, with relative constant K
– short-circuit current Ik at the point of installation of the circuit-breaker.
The protection device selected must offer a breaking capacity (Icu or Ics at the system voltage)
higher than or equal to the short-circuit value at the application point. The operating characteris-
tics of the device selected must also meet the following conditions:
Overload protection
Ib ≤ In ≤ Iz
Note If ≤ 1.45 Iz
With regard to the verification required by
the IEC 60364-4-43 Standards, which where
prescribe that the overload protection must
have a trip current I2 ensuring effective Ib is the operating current of the circuit;
operation of the device at a value lower
than 1.45 Iz (I2 < 1.45 Iz), this is always
Iz is the permanent current-carrying capacity of the conductor;
satisfied since SACE Emax circuit-breakers In is the adjusted rated current of the protection device;
comply with the CEI EN 60947-2 Standards
and this value is 1.3 In. If is the current that ensures effective operation of the protection device.
The above inequalities are easily respected thanks to the wide setting ranges offered by the
PR121-PR122-PR123 releases.
Short-circuit protection
Assuming that a conductor overheats adiabatically during the passage of the short-circuit cur-
rent, the following formula must be verified:
(I2t)circuit-breaker ≤ (K2S2)cable
therefore the specific let-through energy (I2t) of the circuit-breaker must be lower than or equal to
the specific let-through energy (K2S2) withstood by the cable.
Also make sure that the circuit-breaker trips within the limits prescribed by the international
standards regarding the minimum value of the short-circuit current at the end of the line.
The minimum short-circuit current is the current which corresponds to a short-circuit occurring
between phase and neutral (or between phase and phase if the neutral conductor is not distrib-
uted) at the farthest point of the conductor.
6
Protection against indirect contacts
In the event of a fault involving a phase and a part of the installation that is not normally live, it is
best to make sure that the circuit-breaker trips within the times prescribed by the international
standards for current values lower than or equal to the fault current.
Based on the value of this current, it is possible to intervene using function I of the release,
function G or, for extremely low values, the RCQ device.
0.03 A 0.5 A 30 A 50 A 375 A 25200 A
RCQ Function G
1SDC200204F0001
External toroid
Residual current
Residual current Function I
The figure shows which function of the electronic release or device to use on the basis of the fault
current.
6/30 ABB SACE

Example:
In an installation with Un=400V and Ik=45kA, a load with
Ib=1102A is supplied with 4 cables in parallel, insulated in EPR
of 300mm2 and Iz=1193A
With appropriate settings, the E2N2000 In=2000A circuit-breaker
fitted with the PR122 electronic protection release, protects the
cable in accordance with the above conditions, as illustrated in
the following graphs.
Time-Current Curve LLL
I B =1102A
Cable 300 mm2
E2N 20 PR122 LSI In 2000 A
1SDC200205F0001
Specific let-through energy curve LLL
6
Cable 300 mm2
E2N 20 PR122 LSI In 2000 A
Note
For protection against indirect contacts, it
may be necessary to link the setting of the
short-circuit protection to the length of the
line protected. See the Slide rule kit and
DOCwin software package for the
1SDC200206F0001
calculation procedures required .

Special attention must be paid to the
selective coordination of circuit-breakers in
series, to limit disservice in the event of
faults to a minimum.
ABB SACE 6/31

Switching and protection of generators
Emax circuit-breakers are suitable for use with low-voltage gen-

erators employed in the following applications:
A - back-up generators for primary loads
B - generators disconnected from the supply network
C - generators for small power stations connected in parallel
with other generators and, possibly, with the power supply
network.
In cases A and B, the generator does not operate in parallel
with the power supply network: the short-circuit current there-
fore depends on the generator itself and, possibly, on the con-
nected loads.
In case C, the breaking capacity must be determined by as-
sessing the short-circuit current imposed by the network at the
point of circuit-breaker installation.
The main points to check for generator protection are:
– the short-circuit current delivered by the generator; this can
only be assessed if one is familiar with the machine’s typical
reactance and time constants. Here one can simply note that
low short-circuit protection device settings are normally re-
quired (2-4 times In);
– the thermal overload limit of the machine. According to the
IEC 60034-1 Standard, this value is set at 1.5xIn for a period
of 30 seconds.
For a detailed assessment, see the DOCWin program or spe-
cialized books on the topic.
The wide range of settings offered by electronic releases:
PR121 Threshold I (1.5 to 15) x In Threshold S (1 to 10) x In
PR122 Threshold I (1.5 to 15) x In Threshold S (0.6 to 10) x In
PR123 Threshold I (1.5 to 15) x In Threshold S (0.6 to 10) x In
makes SACE Emax circuit-breakers perfectly suitable for pro-
tecting large generators against short-circuit currents and
against thermal overloads.
6/32 ABB SACE

Table for selecting circuit-breakers to
protect generators
The table shows the rated currents of the circuit-breakers, based
on the electrical specifications of the generators. The breaking
capacity required by the application must be defined in order
to select the appropriate circuit-breaker.
The electronic protection releases available are suitable for all
requirements.
Frequency 50 Hz - Voltage 400 V Frequency 60 Hz - Voltage 450 V

Rated Rated Rated Rated Rated Rated
power current current of the power current current of the
of the generator of the generator circuit-breaker of the generator of the generator circuit-breaker
[kVA] [A] [A] [kVA] [A] [A]
630 909 1000 760 975 1000
710 1025 1250 850 1091 1250
800 1155 1250 960 1232 1250
900 1299 1600 1080 1386 1600
1000 1443 1600 1200 1540 1600
1120 1617 2000 1344 - 1350 1724 - 1732 2000
1250 1804 2000 1500 1925 2000
1400 2021 2500 1650 - 1680 - 1700 2117 - 2155 - 2181 2500
1600 2309 2500 1920 - 1900 2463 - 2438 2500
1800 2598 3200 2160 - 2150 2771 - 2758 3200
2000 2887 3200 2400 3079 3200
2250 3248 4000 2700 3464 4000
2500 3608 4000 3000 3849 4000
2800 4041 5000 3360 4311 5000
3150 4547 5000 3780 4850 5000
3500 5052 6300 4200 5389 6300
ABB SACE 6/33

Switching and protection of generators
Reverse power protection RP

The reverse power protection is tripped when active power is
incoming to the generator rather than outgoing as it is under
normal conditions. Power reversal takes place if the mechani-
cal power supplied by the main motor driving the generator
drops sharply. In this condition, the generator acts as a motor,
and can cause serious damage to the prime movers, such as
overheating in steam turbines, cavitation in hydraulic turbines,
or explosions of uncombusted diesel fuel in diesel engines.
Outgoing Active Power Condition OK

PR123 release not tripped
Diesel Gen PR123

Engine
Incoming Active Power Condition not OK

PR123 release tripped
1SDC200207F0001
When the power measured by the release falls below zero, the
PR123 release trips, opening the circuit-breaker and thereby
preventing any damage.
6/34 ABB SACE

Switching and protection of asynchronous
motors
A low voltage automatic air circuit-breaker can, by itself, guar-

antee the following functions in power supply circuits of three-
phase asynchronous motors:
– switching
1SDC200208F0001
– overload protection
– short-circuit protection.
t [s]
A = Circuit-breaker
B = Overload protection (inverse
long time-delay trip)
C = Short-circuit protection
(instantaneous)
M = Asynchronous motor
Diagram showing direct starting of

an asynchronous motor using just
the circuit-breaker fitted with an
electronic overcurrent release.
I [A]
Ie = Rated current of the motor

1SDC200209F0001
Ia = Initial value of the transient starting current
Ip = Maximum instantaneous value of the subtransient starting current
ta = Starting time
ts = Duration of subtransient phase
Trend of current values in the starting phase of a three-phase asynchro-

nous motor.
This solution is particularly suitable if the switching frequency is

not high, as it is normally the case for large motors. In this case,
using only the circuit-breaker for motor switching and protec- 6
tion represents a highly advantageous solution thanks to its
competitive cost-efficiency, reliability, ease of installation and
maintenance, and compact overall dimensions.
The circuit-breakers in the SACE Emax selective (not current-
limiting) series are able to provide the motor switching and pro-
tection function by virtue of their high breaking capacities and
the wide range of possible settings offered by the electronic
releases.
SACE Emax circuit-breakers are suitable for use with motors
with rated powers within the range between 355 kW and 630
kW. For power ratings up to 355 kW, the moulded-case circuit-
breakers in the SACE Isomax and Tmax range are also avail-
able. Medium voltage power supplies are normally used for
powers above 630 kW.
ABB SACE 6/35

motors
The switching of three-phase asynchronous motors demands

considerable attention to the starting operation, since the cur-
rent during this phase follows the typical behaviour shown in
the figure, which must be taken into account when selecting the
protection devices.
It is essential to calculate the typical values of the times and
currents indicated in the figure in order to select the correct
switching and protection devices for the motor. These data are
normally provided by the motor manufacturer.
The following ratios generally apply:

– Ia = 6-10 Ie (Ia and Ie: rms values)
– Ip = 8-15 Ie (Ip and Ie: rms values).
The protection releases must be adjusted so as to:

– prevent unwanted tripping
– ensure that the installation is protected against the
overcurrents which might occur at any point on the load
side of the circuit-breaker (including internal motor faults).
The inverse long time-delay trip protection and instantaneous
short-circuit protection must be set as close as possible to the
motor starting curve without, however, interfering with it.
Note
The IEC 60947-4-1 Standard covers motor starters. The following classes are considered for
overload protection:
Operating Trip time t (s) for I = 7.2 x I1

class (I1 = release setting current)
10A 2 < t ≤ 10
10 4 < t ≤ 10
20 6 < t ≤ 20
30 9 < t ≤ 30
The table specifies that the protection device must trip in a time t within the limits for its class
when the current flowing through the device to be protected is 7.2 times the release setting
current (assumed to be equal to the rated current of the motor).
The overload devices are divided into classes in a manner closely linked to the motor starting
6 time: for example, a motor with a starting time of 5 seconds requires a protection device in
class 20.
The same standards provide specific prescriptions for the protection device in cases of
three-phase operation or with the loss of a phase.
6/36 ABB SACE

Warning
The curves of the motor and releases are not directly compa-
rable, since they both express time-current links, but have con-
ceptually different meanings:
– the motor starting curve represents the values taken by the
starting current instant by instant;
– the release curve represents the currents and correspond-
ing trip times for the protection device.
The overload trip curve is set correctly when it is immediately
above point A (figure below), which identifies the top of the rect-
angle with sides formed by the starting time “ta” and the cur-
rent “Ia” thermally equivalent to the variable starting current re-
spectively.
t [s]
1SDC200210F0001
I [A]
Three-phase operation
The overload protection device at 1.05 times the setting current
shall not trip in less than 2 hours starting from the cold state.
When the current is 1.2 times the setting current, the tripping
shall occur in less than 2 hours, as indicated in the table which
follows (page 6/39)
ABB SACE 6/37

motors
Operation with the loss of a phase

The IEC 60947-4-1 Standard prescribes that a release, with
compensated temperature and sensitive to phase losses, must:
– not trip in less than two hours at 20°C, when one phase car-
ries 90% of In and the other two carry 100% of In
– trip in less than two hours at 20°C, in the event of the loss of
a phase when the current in the energized poles reaches
1.15 times the rated current In.
With the PR122 and PR123 releases by activating the Unbalance
function it is possible to check the losses of phase.
Selecting the circuit-breakers to be used for motor

protection
The tables in the next pages show the rated characteristics for
large motors, from 355 to 630 kW, with circuit-breakers in the
SACE Emax series for switching and protecting motors in cat-
egory AC-3 at 415/690 V - 50 Hz.
The tables show the choice of current transformers able to en-
sure a sufficiently high value for the instantaneous trip thresh-
old setting (I): in the absence of experimental data, it is advis-
able to verify that the ratio between the threshold of protection
device I (I3) and the threshold of protection device L (I1) is:
I3/I1 =12 ... 15.
The PR122 and PR123 electronic releases conform to the in-
ternational IEC 60947-4-1 Standard. In particular, the devices
ensure protection of class 10A, 10, 20 and 30 of motors. PR122
and PR123 protection releases are compensated in tempera-
ture, and their operation is not negatively affected by the loss of
a phase.
Advantages of earth fault protection G

The earth fault protection (G) is recommended in order to:
– improve safety against fire hazards
– improve protection of motors and personnel in the event of
machine faults.
6
Advantages of thermal memory
The advisability of enabling the thermal memory (option offered
by PR122 and PR123 releases) must be evaluated in relation to
the type of load. Enabling the thermal memory (which makes
the electronic protection similar to the one provided by a ther-
momagnetic device) increases the protection level of the motor
when restarting after tripping due to an overload.
Undervoltage protection
The undervoltage protection device in control systems for asyn-
chronous motors demands special attention, performing,
amongst other things, two important functions:
– it prevents simultaneous restarting of all the motors on return
of the power supply, with the risk of making the entire instal-
lation go out of service by tripping the main circuit-breaker
overcurrent protection devices
– it prevents the motor from restarting without a control signal,
which could be a hazard for maintenance personnel or could
damage the processing cycle.
6/38 ABB SACE

This protection can be carried out by:
– undervoltage release,
– protection function UV (undervoltage) on the PR123 release.
I/In 1.05 1.2 1.5 7.2 Operating class

Tp > 2h < 2h < 120 s 2 < t < 10s 10A
< 240 s 4 < t < 10s 10
< 480 s 6 < t < 20s 20
< 720 s 9 < t < 30s 30
Direct On Line – Normal Start-Up – 415V – 50Hz

Motor SACE Emax circuit-breaker Electronic release
Pe Ie Operations (AC-3) Type Icu Iu Type TA
[kW] [A] [No.] [kA] [A] [A]
220 368 10000 E1B 42 800 PR122/PR123 630
250 415 10000 E1B 42 800 PR122/PR123 630
315 521 10000 E1B 42 1000 PR122/PR123 800
355 588 10000 E1B 42 1000 PR122/PR123 800
400 665 10000 E1B 42 1250 PR122/PR123 800
450 743 10000 E1B 42 1250 PR122/PR123 1000
500 819 10000 E1B 42 1600 PR122/PR123 1000
560 916 10000 E1B 42 1600 PR122/PR123 1250
630 1022 10000 E1B 42 1600 PR122/PR123 1250
220 368 10000 E1N 50 800 PR122/PR123 630

250 415 10000 E1N 50 800 PR122/PR123 630
315 521 10000 E1N 50 1000 PR122/PR123 800
355 588 10000 E1N 50 1000 PR122/PR123 800
400 665 10000 E1N 50 1250 PR122/PR123 800
450 743 10000 E1N 50 1250 PR122/PR123 1000
500 819 10000 E1N 50 1600 PR122/PR123 1000
560 916 10000 E1N 50 1600 PR122/PR123 1250
630 1022 10000 E1N 50 1600 PR122/PR123 1250
220 368 15000 E2N 65 1000 PR122/PR123 630

250
315
415
521
15000
15000
E2N
E2N
65
65
1000
1000
PR122/PR123
PR122/PR123
630
800
6
355 588 15000 E2N 65 1250 PR122/PR123 800
400 665 15000 E2N 65 1250 PR122/PR123 800
450 743 15000 E2N 65 1250 PR122/PR123 1000
500 819 12000 E2N 65 1600 PR122/PR123 1000
560 916 12000 E2N 65 1600 PR122/PR123 1250
630 1022 12000 E2N 65 1600 PR122/PR123 1250
220 368 12000 E3H 100 800 PR122/PR123 630

250 415 12000 E3H 100 800 PR122/PR123 630
315 521 12000 E3H 100 1000 PR122/PR123 800
355 588 12000 E3H 100 1000 PR122/PR123 800
400 665 12000 E3H 100 1250 PR122/PR123 800
450 743 12000 E3H 100 1250 PR122/PR123 1000
500 819 10000 E3H 100 1600 PR122/PR123 1000
560 916 10000 E3H 100 1600 PR122/PR123 1250
630 1022 10000 E3H 100 1600 PR122/PR123 1250
ABB SACE 6/39

motors
Direct On Line – Normal Start-Up – 690V – 50Hz

Motor SACE Emax circuit-breaker Electronic release
Pe Ie Operations (AC-3) Type Icu Iu Type TA
[kW] [A] [No.] [kA] [A] [A]
220 221 10000 E1B 36 800 PR122/PR123 630
250 249 10000 E1B 36 800 PR122/PR123 630
315 313 10000 E1B 36 800 PR122/PR123 630
355 354 10000 E1B 36 800 PR122/PR123 630
400 400 10000 E1B 36 800 PR122/PR123 630
450 447 8000 E1B 36 1000 PR122/PR123 800
500 493 8000 E1B 36 1000 PR122/PR123 800
560 551 8000 E1B 36 1250 PR122/PR123 800
630 615 8000 E1B 36 1250 PR122/PR123 800
220 221 15000 E2N 55 1000 PR122/PR123 630

250 249 15000 E2N 55 1000 PR122/PR123 630
315 313 15000 E2N 55 1000 PR122/PR123 630
355 354 15000 E2N 55 1000 PR122/PR123 630
400 400 15000 E2N 55 1000 PR122/PR123 630
450 447 15000 E2N 55 1000 PR122/PR123 800
500 493 15000 E2N 55 1000 PR122/PR123 800
560 551 15000 E2N 55 1000 PR122/PR123 800
630 615 15000 E2N 55 1250 PR122/PR123 800
220 221 12000 E3S 75 1000 PR122/PR123 630

250 249 12000 E3S 75 1000 PR122/PR123 630
315 313 12000 E3S 75 1000 PR122/PR123 630
355 354 12000 E3S 75 1000 PR122/PR123 630
400 400 12000 E3S 75 1000 PR122/PR123 630
450 447 12000 E3S 75 1000 PR122/PR123 800
500 493 12000 E3S 75 1000 PR122/PR123 800
560 551 12000 E3S 75 1000 PR122/PR123 800
630 615 12000 E3S 75 1250 PR122/PR123 800
220 221 12000 E3H 100 800 PR122/PR123 630

250 249 12000 E3H 100 800 PR122/PR123 630
315 313 12000 E3H 100 800 PR122/PR123 630
355 354 12000 E3H 100 800 PR122/PR123 630
400 400 12000 E3H 100 800 PR122/PR123 630
450 447 12000 E3H 100 1000 PR122/PR123 800
500 493 12000 E3H 100 1000 PR122/PR123 800
560 551 12000 E3H 100 1000 PR122/PR123 800
630 615 12000 E3H 100 1250 PR122/PR123 800
6
6/40 ABB SACE

Switching and protection of capacitors
Operating conditions of circuit-breakers

during continuous service for capacitor
banks
According to the IEC 60831-1 and 60931-1 Standards, ca-
pacitors must be able to operate in service conditions with a
rated rms current of up to 1.3 times the rated current Icn of
the capacitor. This prescription is due to the possible pres-
ence of harmonics in the mains voltage.
It should also be kept in mind that a tolerance of +15% is
admissible for the capacitance value corresponding to its
rated power, so that the circuit-breakers for switching ca-
pacitor banks must be selected to permanently carry a maxi-
mum current equal to:
ln = 1.3 x 1.15 x lnc = 1.5 x lnc.
Current for connecting capacitor banks

Connection of a capacitor bank can be compared to a closing
operation under short-circuit conditions, where the transient
making capacity Ip takes on high peak values, above all when
capacitor banks are connected in parallel with others that are
already powered. The value of Ip needs to be calculated for
each individual situation because it depends on the individual
circuit conditions and can in certain cases even have a peak
value equal to 100-200 x Icn for a duration of 1-2 ms.
This fact must be taken into account when selecting the circuit-
breaker, which must have a suitable making capacity, and when
setting the overcurrent release, which must not cause unwanted
trips when the bank is connected.
Selecting the circuit-breaker

Using the information on the rating plate of the three-phase
capacitor bank
Qn = rated power in kvar
Un = rated voltage in V
6
the rated current of the capacitor bank is determined as fol-
lows:
3
Inc = Qn x 10 , in A.
3 x Un
The following conditions must be verified for the circuit-breaker:

Rated current ln > 1.5 lnc
Overload protection setting l1 = 1.5 x lnc
Short-circuit protection setting l3 = OFF
Breaking capacity lcu > Ik, at the point of installation.
ABB SACE 6/41

Switching and protection of capacitors
Table for selecting the protection and

switching circuit-breakers for capacitors
The breaking capacity of the circuit-breaker must take into ac-
count the prospective short-circuit current at the point of instal-
lation. The available sizes are shown in the table.
Rated current Rated current Overload Short-circuit

Maximum power of the capacitor of the current of the capacitor protection protection
bank at 50Hz [kvar] Circuit-breaker transformer bank setting setting
400V 440V 500V 690V Type In [A] Inc [A] I1 [A] I3 [A]
578 636 722 997 E1 - E2 - E3 1250 834 1 x In OFF
739 813 924 1275 E1 - E2 - E3 1600 1067 1 x In OFF
924 1017 1155 1594 E2 - E3 2000 1334 1 x In OFF
1155 1270 1444 1992 E3 2500 1667 1 x In OFF
1478 1626 1848 2550 E3 - E4 - E6 3200 2134 1 x In OFF
Note
The E2L and E2L circuit-breakers are not suitable for switching capacitor banks.
6/42 ABB SACE

6
ABB SACE 6/43

Overall dimensions
Contents
Fixed circuit-breaker .......................................................................................................... 7/2
Withdrawable circuit-breaker ........................................................................................... 7/8
Mechanical interlock ......................................................................................................... 7/15
Circuit-breaker accessories ............................................................................................. 7/16
ABB SACE 7/1

Overall dimensions
Basic version
with horizontal
rear terminals
Y A
5
A 4 POLES
B 3 POLES
80
440 min.
418 379
X X
F E
312
192.5
G 16.5
1SDC200212F0001
13
C 3 POLES 33
D 4 POLES
177 49 50 Max
89 10 Min
Y
Caption E1/E2 E3
View A View A
1 Inside edge of compartment
door
Y Y
397 4 POLES 541 4 POLES
2 Segregation (when
provided)
90 90 90 126 126 126
3 M10 mounting holes for 4 35 60
ø13
4 96
ø13
35
circuit-breaker (use M10 33 18 33 18
screws) N N
2 2
4 1xM12 screw (E1, E2, E3) or
2 x M12 screws (E4, E6) for 252 242 3 252 242 3
earthing (included in the M10 M10
supply)
5 Insulating wall or insulated 45 63

Max +40 1 Max +40 1
metal wall 1SDC200213F0001

Y Y
7
A B C D E F G
E1 386 296 148 148 10 130 117.5
E2 386 296 148 148 26 114 117.5
E3 530 404 202 202 26 114 117.5
E4 656 566 238 328 26 166 91.5
E4/f 746 - - 328 26 166 91.5
E6 908 782 328 454 26 166 91.5
E6/f 1034 - - 454 26 166 91.5
7/2 ABB SACE

E4
Y
View A
577 3 POLES (E4)
180 180
4 35
150
ø13
18
66
3
2 45
510
667 4 POLES (E4)

135 180 180
60
33
N
3
600
757 4 POLES (E4/f)

180 180 180
18 35 35 35
150
66
252 242 3
M10
45
Max +40
1SDC200214F0001
1 690
Y
E6
Y
View A 793 3 POLES (E6)
4
252 252 ø13
222
18
66
63
2
726
919 4 POLES (E6)

189 252 252
96 ø13
35 35 56 35 35 222
35 35 18
66
33
N
7
3
852
1045 4 POLES (E6/f)
252 252 252
18 ø13
35 35 56 35 35 222
222
18
66
3
252 242
M10
Max +40
1SDC200215F0001
63
1 978
Y
ABB SACE 7/3

Overall dimensions
Basic version
with vertical
rear terminals
E1 E2/E4 E3/E6
A A A
ø13
ø13 ø13
80 80 100
166 166 166

35
35 35
104.5 104.5 104.5

20 20 20
50 48 50 48 50 48
E1 E2 E3
View A View A View A
90 90
10 10 10
126
10
12 12 12
10 10
90 90
N N
31
126
N
M12 screws
included in
the supply
E4 E4/f E6 E6/f
View A View A View A View A
180 180
31
31
7 90 90
252 252
10 10 10
10 10 10
135
180 126 126
12 12 12
12 12 12
10 10
10 10
N
N 189
252
N
M12 screws
included in N
the supply
1SDC200216F0001
M12 screws
included in
the supply
7/4 ABB SACE

Version with
front terminals
E1
460
42.5
20
35 60
10 ø13
68 90 90
E2
10
10
N
460
42.5
20
35 60 ø13
20 20
88 90 90
E3
10
10
N
7
460
42.5
1SDC200217F0001
20
35 96 ø13
20 20
88 126 126
ABB SACE 7/5

Overall dimensions
Version with
front terminals
E4 E4 E4/f
35
10
10 N N
460
42.5
20 20
35 35 60 35 35
150 ø13 150
20 20 ø13
88 180 135 180 180
E6 E6 E6/f
35 35
10
10 N N
460
42.5
1SDC200218F0001
20 20
56 35 35 96 ø13 56 35 35 ø13
20 20 222 222
88 252 189 252 252
7/6 ABB SACE

Compartment dimensions Drilling of compartment door
Y
316
306
ø5 100 100
ø5
100
500
X 339 100 374 384 X
100
Depth
R2
242 Min
282 Max
2 holes for IP54
protective cover
A 3 POLES 150
B 168.5
4 POLES
Through-holes for flexible cables Tightening torque for main terminals Nm 70

for mechanical interlocks Tightening torque for earthing screw Nm 70
High strength M12 screw
Number per terminal
PHASE NEUTRAL
N E1-E2 2 2
N E3 3 3
E4-E4/f 4 2-4
38.5 N
73.5
40
7
1SDC200219F0001
135 10
E6-E6/f 6 3-6
N
20 180
A B
E1 400 490
E2 400 490
E3 500 630
E4 700 790
E4/f - 880
E6 1000 1130
E6/f - 1260
ABB SACE 7/7

Overall dimensions
Basic version
with horizontal
rear terminals 5 34 13
3
5,5 Max
6
Y A E1 E2/E3/E4/E6
A 4 POLES
B 3 POLES
E E
10
465 465
461 465 min 465 min
X X X
140 E 140 E
199.5 10 199.5
124.5 124.5 E
1SDC200220F0001
C 3 POLES 18 18
D 4 POLES 348 348
Y
Caption E1/E2 E3
View A Y
View A
1 Inside edge of compartment Y
door 327 435 3 POLES
90 90 3 POLES 126 126
60 35 ø13 96 35 35 ø13
2 Segregation (when
provided) 2 2
3 Ø10 mounting holes for 4 6 4
fixed part (use M8 screws) 100 200
138 240
4 1x M12 screw (E1, E2, E3) 129 183
or 2xM12 screws (E4, E6) 4 POLES 561 4 POLES
417
for earthing (included in the 15 90 90 90 15 126 126 126
60 35 96 35 35
supply) 33 33
N N
45 63
5 Distance from connected for 174
309
testing to isolated 33
393.5
3 393.5 3
40
6 Alternative drilling with 25 380 225 380 225
mm pitch for fixing fixed part 240 84 240
7 Ventilation drilling on the 122

switchgear 70 49 70 49
1SDC200221F0001
175 ø10 325 ø10

7 1 6 220
Y
7 1 370
F
Y
A B C D E F
3 poles 4 poles
E1 414 324 162 162 10 – –
E2 414 324 162 162 8 – –
E3 558 432 216 216 8 370 490
E4 684 594 252 342 8 530 610
E4/f 774 - - 342 8 – 700
E6 936 810 342 468 8 750 870
E6/f 1062 - - 468 8 - 1000
7/8 ABB SACE

E4
View A Y
597 3 POLES (E4)
180
150 35 35 35 ø13
45
2
528 4
200 200
3
687 4 POLES (E4)
15 135 180 180
60 150 ø13
33
N
618
3
245 245
777 4 POLES (E4/f)
15 180 180 180
150 35 35 35 ø13
33
N
708
33
393.5 40
3
380 240
84
122
49
1SDC200222F0001
45 ø10
7 1 290 290
F
Y
E6
View A Y
813 3 POLES (E6)
252 252
222 35 35 56 35 35 ø13
63
2
744
4
310 310
3
939 4 POLES (E6)
189 252 252
15 96 222 35 35 56 35 35 ø13
33
N
870
370 370 3
7
1065 4 POLES (E6/f)
252 252 252
15 222 35 35 56 35 35 ø13
33
N
996
33
393.5 40
3
380 240
84
122
49
1SDC200223F0001
63 ø10
7 1 433 433
F
Y
ABB SACE 7/9

Overall dimensions
Basic version
with vertical
rear terminals
E1 E2/E4 E3/E6
A A A
ø13 ø13 ø13
80 80
100
114 114
134
35 35
35
137.5 137.5
127.5
20 20 20
50 3 50 3 50 3
E1 E2 E3
90 90 126
10
12 12 12
10 10
10 10
10
90 90
N N 126
N
M12 screws
included
in the supply
E4 E4/f E6 E6/f
180 90 180 90
10 10 252 252
10 10
10 10 12 12
1012 1012
90 90 10 10
12 12
135 126 126
180
7 N
N
189
31 252 31
N
M12 screws
included N
in the supply
1SDC200224F0001
M12 screws
included
in the supply
7/10 ABB SACE

Version with
front terminals
E1
460
35.5 20
35 60
10 ø13
71 90 90
E2
10
10 N
460
35.5 20
35 60
20 20 ø13
91
90 90
E3
7
10
10 N
460
35.5 20
1SDC200225F0001
35 35 100
20 20 ø13
91
126 126
ABB SACE 7/11

Overall dimensions
Version with
front terminals
E4 E4 E4/f
10
10 N N
460
35.5
20 20
35 60 60 60 35 60 60 60 60
20 20 ø13 ø13
70 70
91
180 135 180 180
E6 E6 E6/f
10
10 N
N N
460
1SDC200226F0001
35.5 20 20
35 35 100 35 35 100
ø13 ø13
20 20 126 126 126 126
91
252 189 252 252
7/12 ABB SACE

Version with
front terminals
E1 E2
A A
M12 M12
114 114
137.5 137.5
3 3
45 62
E1 E2 E3
90 90
126
35 35
35
90 90
35
60 N 60 N
126
96 N
E4 E4/f E6 E6/f
180 180
35 35 252 252
35 35
150 35 150 35
135
35 35 35
222 56
35
222 56
7
180
35 35
60 35 N 60
189
N
252
96 N
N
1SDC200227F0001
ABB SACE 7/13

Overall dimensions
Compartment dimensions Drilling of compartment door
Y
316
306
ø5 100 100
ø5
100
500 X 339 100 374 384 X
Depth 100
R2
380 2 holes for IP54

protective cover
150
A 3 POLES 168.5
B 4 POLES
Y
Through-holes for flexible cables Tightening torque for fastening screws Nm 20

for mechanical interlocks Tightening torque for main terminals Nm 70
Tightening torque for earthing screw Nm 70
High strength M12 screw
Number per terminal
PHASE NEUTRAL
N E1-E2 2 2
N
E3 3 3
N E4-E4/f 4 2-4
7 35 40
1SDC200228F0001
N E6-E6/f 6 3-6
100 50 35 50
20 210
A B
E1 400 490
E2 400 490
E3 500 630
E4 700 790
E4/f - 880
E6 1000 1130
E6/f - 1260
7/14 ABB SACE

Overall dimensions
Mechanical interlock
Interlock assembly
Type A Type B Type B Type B Type C

Horizontal (emergency (emergency interlock (emergency interlock Horizontal Vertical
Vertical interlock below) in the middle) above)
Horizontal Vertical Horizontal Vertical Horizontal Vertical
5 6
6 6 5 6
2 3 2 2
4 3
Min 500 - Max 750

Min 500 - Max 750
Min 500 - Max 750
Min 500 - Max 750

4 4 3 4 4 3 4
1 2 6 1
2 5 5
Min 500 - Max 750

Min 500 - Max 750
Min 500 - Max 750
Min 500 - Max 750
Min 500 - Max 750
2 2 2 1 2
1 2
1SDC200229F0001
6 6
4 4 4 6 4
Type D
Horizontal Vertical
Horizontal interlocks
Maximum distance between two interlocks 1200 mm
5 6 from one interlock to the other. The cables pass under
the fixed parts, following the same connection layout
shown for vertical circuit-breakers.
3
2
7
Min 500 - Max 750
3 4
Notes
When fitting interlocks between two circuit-
5 1
breakers, it is necessary to make suitable
holes (through the switchboard) in the Take up the excess cable by making it go through one
mounting surface for fixed circuit-breakers or complete turn only or an omega as shown in the figure.
for the fixed part of withdrawable circuit-
breakers in order to pass through the flexible
cables, observing the measurements shown
Min 500 - Max 750
1 2
in the figures on pages 7/7 and 7/14.
For vertical interlocks, align the right-hand
sides vertically and reduce the bends in the
1SDC200230F0001
flexible cables to a minimum (radius R. 70

mm). All the angle values of the bends which
4 6
the cable passes through added together
must not exceed 720°.
ABB SACE 7/15

Overall dimensions
Circuit-breaker accessories
Mechanical
compartment
door lock
Holes in compartment door Minimum distance between circuit-breaker and switchboard wall
Fixed version Withdrawable version
X X
31,5
20
ø6
A
73.5
1SDC200231F0001
Y 35
A
3 POLES 4 POLES
E1 180 180
E2 180 180
E3 234 234
E4 270 360
E4/f - 360
E6 360 486
E6/f - 486
Homopolar toroid
7
1SDC200232F0001
7/16 ABB SACE

Current sensor for
the external neutral
E1 - E2 - E4 E4/f
E3 - E6 E6/f
1SDC200233F0001
ABB SACE 7/17

Overall dimensions
Electrical signalling
of circuit-breaker
open/closed
15 supplementary auxiliary contacts

52,3 193,5
183,5
42,5
Ø 5,5
133
1SDC200234F0001
“B”
A flexible cable 650 mm long is available from point “A” to

point “B”.
7
1SDC200235F0001
7/18 ABB SACE

ATS010
100
50
1SDC200236F0001
50
137
20
AT
S 01
0
137
Electronic
time-delay device
1SDC200237F0001
ABB SACE 7/19

Overall dimensions
IP54 Protective cover
1SDC200238F0001
PR021/K Unit
7
1SDC200239F0001
7/20 ABB SACE

7
ABB SACE 7/21

Circuit diagrams
Contents
Reading information - circuit-breakers ............................................................................ 8/2
Reading information - Automatic transfer-switch ATS010 ............................................ 8/6
Circuit diagram symbols (IEC 60617 and CEI 3-14 ... 3-26 Standards) ........................ 8/7
Circuit diagrams
Circuit-breakers .................................................................................................................... 8/8
Electrical accessories .......................................................................................................... 8/9
Automatic transfer-switch ATS010 ...................................................................................... 8/14
ABB SACE 8/1

Circuit diagrams
Reading information - circuit-breakers
Warning
Before installing the circuit-breaker, carefully read notes F and O on the circuit diagrams.
Operating status shown

The circuit diagram is for the following conditions:
- withdrawable circuit-breaker, open and racked-in
- circuits de-energised
- releases not tripped
- motor operating mechanism with springs discharged.
Versions
Though the diagram shows a circuit-breaker in withdrawable version, it can be applied to a fixed version circuit-
breaker as well.
Fixed version
The control circuits are fitted between terminals XV (connector X is not supplied).
With this version, the applications indicated in figures 31 and 32 cannot be provided.
Withdrawable version
The control circuits are fitted between the poles of connector X (terminal box XV is not supplied).
Version without overcurrent release
With this version, the applications indicated in figures 13, 14, 41, 42, 43, 44, 45, 46, 47 cannot be provided.
Version with PR121/P electronic release
With this version, the applications indicated in figures 42, 43, 44, 45, 46, 47 cannot be provided.
With this version, the applications indicated in figure 41 cannot be provided.
Caption
= Circuit diagram figure number
* = See note indicated by letter
A1 = Circuit-breaker accessories
A3 = Accessories applied to the fixed part of the circuit-breaker (for withdrawable version only)
A4 = Example switchgear and connections for control and signalling, outside the circuit-breaker
AY = SOR TEST UNIT Test/monitoring Unit (see note R)
D = Electronic time-delay device of the undervoltage release, outside the circuit-breaker
F1 = Delayed-trip fuse
K51 = PR121, PR122/P, PR123/P electronic release with the following protection functions (see note G):
- L overload protection with inverse long time-delay trip - setting I1
- S short-circuit protection with inverse or definite short time-delay trip - setting I2
- I short-circuit protection with instantaneous time-delay trip - setting I3
- G earth fault protection with inverse short time-delay trip - setting I4
K51/1...8 = Contacts of the PR021/K signalling unit
K51/GZin = Zone selectivity: input for protection G or “reverse” direction input for protection D (only with Uaux.
(DBin) and PR122/P or PR123/P release)
K51/GZout = Zone selectivity: output for protection G or “reverse” direction output for protection D (only with
(DBout) Uaux. and PR122/P or PR123/P release)
K51/IN1 = Digital programmable input (available only with Uaux and PR122/P or PR123/P release with indicator
module PR120/K)
K51/P1...P4 = Programmable electrical signalling (available only with Uaux and PR122/P or PR123/P release with
indicator module PR120/K)
K51/SZin = Zone selectivity: input for protection S or “direct” input for protection D (only with Uaux. and PR122/P
(DFin) or PR123/P release)
8 K51/SZout
(DFout)
= Zone selectivity: output for protection S or “direct” output for protection D (only with Uaux. and
PR122/P or PR123/P release)
K51/YC = Closing control from PR122/P or PR123/P electronic release with communication module PR120/D-M
K51/YO = Opening control from PR122/P or PR123/P electronic release with communication module PR120/D-M
8/2 ABB SACE

M = Motor for charging the closing springs
Q = Circuit-breaker
Q/1...27 = Circuit-breaker auxiliary contacts
S33M/1...3 = Limit contacts for spring-charging motor
S43 = Switch for setting remote/local control
S51 = Contact for electrical signalling of circuit-breaker open due to tripping of the overcurrent release.
The circuit-breaker may be closed only after pressing the reset pushbutton, or after energizing the
coil for electrical reset (if available).
S75E/1...4 = Contacts for electrical signalling of circuit-breaker in racked-out position (only with withdrawable
circuit-breakers)
S75I/1...5 = Contacts for electrical signalling of circuit-breaker in racked-in position (only with withdrawable
circuit-breakers)
S75T/1..4 = Contacts for electrical signalling of circuit-breaker in test isolated position (only with withdrawable
circuit-breakers)
SC = Pushbutton or contact for closing the circuit-breaker
SO = Pushbutton or contact for opening the circuit-breaker
SO1 = Pushbutton or contact for opening the circuit-breaker with delayed trip
SO2 = Pushbutton or contact for opening the circuit-breaker with instantaneous trip
SR = Pushbutton or contact for electrical circuit-breaker reset
TI/L1 = Current transformer located on phase L1
Uaux. = Auxiliary power supply voltage (see note F)
UI/L1 = Current sensor (Rogowski coil) located on phase L1
UI/N = Current sensor (Rogowski coil) located on neutral
UI/O = Current sensor (Rogowski coil) located on the conductor connecting to earth the star point of the
MV/LV transformer (see note G)
W1 = Serial interface with control system (external bus): EIA RS485 interface (see note E)
W2 = Serial interface with the accessories of PR121/P, PR122/P and PR123/P releases (internal bus)
X = Delivery connector for auxiliary circuits of withdrawable version circuit-breaker
X1...X7 = Connectors for the accessories of the circuit-breaker
XF = Delivery terminal box for the position contacts of the withdrawable circuit-breaker (located on the
fixed part of the circuit-breaker)
XK1 = Connector for power circuits of PR121/P, PR122/P, and PR123/P releases.
XK2 - XK3 = Connectors for auxiliary circuits of PR121/P, PR122/P and PR123/P releases.
XO = Connector for YO1 release
XV = Delivery terminal box for the auxiliary circuits of the fixed circuit-breaker
YC = Shunt closing release
YO = Shunt opening release
YO1 = Overcurrent shunt opening release
YO2 = Second shunt opening release (see note Q)
YR = Coil to electrically reset the circuit-breaker
YU = Undervoltage release (see notes B and Q)
ABB SACE 8/3

Circuit diagrams
Reading information - circuit-breakers
Description of figures
Fig. 1 = Motor circuit to charge the closing springs.
Fig. 2 = Circuit of shunt closing release.
Fig. 4 = Shunt opening release.
Fig. 6 = Instantaneous undervoltage release (see notes B and Q).
Fig. 7 = Undervoltage release with electronic time-delay device, outside the circuit-breaker (see notes B and Q)
Fig. 8 = Second shunt opening release (see note Q).
Fig. 11 = Contact for electrical signalling of springs charged.
Fig. 12 = Contact for electrical signalling of undervoltage release energized (see notes B and S).
Fig. 13 = Contact for electrical signalling of circuit-breaker open due to tripping of the overcurrent release. The
circuit-breaker may be closed only after pressing the reset pushbutton.
Fig. 14 = Contact for electrical signalling of circuit-breaker open due to tripping of the overcurrent release and
electrical reset coil. The circuit-breaker may be closed only after pressing the reset pushbutton or
energizing the coil.
Fig. 21 = First set of circuit-breaker auxiliary contacts.
Fig. 22 = Second set of circuit-breaker auxiliary contacts (see note V).
Fig. 23 = Third set of supplementary auxiliary contacts outside the circuit-breaker.
Fig. 31 = First set of contacts for electrical signalling of circuit-breaker in racked-in, test isolated, racked-out position.
Fig. 32 = Second set of contacts for electrical signalling of circuit-breaker in racked-in, test isolated, racked-out
position.
Fig. 41 = Auxiliary circuits of PR121/P release (see note F).
Fig. 42 = Auxiliary circuits of PR122/P and PR123/P releases (see notes F, N and V).
Fig. 43 = Circuits of the measuring module PR120/V of the PR122/P and PR123/P releases internally connected to
the circuit-breaker (optional for the release PR122/P) (see notes T and U).
Fig. 44 = Circuits of the measuring module PR120/V of the PR122/P and PR123/P releases externally connected to
the circuit-breaker (optional for the release PR122/P) (see notes O and U).
Fig. 45 = Circuits of the communication module PR120/D-M of the PR122/P and PR123/P releases (optional) (see
note E).
Fig. 46 = Circuits of the indicator module PR120/K of the PR122/P and PR123/P releases - connection 1 (optional)
(see note V).
Fig. 47 = Circuits of the indicator module PR120/K of the PR122/P and PR123/P releases - connection 2 (optional)
(see note V).
Fig. 61 = SOR TEST UNIT Test/monitoring unit (see note R).
Fig. 62 = Circuits of the PR021/K signalling module.
Incompatibilities
The circuits indicated in the following figures cannot be supplied simultaneously on the same circuit-breaker:
6-7-8
13 - 14
22 - 46 - 47
43 - 44
8/4 ABB SACE

Notes
A) The circuit-breaker is only fitted with the accessories specified in the ABB SACE order acknowledgement.
Consult this catalogue for information on how to make out an order.
B) The undervoltage release is supplied for operation using a power supply branched on the supply side of the
circuit-breaker or from an independent source. The circuit-breaker can only close when the release is energized
(there is a mechanical lock on closing).
If the same power supply is used for the closing and undervoltage releases and the circuit-breaker is required
to close automatically when the auxiliary power supply comes back on, a 30 ms delay must be introduced
between the undervoltage release accept signal and the energizing of the closing release. This may be achieved
using an external circuit comprising a permanent make contact, the contact shown in fig. 12 and a time-delay
relay.
E) For the EIA RS485 serial interface connection see document ITSCE - RH0298 regarding MODBUS communica-
tion
F) The auxiliary voltage Uaux allows actuation of all operations of the PR121/P, PR122/P and PR123/P releases.
Having requested a Uaux insulated from earth, one must use “galvanically separated converters” in compliance
with IEC 60950 (UL 1950) or equivalent standards that ensure a common mode current or leakage current (see
IEC 478/1, CEI 22/3) not greater than 3.5 mA, IEC 60364-41 and CEI 64-8.
G) Earth fault protection is available with the PR122/P and PR123/P releases by means of a current sensor located
on the conductor connecting to earth the star center of the MV/LV transformer.
The connections between terminals 1 and 2 (or 3) of current transformer UI/O and poles T7 and T8 of the X
(or XV) connector must be made with a two-pole shielded and stranded cable (see user manual), no more than
15 m long. The shield must be earthed on the circuit-breaker side and current sensor side.
N) With PR122/P and PR123/P releases, the connections to the zone selectivity inputs and outputs must be made
with a two-pole shielded and stranded cable (see user manual), no more than 300 m long. The shield must be
earthed on the selectivity input side.
O) Systems with rated voltage of less than 100V or greater than 690V require the use of an insulation voltage
transformer to connect to the busbars (connect according to the insertion diagrams provided in the manual).
P) With PR122/P and PR123/P releases with communication module PR120/D-M, the power supply for coils YO and YC
must not be taken from the main power supply. The coils can be controlled directly from contacts K51/YO and K51/
YC with maximum voltages of 60 V DC and 240-250 V AC.
Q) The second opening release may be installed as an alternative to the undervoltage release.
R) The SACE SOR TEST UNIT + opening release (YO) is guaranteed to operate starting at 75% of the Uaux of the
opening release itself.
While the YO power supply contact is closing (short-circuit on terminals 4 and 5), the SACE SOR TEST UNIT is
unable to detect the opening coil status. Consequently:
- For continuously powered opening coil, the TEST FAILED and ALARM signals will be activated
- If the coil opening command is of the pulsing type, the TEST FAILED signal may appear at the same time. In
this case, the TEST FAILED signal is actually an alarm signal only if it remains lit for more than 20s.
S) Also available in the version with normally-closed contact
T) The connection between pin 1 of the connector XK5 to the internal neutral conductor is provided by four-pole
circuit-breakers, while pin 1 of the connector XK5 is connected to pin T1 of the connector X (or XV) by means of
three-pole circuit-breakers.
U) The measuring module PR120/V is always supplied with relay PR123/P.
V) If fig. 22 is present (second set of auxiliary contacts) simultaneously as PR122/P or PR123/P release, the contacts
for the zone selectivity in fig. 42 (K51/Zin, K51/Zout, K51/Gzin and K51/Gzout) are not wired. In addition, the
indicator module PR120/K in figures 46 and 47 cannot be supplied.
ABB SACE 8/5

Circuit diagrams
Reading information - Automatic transfer switch ATS010
Operating status shown of the automatic transfer switch ATS010

– circuit-breakers open and racked-in #
– generator not in alarm
– closing springs discharged
– overcurrent relays not tripped
– ATS010 not powered
*
– generator in automatic mode and not started
– generator switching enabled
– circuits de-energised
– logic enabled via input provided (terminal 47).
# The present diagram shows withdrawable circuit-breakers, but is also valid for fixed circuit-breakers: the auxiliary
circuits of the circuit-breakers do not connect to connector X but to terminal box XV; also connect terminal 17 to
20 and terminal 35 to 38 on the ATS010 device.
The present diagram shows circuit-breakers with overcurrent relays, but is also valid for circuit-breakers without
* overcurrent relays: connect terminal 18 to 20 and terminal 35 to 37 of the ATS010 device.
@The present diagram shows four-pole circuit-breakers but is also valid for two-pole circuit-breakers: use only
terminals 26 and 24 (phase and neutral) for the voltage connection of the normal power supply to the ATS010
device; also use the Q61/2 two-pole rather than four-pole auxiliary protection circuit-breaker.
Caption
A1 = Circuit-breaker applications
A = ATS010 device for automatic switching of two circuit-breakers
K1 = Auxiliary contact for emergency power supply voltage present
K2 = Auxiliary contact for normal supply voltage present
K51/Q1 = Overcurrent relay of the emergency power supply line *
K51/Q2 = Overcurrent relay of the normal power supply line *
Q/1 = Auxiliary contact of the circuit-breaker
Q1 = Emergency power supply line circuit-breaker
Q = Normal power supply line circuit-breaker
Q61/1-2 = Thermomagnetic circuit-breakers to isolate and protect the auxiliary circuits @
S11...S16 = Signal contacts for the inputs of the ATS010 device
S33M/1 = Limit contact of the closing springs
S51 = Contact for the electrical signal of circuit-breaker open due to overcurrent relay tripped *
S75I/1 = Contact for the electrical signal of withdrawable circuit-breaker racked-in #
TI/ ... = Current transformers for the overcurrent relay power supply
X = Connector for the auxiliary circuits of the withdrawable circuit-breaker
XF = Delivery terminal box for the position contacts of the withdrawable circuit-breaker
YC = Closing release
YO = Opening release
Note
A) For the auxiliary circuits of the circuit-breakers, see the circuit diagram of the circuit-breaker/accessory.
The applications shown in the following figures are required: 1 - 2 - 4 - 13 (only if the overcurrent relay is supplied)
- 21 - 31 (only for withdrawable circuit-breakers).
8/6 ABB SACE

Circuit diagrams
Circuit diagram symbols (IEC 60617 and CEI 3-14 ... 3-26
Standards)
Shield Terminal Position switch (limit switch)

(may be drawn change-over break before
in any shape) make contact
Delay Plug and socket Circuit-breaker-

(male and female) disconnector with automatic
release
Mechanical connection Motor Switch-disconnector

(link) (general symbol) (on-load isolating switch)
Manually operated Current transformer Operating device

control (general case) (general symbol)
Operated by turning Voltage transformer Instantaneous

overcurrent or rate-of-rise
relay
Operated by pushing Winding of three-phase Overcurrent relay with

transformer, connection adjustable short time-lag
star characteritic
Equipotentiality Make contact Overcurrent relay with

inverse short time-lag
characteritic
Converter with Break contact Overcurrent relay

galvanic separator with inverse long time-lag
characteritic
Conductors in a screened Change-over break before Earth fault overcurrent relay

cable (i.e., 3 conductors make contact with inverse short time-lag
shown) characteritic
Twisted conductors (i.e., 3 Position switch (limit Fuse

conductors shown) switch), make contact (general symbol)
Connection of conductors Position switch (limit Current sensing

switch), break contact element
ABB SACE 8/7

Circuit diagrams
Circuit-breakers
Operating status
1SDC200242F0001
Three-pole circuit-breaker with PR121/P, PR122/P or PR123/P electronic release
1SDC200243F0001
1SDC200244F0001
8
Three- or four-pole switch- Four-pole circuit-breaker with PR121/P, PR22/P or PR123P electronic release
disconnector
8/8 ABB SACE

Circuit diagrams
Electrical accessories
Motor operating mechanism, opening, closing and undervoltage

releases
1SDC200245F0001
Signalling contacts
8
1SDC200246F0001
ABB SACE 8/9

Circuit diagrams
Signalling contacts
1SDC200247F0001
8
1SDC200248F0001
8/10 ABB SACE

Auxiliary circuits of the PR121, PR122 and PR123 releases
1SDC200249F0001
Measuring module PR120/V
8
1SDC200250F0001
ABB SACE 8/11

Circuit diagrams
Communication module PR120/D-M
1SDC200251F0001
Signalling module PR120/K
8
1SDC200252F0001
8/12 ABB SACE

PR021/K Signalling unit
1SDC200253F0001
ABB SACE 8/13

Circuit diagrams
Automatic transfer switch ATS010
EMERGENCY POWER SUPPLY NORMAL POWER SUPPLY
TO DIAGRAM 2
1SDC200254F0001
USERS
WITHOUT AUXILIARY SAFETY POWER SUPPLY

FROM DIAGRAM 1
1SDC200255F0001
8/14 ABB SACE

ABB SACE
GENERATOR START CONTROL
ATS010 ALARM SIGNAL
LOGIC ACTIVATED SIGNAL

WITH AUXILIARY SAFETY POWER SUPPLY
DISCONNECT CONTROL
NON-PRIORITY LOADS
1SDC200256F0001
REMOTE SWITCHING CONTROL
SWITCHING INTERFACE
AUTOMATIC GENERATOR
GENERATOR ALARM
LOGIC ENABLING CONTROL
ATS010 RESET CONTROL
8/15
1SDC200257F0001
8
Ordering codes
Contents
General information ............................................................................................................ 9/2

SACE Emax E1 .................................................................................................................... 9/3
SACE Emax E2 .................................................................................................................... 9/7
SACE Emax E3 .................................................................................................................... 9/11
SACE Emax E4 .................................................................................................................... 9/19
SACE Emax E6 .................................................................................................................... 9/21
SACE Emax automatic circuit-breakers with full-size neutral conductor

SACE Emax E4/f .................................................................................................................. 9/23
SACE Emax E6/f .................................................................................................................. 9/24
SACE Emax switch-disconnectors

SACE Emax E1/MS .............................................................................................................. 9/25
SACE Emax E2/MS .............................................................................................................. 9/27
SACE Emax E3/MS .............................................................................................................. 9/29
SACE Emax E4/MS .............................................................................................................. 9/32
SACE Emax E6/MS .............................................................................................................. 9/33
SACE Emax switch-disconnectors with full-size neutral conductor

SACE Emax E4/f MS ............................................................................................................ 9/34
SACE Emax E6/f MS ............................................................................................................ 9/35
SACE Emax automatic circuit-breakers for applications up to 1150V AC

SACE Emax E2/E ................................................................................................................. 9/36
SACE Emax E3/E ................................................................................................................. 9/37
SACE Emax E4/E ................................................................................................................. 9/38
SACE Emax E6/E ................................................................................................................. 9/38
SACE Emax switch-disconnectors for applications up to 1150V AC

SACE Emax E2/E MS .......................................................................................................... 9/39
SACE Emax E3/E MS .......................................................................................................... 9/40
SACE Emax E4/E MS .......................................................................................................... 9/42
SACE Emax E6/E MS .......................................................................................................... 9/42
SACE Emax switch-disconnectors for applications up to 1000V DC

SACE Emax E1/E MS .......................................................................................................... 9/43
SACE Emax E2/E MS .......................................................................................................... 9/44
SACE Emax E3/E MS .......................................................................................................... 9/45
SACE Emax E4/E MS .......................................................................................................... 9/46
SACE Emax E6/E MS .......................................................................................................... 9/47
SACE Emax CS sectionalizing trucks .............................................................................. 9/48

SACE Emax MTP earthing switches with making capacity ........................................... 9/49
SACE Emax MT earthing trucks ........................................................................................ 9/50
SACE Emax FP fixed parts ................................................................................................ 9/51
Conversion kit for fixed circuit-breaker and fixed parts ................................................ 9/53
Extra codes ......................................................................................................................... 9/54
SACE Emax accessories ................................................................................................... 9/55 9
Electronic releases and current sensors (for loose supplies) .................................... 9/61
Order examples ................................................................................................................... 9/62
ABB SACE 9/1

Ordering codes
General information
Abbreviations used in switchgear descriptions
HR = Horizontal rear VR = Vertical rear F = Front terminals FL = Flat terminals

terminals terminals
F Fixed
W Withdrawable
MP Moving part for withdrawable circuit-breakers
FP Fixed part for withdrawable circuit-breakers
PR121/P PR121/P Electronic release (LI, LSI, LSIG functions)

PR122/P PR122/P Electronic release (LSI, LSIG, LSIRc functions)
PR123/P PR123/P Electronic release (LSIG functions)
Functions:
L Protection against overload with long inverse time-delay trip
S Selective protection against short-circuit with short inverse or
definite time-delay trip
I Protection against instantaneous short-circuit with adjustable
trip current threshold
G Protection against earth faults
Rc Protection against residual current earth faults
Iu Rated uninterrupted current of the circuit-breaker

In Rated current of the electronic release current transformers
Icu Rated ultimate short-circuit breaking capacity
Icw Rated short-time withstand current
AC AC applications
DC DC applications
/MS Switch-disconnector
/E Automatic circuit-breaker for applications up to 1150 V
/E MS Switch-disconnector for applications up to 1150 V AC and
1000 V DC
CS Sectionalizing truck
MTP Earthing switch
MT Earthing truck
9 /2 ABB SACE
Ordering codes
1SDC200259F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1
3 Poles 4 Poles 3 Poles 4 Poles 3 Poles 4 Poles
E1B 08 Iu (40 °C) = 800 A Icu (415 V) = 42 kA Icw (1 s) = 42 kA

HR = Horizontal rear terminals
Fixed (F) LI 055600 055608 055603 055611
LSI 055601 055609 055604 055612 055606 055614
LSIG 055602 055610 055605 055613 055607 055615
LSIRc 058553 058555
E1N 08 Iu (40 °C) = 800 A Icu (415 V) = 50 kA Icw (1 s) = 50 kA

Fixed (F) LI 055696 055704 055699 055707
LSI 055697 055705 055700 055708 055702 055710
LSIG 055698 055706 055701 055709 055703 055711
LSIRc 058577 058579

Fixed (F) LI 059169 059171 059181 059183
LSI 059173 059175 059185 059187 059197 059199
LSIG 059177 059179 059189 059191 059201 059203
LSIRc 059193 059195

Fixed (F) LI 059213 059215 059225 059227
LSI 059217 059219 059229 059231 059241 059243
LSIG 059221 059223 059233 059235 059245 059247
LSIRc 059237 059239

Fixed (F) LI 055632 055640 055635 055643
LSI 055633 055641 055636 055644 055638 055646
LSIG 055634 055642 055637 055645 055639 055647
LSIRc 058561 058563

Fixed (F) LI 055728 055736 055731 055739
LSI 055729 055737 055732 055740 055734 055742
LSIG 055730 055738 055733 055741 055735 055743
LSIRc 058585 058587
9
Fixed parts ......................... page 9/51 Terminals ............................ page 9/53 Extra codes ...................... page 9/54
ABB SACE 9 /3
Ordering codes
1SDC200259F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1

Fixed (F) LI 055664 055672 055667 055675
LSI 055665 055673 055668 055676 055670 055678
LSIG 055666 055674 055669 055677 055671 055679
LSIRc 058569 058571

Fixed (F) LI 055760 055768 055763 055771
LSI 055761 055769 055764 055772 055766 055774
LSIG 055762 055770 055765 055773 055767 055775
LSIRc 058593 058595
9
9 /4 ABB SACE
1SDC200259F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1

MP = Moving part
Withdrawable (W) - LI 055616 055624 055619 055627
MP LSI 055617 055625 055620 055628 055622 055630
LSIG 055618 055626 055621 055629 055623 055631
LSIRc 058557 058559

MP = Moving part
MP LSI 055713 055721 055716 055724 055718 055726
LSIG 055714 055722 055717 055725 055719 055727
LSIRc 058581 058583

MP = Moving part
MP LSI 059174 059176 059186 059188 059198 059200
LSIG 059178 059180 059190 059192 059202 059204
LSIRc 059194 059196

MP = Moving part
MP LSI 059218 059220 059230 059232 059242 059244
LSIG 059222 059224 059234 059236 059246 059248
LSIRc 059238 059240

MP = Moving part
MP LSI 055649 055657 055652 055660 055654 055662
LSIG 055650 055658 055653 055661 055655 055663
LSIRc 058565 058567

MP = Moving part
MP LSI 055745 055753 055748 055756 055750 055758
LSIG 055746 055754 055749 055757 055751 055759
LSIRc 058589 058591
9
ABB SACE 9 /5
Ordering codes
1SDC200259F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1

MP = Moving part
MP LSI 055681 055689 055684 055692 055686 055694
LSIG 055682 055690 055685 055693 055687 055695
LSIRc 058573 058575

MP = Moving part
MP LSI 055777 055785 055780 055788 055782 055790
LSIG 055778 055786 055781 055789 055783 055791
LSIRc 058597 058599
9
9 /6 ABB SACE
1SDC200259F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1
E2S 08 Iu (40 °C) = 800 A Icu (415 V) = 85 kA Icw (1 s) = 65 kA

Fixed (F) LI 058282 058290 058285 058293
LSI 058283 058291 058286 058294 058288 058296
LSIG 058284 058292 058287 058295 058289 058297
LSIRc 058657 058659

Fixed (F) LI 059257 059259 059269 059271
LSI 059261 059263 059273 059275 059285 059287
LSIG 059265 059267 059277 059279 059289 059291
LSIRc 059281 059283

Fixed (F) LI 059301 059303 059313 059315
LSI 059305 059307 059317 059319 059329 059331
LSIG 059309 059311 059321 059323 059333 059335
LSIRc 059325 059327

Fixed (F) LI 055856 055864 055859 055867
LSI 055857 055865 055860 055868 055862 055870
LSIG 055858 055866 055861 055869 055863 055871
LSIRc 058633 058635

Fixed (F) LI 055952 055960 055955 055963
LSI 055953 055961 055956 055964 055958 055966
LSIG 055954 055962 055957 055965 055959 055967
LSIRc 058665 058667
E2L 12 Iu (40 °C) = 1250 A Icu (415 V) = 130 kA Icw (1 s) = 10 kA

Fixed (F) LI 056048 056056 056051 056059
LSI 056049 056057 056052 056060 056054 056062
LSIG 056050 056058 056053 056061 056055 056063
LSIRc 058617 058619

Fixed (F) LI 055792 055800 055795 055803
LSI 055793 055801 055796 055804 055798 055806
LSIG
LSIRc
055794 055802 055797
058601
055805
058603
055799 055807 9
ABB SACE 9 /7
Ordering codes
1SDC200259F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1

Fixed (F) LI 055888 055896 055891 055899
LSI 055889 055897 055892 055900 055894 055902
LSIG 055890 055898 055893 055901 055895 055903
LSIRc 058641 058643

Fixed (F) LI 055984 055992 055987 055995
LSI 055985 055993 055988 055996 055990 055998
LSIG 055986 055994 055989 055997 055991 055999
LSIRc 058673 058675

Fixed (F) LI 056080 056088 056083 056091
LSI 056081 056089 056084 056092 056086 056094
LSIG 056082 056090 056085 056093 056087 056095
LSIRc 058625 058627

Fixed (F) LI 055824 055832 055827 055835
LSI 055825 055833 055828 055836 055830 055838
LSIG 055826 055834 055829 055837 055831 055839
LSIRc 058609 058611

Fixed (F) LI 055920 055928 055923 055931
LSI 055921 055929 055924 055932 055926 055934
LSIG 055922 055930 055925 055933 055927 055935
LSIRc 058649 058651

Fixed (F) LI 056016 056024 056019 056027
LSI 056017 056025 056020 056028 056022 056030
LSIG 056018 056026 056021 056029 056023 056031
LSIRc 058681 058683
9
9 /8 ABB SACE
1SDC200259F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1

MP = Moving part
MP LSI 058299 058307 058302 058310 058304 058312
LSIG 058300 058308 058303 058311 058305 058313
LSIRc 058661 058663

MP = Moving part
MP LSI 059262 059264 059274 059276 059286 059288
LSIG 059266 059268 059278 059280 059290 059292
LSIRc 059282 059284

MP = Moving part
MP LSI 059306 059308 059318 059320 059330 059332
LSIG 059310 059312 059322 059324 059334 059336
LSIRc 059326 059328

MP = Moving part
MP LSI 055873 055881 055876 055884 055878 055886
LSIG 055874 055882 055877 055885 055879 055887
LSIRc 058637 058639

MP = Moving part
MP LSI 055969 055977 055972 055980 055974 055982
LSIG 055970 055978 055973 055981 055975 055983
LSIRc 058669 058671

MP = Moving part
MP LSI 056065 056073 056068 056076 056070 056078
LSIG 056066 056074 056069 056077 056071 056079
LSIRc 058621 058623

MP = Moving part
MP LSI 055809 055817 055812 055820 055814 055822
LSIG
LSIRc
055810 055818 055813
058605
055821
058607
055815 055823 9
ABB SACE 9 /9
Ordering codes
1SDC200259F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1

MP = Moving part
MP LSI 055905 055913 055908 055916 055910 055918
LSIG 055906 055914 055909 055917 055911 055919
LSIRc 058645 058647

MP = Moving part
MP LSI 056001 056009 056004 056012 056006 056014
LSIG 056002 056010 056005 056013 056007 056015
LSIRc 058677 058679

MP = Moving part
MP LSI 056097 056105 056100 056108 056102 056110
LSIG 056098 056106 056101 056109 056103 056111
LSIRc 058629 058631

MP = Moving part
Withdrawable(W) - LI 055840 055848 055843 055851
MP LSI 055841 055849 055844 055852 055846 055854
LSIG 055842 055850 055845 055853 055847 055855
LSIRc 058613 058615

MP = Moving part
MP LSI 055937 055945 055940 055948 055942 055950
LSIG 055938 055946 055941 055949 055943 055951
LSIRc 058653 058655

MP = Moving part
MP LSI 056033 056041 056036 056044 056038 056046
LSIG 056034 056042 056037 056045 056039 056047
LSIRc 058685 058687
9
9/10 ABB SACE

1SDC200260F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1
E3H 08 Iu (40 °C) = 800 A Icu (415 V) = 100 kA Icw (1 s) = 75 kA

Fixed (F) LI 056336 056344 056339 056347
LSI 056337 056345 056340 056348 056342 056350
LSIG 056338 056346 056341 056349 056343 056351
LSIRc 058689 058691
E3V 08 Iu (40 °C) = 800 A Icu (415 V) = 130 kA Icw (1 s) = 85 kA

Fixed (F) LI 056528 056536 056531 056539
LSI 056529 056537 056532 056540 056534 056542
LSIG 056530 056538 056533 056541 056535 056543
LSIRc 058809 058811

Fixed (F) LI 059285 059387 059397 059399
LSI 059389 059391 059401 059403 059413 059415
LSIG 059393 059395 059405 059407 059417 059419
LSIRc 059409 059411

Fixed (F) LI 059345 059347 059357 059359
LSI 059349 059351 059361 059363 059373 059375
LSIG 059353 059355 059365 059367 059377 059379
LSIRc 059369 059371

Fixed (F) LI 056176 056184 056179 056187
LSI 056177 056185 056180 056188 056182 056190
LSIG 056178 056186 056181 056189 056183 056191
LSIRc 058769 058771

Fixed (F) LI 056368 056376 056371 056379
LSI 056369 056377 056372 056380 056374 056382
LSIG 056370 056378 056373 056381 056375 056383
LSIRc 058697 058699

Fixed (F) LI 056560 056568 056563 056571
LSI 056561 056569 056564 056572 056566 056574
LSIG
LSIRc
056562 056570 056565
058817
056573
058819
056567 056575 9
ABB SACE 9/11

Ordering codes
1SDC200260F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1

Fixed (F) LI 056208 056216 056211 056219
LSI 056209 056217 056212 056220 056214 056222
LSIG 056210 056218 056213 056221 056215 056223
LSIRc 058777 058779

Fixed (F) LI 056400 056408 056403 056411
LSI 056401 056409 056404 056412 056406 056414
LSIG 056402 056410 056405 056413 056407 056415
LSIRc 058705 058707

Fixed (F) LI 056592 056600 056595 056603
LSI 056593 056601 056596 056604 056598 056606
LSIG 056594 056602 056597 056605 056599 056607
LSIRc 058825 058827

Fixed (F) LI 056240 056248 056243 056251
LSI 056241 056249 056244 056252 056246 056254
LSIG 056242 056250 056245 056253 056247 056255
LSIRc 058785 058787

Fixed (F) LI 056432 056440 056435 056443
LSI 056433 056441 056436 056444 056438 056446
LSIG 056434 056442 056437 056445 056439 056447
LSIRc 058713 058715

Fixed (F) LI 056624 056632 056627 056635
LSI 056625 056633 056628 056636 056630 056638
LSIG 056626 056634 056629 056637 056631 056639
LSIRc 058833 058835

Fixed (F) LI 056720 056728 056723 056731
LSI 056721 056729 056724 056732 056726 056734
9 LSIG
LSIRc
056722 056730 056725
058737
056733
058739
056727 056735
9/12 ABB SACE

1SDC200260F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1

Fixed (F) LI 056112 056120 056115 056123
LSI 056113 056121 056116 056124 056118 056126
LSIG 056114 056122 056117 056125 056119 056127
LSIRc 058753 058755

Fixed (F) LI 056272 056280 056275 056283
LSI 056273 056281 056276 056284 056278 056286
LSIG 056274 056282 056277 056285 056279 056287
LSIRc 058793 058795

Fixed (F) LI 056464 056472 056467 056475
LSI 056465 056473 056468 056476 056470 056478
LSIG 056466 056474 056469 056477 056471 056479
LSIRc 058721 058723

Fixed (F) LI 056656 056664 056659 056667
LSI 056657 056665 056660 056668 056662 056670
LSIG 056658 056666 056661 056669 056663 056671
LSIRc 058841 058843

Fixed (F) LI 056752 056760 056755 056763
LSI 056753 056761 056756 056764 056758 056766
LSIG 056754 056762 056757 056765 056759 056767
LSIRc 058745 058747

Fixed (F) LI 056144 056152 056147 056155
LSI 056145 056153 056148 056156 056150 056158
LSIG 056146 056154 056149 056157 056151 056159
LSIRc 058761 058763

Fixed (F) LI 056304 056312 056307 056315
LSI 056305 056313 056308 056316 056310 056318
LSIG
LSIRc
056306 056314 056309
058801
056317
058803
056311 056319 9
ABB SACE 9/13

Ordering codes
1SDC200260F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1

Fixed (F) LI 056496 056504 056499 056507
LSI 056497 056505 056500 056508 056502 056510
LSIG 056498 056506 056501 056509 056503 056511
LSIRc 058729 058731

Fixed (F) LI 056688 056696 056691 056699
LSI 056689 056697 056692 056700 056694 056702
LSIG 056690 056698 056693 056701 056695 056703
LSIRc 058849 058851
9
9/14 ABB SACE

1SDC200260F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1

MP = Moving part
MP LSI 056353 056361 056356 056364 056358 056366
LSIG 056354 056362 056357 056365 056359 056367
LSIRc 058693 058695

MP = Moving part
MP LSI 056545 056553 056548 056556 056550 056558
LSIG 056546 056554 056549 056557 056551 056559
LSIRc 058813 058815

MP = Moving part
MP LSI 059390 059392 059402 059404 059414 059416
LSIG 059394 059396 059406 059408 059418 059420
LSIRc 059410 059412

MP = Moving part
MP LSI 059350 059352 059362 059364 059374 059376
LSIG 059354 059356 059366 059368 059378 059380
LSIRc 059370 059372

MP = Moving part
MP LSI 056193 056201 056196 056204 056198 056206
LSIG 056194 056202 056197 056205 056199 056207
LSIRc 058773 058775

MP = Moving part
MP LSI 056385 056393 056388 056396 056390 056398
LSIG 056386 056394 056389 056397 056391 056399
LSIRc 058701 058703

MP = Moving part
MP LSI 056577 056585 056580 056588 056582 056590
LSIG
LSIRc
056578 056586 056581
058821
056589
058823
056583 056591 9
ABB SACE 9/15

Ordering codes
1SDC200260F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1

MP = Moving part
MP LSI 056225 056233 056228 056236 056230 056238
LSIG 056226 056234 056229 056237 056231 056239
LSIRc 058781 058783

MP = Moving part
MP LSI 056417 056425 056420 056428 056422 056430
LSIG 056418 056426 056421 056429 056423 056431
LSIRc 058709 058711

MP = Moving part
MP LSI 056609 056617 056612 056620 056614 056622
LSIG 056610 056618 056613 056621 056615 056623
LSIRc 058829 058831

MP = Moving part
MP LSI 056257 056265 056260 056268 056262 056270
LSIG 056258 056266 056261 056269 056263 056271
LSIRc 058789 058791

MP = Moving part
MP LSI 056449 056457 056452 056460 056454 056462
LSIG 056450 056458 056453 056461 056455 056463
LSIRc 058717 058719

MP = Moving part
MP LSI 056641 056649 056644 056652 056646 056654
LSIG 056642 056650 056645 056653 056647 056655
LSIRc 058837 058839

MP = Moving part
MP LSI 056737 056745 056740 056748 056742 056750
9 LSIG
LSIRc
056738 056746 056741
058741
056749
058743
056743 056751
9/16 ABB SACE

1SDC200260F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1

MP = Moving part
MP LSI 056129 056137 056132 056140 056134 056142
LSIG 056130 056138 056133 056141 056135 056143
LSIRc 058757 058759

MP = Moving part
MP LSI 056289 056297 056292 056300 056294 056302
LSIG 056290 056298 056293 056301 056295 056303
LSIRc 058797 058799

MP = Moving part
MP LSI 056481 056489 056484 056492 056486 056494
LSIG 056482 056490 056485 056493 056487 056495
LSIRc 058725 058727

MP = Moving part
MP LSI 056673 056681 056676 056684 056678 056686
LSIG 056674 056682 056677 056685 056679 056687
LSIRc 058845 058847

MP = Moving part
MP LSI 056769 056777 056772 056780 056774 056782
LSIG 056770 056778 056773 056781 056775 056783
LSIRc 058749 058751

MP = Moving part
MP LSI 056161 056169 056164 056172 056166 056174
LSIG 056162 056170 056165 056173 056167 056175
LSIRc 058765 058767

MP = Moving part
MP LSI 056321 056329 056324 056332 056326 056334
LSIG
LSIRc
056322 056330 056325
058805
056333
058807
056327 056335 9
ABB SACE 9/17

Ordering codes
1SDC200261F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1

MP = Moving part
MP LSI 056513 056521 056516 056524 056518 056526
LSIG 056514 056522 056517 056525 056519 056527
LSIRc 058733 058735

MP = Moving part
MP LSI 056705 056713 056708 056716 056710 056718
LSIG 056706 056714 056709 056717 056711 056719
LSIRc 058853 058855
9
9/18 ABB SACE

1SDC200261F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1

Fixed (F) LI 056816 056824 056819 056827
LSI 056817 056825 056820 056828 056822 056830
LSIG 056818 056826 056821 056829 056823 056831

Fixed (F) LI 056880 056888 056883 056891
LSI 056881 056889 056884 056892 056886 056894
LSIG 056882 056890 056885 056893 056887 056895

Fixed (F) LI 056784 056792 056787 056795
LSI 056785 056793 056788 056796 056790 056798
LSIG 056786 056794 056789 056797 056791 056799

Fixed (F) LI 056848 056856 056851 056859
LSI 056849 056857 056852 056860 056854 056862
LSIG 056850 056858 056853 056861 056855 056863

Fixed (F) LI 056912 056920 056915 056923
LSI 056913 056921 056916 056924 056918 056926
LSIG 056914 056922 056917 056925 056919 056927
9
ABB SACE 9/19

Ordering codes
1SDC200261F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1

MP = Moving part
MP LSI 056833 056841 056836 056844 056838 056846
LSIG 056834 056842 056837 056845 056839 056847

MP = Moving part
MP LSI 056897 056905 056900 056908 056902 056910
LSIG 056898 056906 056901 056909 056903 056911

MP = Moving part
MP LSI 056801 056809 056804 056812 056806 056814
LSIG 056802 056810 056805 056813 056807 056815

MP = Moving part
MP LSI 056865 056873 056868 056876 056870 056878
LSIG 056866 056874 056869 056877 056871 056879

MP = Moving part
MP LSI 056929 056937 056932 056940 056934 056942
LSIG 056930 056938 056933 056941 056935 056943
9
9/20 ABB SACE

1SDC200262F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1

Fixed (F) LI 057040 057048 057043 057051
LSI 057041 057049 057044 057052 057046 057054
LSIG 057042 057050 057045 057053 057047 057055

Fixed (F) LI 056944 056952 056947 056955
LSI 056945 056953 056948 056956 056950 056958
LSIG 056946 056954 056949 056957 056951 056959

Fixed (F) LI 057072 057080 057075 057083
LSI 057073 057081 057076 057084 057078 057086
LSIG 057074 057082 057077 057085 057079 057087

Fixed (F) LI 056976 056984 056979 056987
LSI 056977 056985 056980 056988 056982 056990
LSIG 056978 056986 056981 056989 056983 056991

Fixed (F) LI 057104 057112 057107 057115
LSI 057105 057113 057108 057116 057110 057118
LSIG 057106 057114 057109 057117 057111 057119

Fixed (F) LI 057008 057016 057011 057019
LSI 057009 057017 057012 057020 057014 057022
LSIG 057010 057018 057013 057021 057015 057023

Fixed (F) LI 057136 057144 057139 057147
LSI 057137 057145 057140 057148 057142 057150
LSIG 057138 057146 057141 057149 057143 057151
9
ABB SACE 9/21

Ordering codes
1SDC200262F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1

MP = Moving part
MP LSI 057057 057065 057060 057068 057062 057070
LSIG 057058 057066 057061 057069 057063 057071

MP = Moving part
MP LSI 056961 056969 056964 056972 056966 056974
LSIG 056962 056970 056965 056973 056967 056975

MP = Moving part
MP LSI 057089 057097 057092 057100 057094 057102
LSIG 057090 057098 057093 057101 057095 057103

MP = Moving part
MP LSI 056993 057001 056996 057004 056998 057006
LSIG 056994 057002 056997 057005 056999 057007

MP = Moving part
MP LSI 057121 057129 057124 057132 057126 057134
LSIG 057122 057130 057125 057133 057127 057135

MP = Moving part
MP LSI 057025 057033 057028 057036 057030 057038
LSIG 057026 057034 057029 057037 057031 057039

MP = Moving part
MP LSI 057153 057161 057156 057164 057158 057166
LSIG 057154 057162 057157 057165 057159 057167
9
9/22 ABB SACE

Ordering codes
SACE Emax automatic circuit-breakers with full-size neutral
1SDC200263F0001
conductor
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1
4 Poles 4 Poles 4 Poles
E4H/f 32 Iu (40 °C) = 3200 A Icu (415 V) = 100 kA Icw (1 s) = 85 kA

Fixed (F) LI 059429 059432
LSI 059430 059433 059435
LSIG 059431 059434 059436
E4S/f 40 Iu (40 °C) = 4000 A Icu (415 V) = 80 kA Icw (1 s) = 80 kA

Fixed (F) LI 055536 055539
LSI 055537 055540 055542
LSIG 055538 055541 055543

Fixed (F) LI 055520 055523
LSI 055521 055524 055526
LSIG 055522 055525 055527

MP = Moving part
Withdrawable (W) - LI 059437 059440
MP LSI 059438 059441 059443
LSIG 059439 059442 059444
E4S/f 40 Iu (40 °C) = 4000 A Icu (415 V) = 80 kA Icw (1 s) = 80 kA

MP = Moving part
MP LSI 055545 055548 055550
LSIG 055546 055549 055551

MP = Moving part
MP LSI 055529 055532 055534
LSIG 055530 055533 055535
9
ABB SACE 9/23

Ordering codes
SACE Emax automatic circuit-breakers with full-size neutral
conductor
1SDC200264F0001
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1
4 Poles 4 Poles 4 Poles

Fixed (F) LI 055552 055555
LSI 055553 055556 055558
LSIG 055554 055557 055559

Fixed (F) LI 055568 055571
LSI 055569 055572 055574
LSIG 055570 055573 055575

Fixed (F) LI 055584 055587
LSI 055585 055588 055590
LSIG 055586 055589 055591

MP = Moving part
MP LSI 055561 055564 055566
LSIG 055562 055565 055567

MP = Moving part
MP LSI 055577 055580 055582
LSIG 055578 055581 055583

MP = Moving part
MP LSI 055593 055596 055598
LSIG 055594 055597 055599
9
9/24 ABB SACE

Ordering codes
1SDC200259F0001
1SDA......R1
3 Poles 4 Poles
E1B/MS 08 Iu (40 °C) = 800 A Icw (1s) = 42 kA

Fixed (F) 058931 058932
E1N/MS 08 Iu (40 °C) = 800 A Icw (1s) = 50 kA

Fixed (F) 058933 058934
E1B/MS 10 Iu (40 °C) = 1000 A Icw (1s) = 42 kA

Fixed (F) 059209 059211
E1N/MS 10 Iu (40 °C) = 1000 A Icw (1s) = 50 kA

Fixed (F) 059253 059255
E1B/MS 12 Iu (40 °C) = 1250 A Icw (1s) = 42 kA

Fixed (F) 058935 058936
E1N/MS 12 Iu (40 °C) = 1250 A Icw (1s) = 50 kA

Fixed (F) 058937 058938
E1B/MS 16 Iu (40 °C) = 1600 A Icw (1s) = 42 kA

Fixed (F) 058857 058858
E1N/MS 16 Iu (40 °C) = 1600 A Icw (1s) = 50 kA

Fixed (F) 058861 058862
9
Fixed parts ...................... page 9/51 Terminals ............................ page 9/53
ABB SACE 9/25

Ordering codes
1SDC200259F0001
1SDA......R1
3 Poles 4 Poles
E1B/MS 08 Iu (40 °C) = 800 A Icw (1s) = 42 kA

MP = Moving part
Withdrawable (W) - 058939 058940
MP
E1N/MS 08 Iu (40 °C) = 800 A Icw (1s) = 50 kA

MP = Moving part
MP
E1B/MS 10 Iu (40 °C) = 1000 A Icw (1s) = 42 kA

MP = Moving part
MP
E1N/MS 10 Iu (40 °C) = 1000 A Icw (1s) = 50 kA

MP = Moving part
MP
E1B/MS 12 Iu (40 °C) = 1250 A Icw (1s) = 42 kA

MP = Moving part
Withdrawable(W) - 058943 058944
MP
E1N/MS 12 Iu (40 °C) = 1250 A Icw (1s) = 50 kA

MP = Moving part
MP
E1B/MS 16 Iu (40 °C) = 1600 A Icw (1s) = 42 kA

MP = Moving part
Withdrawable(W) - 058859 058860
MP
E1N/MS 16 Iu (40 °C) = 1600 A Icw (1s) = 50 kA

MP = Moving part
MP
9
9/26 ABB SACE

1SDC200259F0001
1SDA......R1
3 Poles 4 Poles
E2N/MS 10 Iu (40 °C) = 1000 A Icw (1s) = 55 kA

Fixed (F) 059297 059299
E2S/MS 10 Iu (40 °C) = 1000 A Icw (1s) = 65 kA

Fixed (F) 059341 059343
E2N/MS 12 Iu (40 °C) = 1250 A Icw (1s) = 55 kA

Fixed (F) 058947 058948
E2S/MS 12 Iu (40 °C) = 1250 A Icw (1s) = 65 kA

Fixed (F) 058865 058866
E2B/MS 16 Iu (40 °C) = 1600 A Icw (1s) = 42 kA

Fixed (F) 058949 058950
E2N/MS 16 Iu (40 °C) = 1600 A Icw (1s) = 55 kA

Fixed (F) 058951 058952
E2S/MS 16 Iu (40 °C) = 1600 A Icw (1s) = 65 kA

Fixed (F) 058869 058870
E2B/MS 20 Iu (40 °C) = 2000 A Icw (1s) = 42 kA

Fixed (F) 058953 058954
E2N/MS 20 Iu (40 °C) = 2000 A Icw (1s) = 55 kA

Fixed (F) 058955 058956
E2S/MS 20 Iu (40 °C) = 2000 A Icw (1s) = 65 kA

Fixed (F) 058873 058874 9
ABB SACE 9/27

Ordering codes
1SDC200259F0001
1SDA......R1
3 Poles 4 Poles
E2N/MS 10 Iu (40 °C) = 1000 A Icw (1s) = 55 kA

MP = Moving part
MP
E2S/MS 10 Iu (40 °C) = 1000 A Icw (1s) = 65 kA

MP = Moving part
MP
E2N/MS 12 Iu (40 °C) = 1250 A Icw (1s) = 55 kA

MP = Moving part
MP
E2S/MS 12 Iu (40 °C) = 1250 A Icw (1s) = 65 kA

MP = Moving part
MP
E2B/MS 16 Iu (40 °C) = 1600 A Icw (1s) = 42 kA

MP = Moving part
MP
E2N/MS 16 Iu (40 °C) = 1600 A Icw (1s) = 55 kA

MP = Moving part
MP
E2S/MS 16 Iu (40 °C) = 1600 A Icw (1s) = 65 kA

MP = Moving part
MP
E2B/MS 20 Iu (40 °C) = 2000 A Icw (1s) = 42 kA

MP = Moving part
MP
E2N/MS 20 Iu (40 °C) = 2000 A Icw (1s) = 55 kA

MP = Moving part
MP
E2S/MS 20 Iu (40 °C) = 2000 A Icw (1s) = 65 kA

MP = Moving part
9 Withdrawable (W) - 058875 058876
MP
9/28 ABB SACE

1SDC200260F0001
1SDA......R1
3 Poles 4 Poles
E3V/MS 08 Iu (40 °C) = 800 A Icw (1s) = 85 kA

Fixed (F) 058877 058878
E3S/MS 10 Iu (40 °C) = 1000 A Icw (1s) = 75 kA

Fixed (F) 059425 059427
E3S/MS 12 Iu (40 °C) = 1250 A Icw (1s) = 75 kA

Fixed (F) 058967 058968
E3V/MS 12 Iu (40 °C) = 1250 A Icw (1s) = 85 kA

Fixed (F) 058881 058882
E3S/MS 16 Iu (40 °C) = 1600 A Icw (1s) = 75 kA

Fixed (F) 058969 058970
E3V/MS 16 Iu (40 °C) = 1600 A Icw (1s) = 85 kA

Fixed (F) 058885 058886
E3S/MS 20 Iu (40 °C) = 2000 A Icw (1s) = 75 kA

Fixed (F) 058971 058972
E3V/MS 20 Iu (40 °C) = 2000 A Icw (1s) = 85 kA

Fixed (F) 058889 058890
E3N/MS 25 Iu (40 °C) = 2500 A Icw (1s) = 65 kA

Fixed (F) 058973 058974
E3S/MS 25 Iu (40 °C) = 2500 A Icw (1s) = 75 kA

Fixed (F) 058975 058976 9
ABB SACE 9/29

Ordering codes
1SDC200260F0001
1SDA......R1
3 Poles 4 Poles
E3V/MS 25 Iu (40 °C) = 2500 A Icw (1s) = 85 kA

Fixed (F) 058893 058894
E3N/MS 32 Iu (40 °C) = 3200 A Icw (1s) = 65 kA

Fixed (F) 058977 058978
E3S/MS 32 Iu (40 °C) = 3200 A Icw (1s) = 75 kA

Fixed (F) 058979 058980
E3V/MS 32 Iu (40 °C) = 3200 A Icw (1s) = 85 kA

Fixed (F) 058897 058898
E3V/MS 08 Iu (40 °C) = 800 A Icw (1s) = 85 kA

MP = Moving part
MP
E3S/MS 10 Iu (40 °C) = 1000 A Icw (1s) = 75 kA

MP = Moving part
MP
E3S/MS 12 Iu (40 °C) = 1250 A Icw (1s) = 75 kA

MP = Moving part
MP
E3V/MS 12 Iu (40 °C) = 1250 A Icw (1s) = 85 kA

MP = Moving part
MP
E3S/MS 16 Iu (40 °C) = 1600 A Icw (1s) = 75 kA

MP = Moving part
Withdrawable (W) -
9 MP
058983 058984
9/30 ABB SACE

1SDC200260F0001
1SDA......R1
3 Poles 4 Poles
E3V/MS 16 Iu (40 °C) = 1600 A Icw (1s) = 85 kA

MP = Moving part
MP
E3S/MS 20 Iu (40 °C) = 2000 A Icw (1s) = 75 kA

MP = Moving part
MP
E3V/MS 20 Iu (40 °C) = 2000 A Icw (1s) = 85 kA

MP = Moving part
MP
E3N/MS 25 Iu (40 °C) = 2500 A Icw (1s) = 65 kA

MP = Moving part
Withdrawable (W) -
058987 058988
MP
E3S/MS 25 Iu (40 °C) = 2500 A Icw (1s) = 75 kA

MP = Moving part
Withdrawable (W) -
058989 058990
MP
E3V/MS 25 Iu (40 °C) = 2500 A Icw (1s) = 85 kA

MP = Moving part
MP
E3N/MS 32 Iu (40 °C) = 3200 A Icw (1s) = 65 kA

MP = Moving part
MP
E3S/MS 32 Iu (40 °C) = 3200 A Icw (1s) = 75 kA

MP = Moving part
MP
E3V/MS 32 Iu (40 °C) = 3200 A Icw (1s) = 85 kA

MP = Moving part
Withdrawable (W) -
058899 058900
MP 9
ABB SACE 9/31

Ordering codes
1SDC200261F0001
1SDA......R1
3 Poles 4 Poles
E4H/MS 32 Iu (40 °C) = 3200 A Icw (1s) = 100 kA

Fixed (F) 058995 058996
E4S/MS 40 Iu (40 °C) = 4000 A Icw (1s) = 75 kA

Fixed (F) 058997 058998
E4H/MS 40 Iu (40 °C) = 4000 A Icw (1s) = 100 kA

Fixed (F) 058999 059000
E4H/MS 32 Iu (40 °C) = 3200 A Icw (1s) = 100 kA

MP = Moving part
MP
E4S/MS 40 Iu (40 °C) = 4000 A Icw (1s) = 75 kA

MP = Moving part
MP
E4H/MS 40 Iu (40 °C) = 4000 A Icw (1s) = 100 kA

MP = Moving part
MP
9
9/32 ABB SACE

1SDC200262F0001
1SDA......R1
3 Poles 4 Poles
E6H/MS 40 Iu (40 °C) = 4000 A Icw (1s) = 100 kA

Fixed (F) 058905 058906
E6H/MS 50 Iu (40 °C) = 5000 A Icw (1s) = 100 kA

Fixed (F) 059007 059008
E6H/MS 63 Iu (40 °C) = 6300 A Icw (1s) = 100 kA

Fixed (F) 059009 059010
E6H/MS 40 Iu (40 °C) = 4000 A Icw (1s) = 100 kA

MP = Moving part
MP
E6H/MS 50 Iu (40 °C) = 5000 A Icw (1s) = 100 kA

MP = Moving part
MP
E6H/MS 63 Iu (40 °C) = 6300 A Icw (1s) = 100 kA

MP = Moving part
MP
9
ABB SACE 9/33

Ordering codes
SACE Emax switch-disconnectors with full size neutral
conductor
1SDC200263F0001
1SDA......R1
4 Poles
E4H/f MS 32 Iu (40 °C) = 3200 A Icw (1s) = 85 kA

Fixed (F) 058901
E4S/f MS 40 Iu (40 °C) = 4000 A Icw (1s) = 80 kA

Fixed (F) 059015

Fixed (F) 058903

MP = Moving part
Withdrawable (W) - 058902
MP
E4S/f MS 40 Iu (40 °C) = 4000 A Icw (1s) = 80 kA

MP = Moving part
MP

MP = Moving part
MP
9
9/34 ABB SACE

1SDC200264F0001
1SDA......R1
4 Poles

Fixed (F) 058909

Fixed (F) 059017

Fixed (F) 059018

MP = Moving part
MP

MP = Moving part
MP

MP = Moving part
MP
9
ABB SACE 9/35

Ordering codes
1SDC200259F0001
for applications up to 1150V AC
1SDA......R1
E2B/E 16 Iu (40 °C) = 1600 A Icu (1150 V AC) = 20 kA

059633
Note: to be specified in addition to the code of the standard version E2B 16 circuit-breaker (Ue=690 V AC) page 9/7
E2B/E 20 Iu (40 °C) = 2000 A Icu (1150 V AC) = 20 kA

059634
Note: to be specified in addition to the code of the standard version E2B 20 circuit-breaker (Ue=690 V AC) page 9/8
E2N/E 12 Iu (40 °C) = 1250 A Icu (1150 V AC) = 30 kA

059635
Note: to be specified in addition to the code of the standard version E2N 12 circuit-breaker (Ue=690 V AC) page 9/9

059636

059637
9
9/36 ABB SACE

1SDC200260F0001
1SDA......R1
E3H/E 12 Iu (40 °C) = 1250 A Icu (1150 V AC) = 30 kA

059638
Note: to be specified in addition to the code of the standard version E3H 12 circuit-breaker (Ue=690 V AC) page 9/11

059639

059640

059641

059642
9
ABB SACE 9/37

Ordering codes
1SDC200261F0001
1SDA......R1

059643

059644
1SDC200262F0001
1SDA......R1

058550

058551

058552
9
9/38 ABB SACE

Ordering codes
1SDC200259F0001
1SDA......R1
E2B/E MS 16 Iu (40 °C) = 1600 A Icw (1 s) = 20 kA

059633
Note: to be specified with the code of the standard version circuit-breaker (Ue = 690V AC) page 9/7

059634
E2N/E MS 12 Iu (40 °C) = 1250 A Icw (1 s) = 30 kA

059635

059636

059637
9
ABB SACE 9/39

Ordering codes
1SDC200260F0001
1SDA......R1
3 Poles 4 Poles
E3H/E MS 12 Iu (40 °C) = 1250 A Icw (1 s) = 30 kA

Fixed (F) Circuit-breaker code 059021 059022
Additional code to be specified with the circuit-breaker 059638 059638




9
9/40 ABB SACE

1SDC200260F0001
1SDA......R1
3 Poles 4 Poles

MP = Moving part
Withdrawable (W) - Circuit-breaker code 059031 059032
MP Additional code to be specified with the circuit-breaker 059638 059638

MP = Moving part

MP = Moving part

MP = Moving part

MP = Moving part
9
Parti fisse ........................ pag. 9/51 Terminali ............................. pag. 9/53
ABB SACE 9/41

Ordering codes
1SDC200261F0001
1SDA......R1

059643
Note: to be specified in addition to the code of the standard version E4H/MS 32 circuit-breaker (Ue=690 V AC) page 9/32

059644
1SDC200262F0001
1SDA......R1

058550

058551

058552
9
9/42 ABB SACE

Ordering codes
1SDC200259F0001
1SDA......R1
3 Poles 4 Poles
750V DC 1000V DC

Fixed (F) 059041 059042

Fixed (F) 059043 059044

MP = Moving part
MP

MP = Moving part
MP
9
ABB SACE 9/43

Ordering codes
1SDC200259F0001
1SDA......R1
3 Poles 4 Poles
750V DC 1000V DC

Fixed (F) 059049 059050

Fixed (F) 059051 059052

Fixed (F) 059053 059054

MP = Moving part
MP

MP = Moving part
MP

MP = Moving part
MP
9
9/44 ABB SACE

1SDC200260F0001
1SDA......R1
3 Poles 4 Poles
750V DC 1000V DC

Fixed (F) 059061 059062

Fixed (F) 059063 059064

Fixed (F) 059065 059066

Fixed (F) 059067 059068

Fixed (F) 059069 059070

MP = Moving part
MP
MP = Moving part
MP
MP = Moving part
MP
MP = Moving part
MP
MP = Moving part
MP
9
ABB SACE 9/45

Ordering codes
1SDC200261F0001
1SDA......R1
3 Poles 4 Poles
750V DC 1000V DC

Fixed (F) 059081 058911

Fixed (F) 059082 058913

MP = Moving part
MP

MP = Moving part
MP
9
9/46 ABB SACE

1SDC200262F0001
1SDA......R1
3 Poles 4 Poles
750V DC 1000V DC

Fixed (F) 058915 058921

Fixed (F) 058917 058923

Fixed (F) 058919 058925

MP = Moving part
MP

MP = Moving part
MP

MP = Moving part
MP
9
ABB SACE 9/47

Ordering codes
SACE Emax CS sectionalizing trucks
1SDA......R1
3 Poles 4 Poles
E1/CS 12 Iu (40 °C) = 1250 A

MP = Moving part
MP
E2/CS 20 Iu (40 °C) = 2000 A

MP = Moving part
MP
E3/CS 32 Iu (40 °C) = 3200 A

MP = Moving part
MP
E4/CS 40 Iu (40 °C) = 4000 A

MP = Moving part
MP
E6/CS 63 Iu (40 °C) = 6300 A

MP = Moving part
MP
9
Fixed parts ................... page 9/51
9/48 ABB SACE

Ordering codes
SACE Emax MTP earthing switches with making capacity
Earthing of Earthing of
upper terminals lower terminals
1SDA......R1 1SDA......R1
3 Poles 4 Poles 3 Poles 4 Poles
E1 MTP 12 Iu (40 °C) = 1250 A

MP = Moving part
Withdrawable (W) - 059095 059097 059096 059098
MP
E2 MTP 20 Iu (40 °C) = 2000 A

MP = Moving part
Withdrawable (W) - 059099 059101 059100 059102
MP
E3 MTP 32 Iu (40 °C) = 3200 A

MP = Moving part
Withdrawable (W) - 059103 059105 059104 059106
MP
E4 MTP 40 Iu (40 °C) = 4000 A

MP = Moving part
Withdrawable (W) - 059107 059109 059108 059110
MP
E6 MTP 63 Iu (40 °C) = 6300 A

MP = Moving part
Withdrawable (W) - 059111 059113 059112 059114
MP
9
Fixed parts ................... page 9/51
ABB SACE 9/49

Ordering codes
SACE Emax MT earthing trucks
Earthing of Earthing of
upper terminals lower terminals
1SDA......R1 1SDA......R1
E1 MT 12 Iu (40 °C) = 1250 A

MP = Moving part
Withdrawable (W) - 059115 059117 059116 059118
MP
E2 MT 20 Iu (40 °C) = 2000 A

MP = Moving part
Withdrawable (W) - 059119 059121 059120 059122
MP
E3 MT 32 Iu (40 °C) = 3200 A

MP = Moving part
Withdrawable (W) - 059123 059125 059124 059126
MP
E4 MT 40 Iu (40 °C) = 4000 A

MP = Moving part
Withdrawable (W) - 059127 059129 059128 059130
MP
E6 MT 63 Iu (40 °C) = 6300 A

MP = Moving part
Withdrawable (W) - 059131 059133 059132 059134
MP
9
Fixed parts ................... page 9/51
9/50 ABB SACE

Ordering codes
SACE Emax FP fixed parts
HR VR F FL 750 V DC 1000 V DC
1SDA......R1 1SDA......R1
E1 FP = Fixed part
HR 059666 059762 059890 059902
Withdrawable (W) - VR 059672 059770 059894 059905
FP F 059678 059778
FL 059684 059786 059898 059908
HR-VR 059690 059794
VR-HR 059708 059818
E2 FP = Fixed part
HR 059667 059763 059891 059903
FP F 059679 059779
FL 059685 059787 059899 059909
HR-VR 089691 059795
VR-HR 059709 059819
E2S FP = Fixed part

HR 059668 059764
Withdrawable (W) - VR 059674 059772
FP F 059680 059780
FL 059686 059788
HR-VR 089692 059796
VR-HR 059710 059820
E3 FP = Fixed part
HR 059669 059765 059892 059904
FP F 059681 059781
FL 059687 059789 059900 059910
HR-VR 059693 059797
VR-HR 059711 059821
E4 FP = Fixed part
HR 059670 059766 059893 059136
FP F 059682 059782
FL 059688 059790 059901 059138
HR-VR 059694 059798
VR-HR 059712 059822
E4/f FP = Fixed part

HR 059767
Withdrawable (W) - VR 059775
FP F 059783
FL 059791
HR-VR 059799
VR-HR 059823
Note: HR-VR = Upper HR teminals, lower VR terminals;

9
VR-HR = Upper VR teminals, lower HR terminals.
ABB SACE 9/51

Ordering codes
HR VR F FL 750 V DC 1000 V DC
1SDA......R1 1SDA......R1
E6 FP = Fixed part
HR 059671 059768 059139 059142
FP F 059683 059784
FL 059689 059792 059141 059144
HR-VR 059695 059800
VR-HR 059713 059824
E6/f FP = Fixed part

HR 059769
Withdrawable (W) - VR 059777
FP F 059785
FL 059793
HR-VR 059801
VR-HR 059825
Note: HR-VR = Upper HR teminals, lower VR terminals;

VR-HR = Upper VR teminals, lower HR terminals.
9/52 ABB SACE

Ordering codes
Conversion kit for fixed circuit-breaker and fixed parts
1SDA......R1
3 Poles 4 Poles
Conversion kit Kit for converting fixed circuit-breaker with horizontal rear terminals to vertical rear terminals
E1 038052 038057
for fixed circuit- E2 038053 038058
breaker and fixed E3 038054 038059
E4 038055 038060
parts E6 038056 038061
E4/f – 048720
E6/f – 050833
Note: Each kit is prepared for top or bottom application. For conversion of a complete circuit-breaker, order 2 kits.
Kit for converting fixed circuit-breaker with horizontal rear terminals to front terminals
E1 038062 038067
E2 038063 038068
E3 038064 038069
E4 038065 038070
E6 038066 038071
E4/f – 048719
E6/f – 050834
Note: Each kit is prepared for top or bottom application. For conversion of a complete circuit-breaker, order 2 kits.
Kit for converting fixed parts with horizontal rear terminals to front terminals
E1 038062 038067
E2 045031 045035
E3 045032 045036
E4 045033 045037
E6 045034 045038
E4/f – 048718
E6/f – 050837
Note: Each kit is prepared for top or bottom application. For conversion of a complete fixed part, order 2 kits. To be specified as spare parts.
Kit for converting fixed parts with horizontal rear terminals to vertical rear terminals
E1 055481 055486
E2 055482 055487
E3 055483 055488
E4 055484 055489
E6 055485 055490
E4/f – 058537
E6/f – 058538
Kit for converting fixed parts with vertical rear terminals to horizontal rear terminals
E1 055491 055496
E2 055492 055497
E3 055493 055498
E4 055494 055499
E6 055495 055500
E4/f – 058539
E6/f – 058540
Kit for converting fixed part from previews versions to new versions
E1/E6 059645 059645
9
ABB SACE 9/53

Ordering codes
Extra codes
1SDA......R1
Extra codes for To be specified with the code of the standard version circuit-breaker
E1-E3 In = 400A 058235
rating plug E1-E3 In = 630A 058236
E1-E6 In = 800A 058237
E1-E6 In = 1000A 058238
E1-E6 In = 1250A 058240
E1-E6 In = 1600A 058241
E2-E6 In = 2000A 058242
E3-E6 In = 2500A 058243
E3-E6 In = 3200A 058245
E4-E6 In = 4000A 058247
E6 In = 5000A 058248
E6 In = 6300A 058249
Extra code for

To be specified with PR122/P and PR123/P when the input for voltage measurement in terminal box/sliding contacts
connection of voltage instead of internal connection on the bottom terminals is required
measurement PR120/V - External measurements 058250
PR120/V - Internal connection on the upper terminals 058251
9/54 ABB SACE

Ordering codes
SACE Emax accessories
1SDA.....R1
Electrical Shunt opening release - YO (1a)

E1/6 24V DC 038286
accessories E1/6 30V AC / DC 038287
E1/6 48V AC / DC 038288
E1/6 60V AC / DC 038289
E1/6 110...120V AC / DC 038290
E1/6 120…127V AC / DC 038291
E1/6 220…240V AC / DC 038292
E1/6 240…250V AC / DC 038293
E1/6 380…400V AC 038294
E1/6 440…480V AC 038295
Note: The shunt opening release (YO) and closing release (YC) share the same construction and are therefore interchangeable.
Their function is determined by the position in which they are mounted on the circuit-breaker.
Second shunt opening release - YO2 (1a)

E1/6 24V DC 050157
E1/6 30V AC / DC 050158
E1/6 48V AC / DC 050159
E1/6 60V AC / DC 050160
E1/6 110...120V AC / DC 050161
E1/6 120…127V AC / DC 050162
E1/6 220…240V AC / DC 050163
E1/6 240…250V AC / DC 050164
E1/6 380…400V AC 050165
E1/6 440…480V AC 050166
Note: supplied with special release support.
Shunt closing release - YC (1a)

E1/6 24V DC 038296
E1/6 30V AC / DC 038297
E1/6 48V AC / DC 038298
E1/6 60V AC / DC 038299
E1/6 110...120V AC / DC 038300
E1/6 120…127V AC / DC 038301
E1/6 220…240V AC / DC 038302
E1/6 240…250V AC / DC 038303
E1/6 380…400V AC 038304
E1/6 440…480V AC 038305
Note: The shunt opening release (YO) and closing release (YC) share the same construction and are therefore interchangeable.
Their function is determined by the position in which they are mounted on the circuit-breaker.
SOR Test Unit - (1b)

E1/6 050228
ABB SACE 9/55

Ordering codes
1SDA.....R1
Undervoltage release - YU (2a)

E1/6 24V DC 038306
E1/6 30V AC / DC 038307
E1/6 48V AC / DC 038308
E1/6 60V AC / DC 038309
E1/6 110...120V AC / DC 038310
E1/6 120…127V AC / DC 038311
E1/6 220…240V AC / DC 038312
E1/6 240…250V AC / DC 038313
E1/6 380…400V AC 038314
E1/6 440…480V AC 038315
Electronic time-delay device for undervoltage release - D (2b)

E1/6 24...30V AC / DC 038316
E1/6 48V AC / DC 038317
E1/6 60V AC / DC 038318
E1/6 110...127V AC / DC 038319
E1/6 220…250V AC / DC 038320
Geared motor for the automatic charging of the closing springs - M (3)
E1/6 24...30V AC / DC 038321
E1/6 48…60V AC / DC 038322
E1/6 100...130V AC / DC 038323
E1/6 220…250V AC / DC 038324
Note: supplied as standard with limit contact and microswitch to signal when the closing springs are charged (accessory 5d).
Electrical signalling of overcurrent releases tripped - (4a)

E1/6 058260
Electrical signalling of overcurrent releases tripped with

remote reset command - (4b)
E1/6 220...240V AC/DC 058261
E1/6 110...130V AC/DC 058262
E1/6 24...30V AC/DC 058263
9/56 ABB SACE

1SDA.....R1
Electrical signalling of circuit-breaker open/closed - Q1 ... 10 - (5a)

E1/6 - PR121/P 4 auxiliary contacts 038326 (a)
E1/6 - PR121/P 4 auxiliary contacts for digital signals 050153
E1/6 - PR121/P 10 auxiliary contacts (installed) 046523 (b)
E1/6 - PR121/P 10 auxiliary contacts (not installed) 038327 (c)
E1/6 - PR121/P 10 auxiliary contacts for digital signals 050152
E1/6 - PR122-3/P 4 auxiliary contacts (2NA+2NC+2PR122-3) 058264 (d)

E1/6 - PR122-3/P 4 auxiliary contacts (2NA+2NC+2PR122-3) for digital signals 058265
E1/6 - PR122-3/P 10 auxiliary contacts (5NA+5NC+2PR122-3 - installed) 058267 (b)
E1/6 - PR122-3/P 10 auxiliary contacts (5NA+5NC+2PR122-3 - not installed) 058266 (c)
E1/6 - PR122-3/P 10 auxiliary contacts (5NA+5NC+2PR122-3) for digital signals 058268
E1/6 MS - E1/6 MTP 4 auxiliary contacts 038326

E1/6 MS - E1/6 MTP 4 auxiliary contacts for digital signals 050153
E1/6 MS - E1/6 MTP 10 auxiliary contacts 038327
E1/6 MS - E1/6 MTP 10 auxiliary contacts for digital signals 050152
Note: (a) Already included with automatic circuit-breakers c/w PR121/P. Can be ordered as loose accessories.
(b) Can only be ordered mounted with automatic circuit-breakers.
(c) Can only be ordered loose in the case of automatic circuit-breakers.
(d) Already included for circuit-breakers with PR122/P e PR123/P. Can only be ordered as loose accessories.
External supplementary of circuit-breaker open/closed

auxiliary contacts - Q11 ... 25 - (5b)
E1/6 15 supplementary auxiliary contacts 043475
E1/6 15 supplementary auxiliary contacts (for withdrawable version) 048827
E1/6 15 supplementary auxiliary contacts for digital signals 050145
E1/6 15 supplementary auxiliary contacts for digital signals (for withdrawable version) 050151
Note: outside the circuit-breaker. Order as an alternative to the various types of mechanical interlocks (accessory 10) and mechanical
compartment door lock (accessory 8f). For mounting on fixed circuit-breaker requires accessory 10.4 as well (Interlock plate for fixed
circuit-breaker).
1SDA.....R1
3 Poles 4 Poles
Electrical signalling of circuit-breaker

racked-in/test isolated/racked-out S75 - (5c)
E1/6 5 auxiliary contacts 038361 038361
E1-E2 10 auxiliary contacts 038360 043467
E3 10 auxiliary contacts 043468 043469
E4-E6 10 auxiliary contacts 043470 043470
E1/6 5 auxiliary contacts for digital signals 050146 050146
E1-E2 10 auxiliary contacts for digital signals 050147 050148
E4-6 10 auxiliary contacts for digital signals 050147 050147
E3 10 auxiliary contacts for digital signals 050149 050150
Contact for signalling closing spring charged S33 M/2- (5d)

E1/6 038325
Note: already supplied with the geared motor for automatic closing spring charging.
Contact for signalling undervoltage release de-energized - (5e)

E1/6
E1/6
1 normally-closed contact
1 normally-open contact
038341
038340
9
ABB SACE 9/57

Ordering codes
1SDA.....R1
Current sensor for neutral conductor outside

circuit-breaker UI/N - (6a)
E1-E2-E4 Iu N = 2000A 058191
E3-E6 Iu N = 3200A 058218
E4/f Iu N = 4000A 058216
E6/f Iu N = 6300A 058220
Note: Iu N refers to the maximum neutral conductor capacity.
Homopolar toroid for the main power supply earthing conductor

(star centre of the transformer) UI/O - (6b)
E1/6 059145
Mechanical Mechanical operation counter - (7)

E1/6 038345
accessories
Lock in open position - (8a-8b)

key locks (8a)
E1/6 for 1 circuit-breaker (different keys) 058271
E1/6 for groups of circuit-breakers (same keys N.20005) 058270
padlocks (8b)
E1/6 038351 (a)
Note: (a) To be ordered as alternative to the opening and closing pushbutton protective cover (accessory 9a).
Circuit-breaker lock in racked-in/test isolated/racked-out

position - (8c)
E1/6 for 1 circuit-breaker (different keys) 058278
Accessory for lock in test isolated/racked-out position - (8d)

E1/6 038357
Note: Must always be ordered to complete the circuit-breaker lock in racked-in/test/racked-out position (accessory 8b)
Accessory for shutter padlock device - (8e)

9 E1/6 038363
9/58 ABB SACE

1SDA.....R1
Mechanical compartment door lock - (8f)

E1/6 045039
Note: – Order with interlock for fixed circuit-breaker/moving part of withdrawable circuit-breaker (accessory 10.2)
– for fixed version, also order the interlock plate 10.4
– order as an alternative to cable interlocks (accessory 10.1), and to the 15 supplementary auxiliary contacts (accessory 5b).
Protective cover for opening and closing pushbuttons - (9a)

E1/6 038343
Note: Order as an alternative to the padlock device in open position (accessory 8b).
IP54 door protection - (9b)

E1/6 038344
Sealable relay protection - (9c)

E1/6 for PR121 058316
E1/6 for PR122/PR123 058317
Mechanical interlock - (10)

For instructions see pages 9/63 and following.
10.1 Interlock cables for fixed circuit-breakers or fixed parts

E1/6 A - horizontal 038329
E1/6 B - horizontal 038330
E1/6 C - horizontal 038331
E1/6 D - horizontal 038332
E1/6 A - vertical 038333
E1/6 B - vertical 038334
E1/6 C - vertical 038335
E1/6 D - vertical 038336
Note: Order one type of cable for each interlock. Order on one of the fixed circuit-breakers or on one of the fixed parts.
1SDA.....R1
3 Poles 4 Poles
10.2 Interlock for fixed circuit-breaker/moving part of withdrawable circuit-breaker

E1-E2 038366 038366
E3 038367 038367
E4 038368 043466
E6 043466 038369
Note: Order one accessory for each fixed circuit-breaker/moving part of withdrawable circuit-breaker.
10.3 Interlock for fixed circuit-breaker/fixed part of withdrawable circuit-breaker

E1/6 Interlock A / B / D 038364
E1/6 Interlock C 038365
Note: Order one accessory for each fixed circuit-breaker/fixed part of withdrawable circuit-breaker.
10.4 Interlock plate for fixed circuit-breaker

E1/6 038358
9
Note: Order only for fixed circuit-breaker.
ABB SACE 9/59

Ordering codes
1SDA.....R1
Auxiliary units Automatic transfer switch ATS010 - (11)

E1/6 ATS010 052927
PR010/T configuration test unit

E1/6 PR010/T 048964

E1/6 PR021/K 059146
PR120/K Signalling module

E1/6 PR120/K (4 Output with independent terminals) 058255
E1/6 PR120/K (4 Output + 1 Input with a common terminal) 058256
PR120/V Voltage measuring module

E1/6 PR120/V 058252
Note: For the supply of circuit-breakers with connection on the upper terminals or terminal box, please see also the extra codes (page 9/54).
PR120/D-M Communication module (Modbus RTU)

E1/6 PR120/D-M 058254
PR120/D-BT Internal wireless communication module

E1/6 PR120/D-BT 058257
BT030 External wireless communication module

E1/6 BT030 058259
9 EP010 - ABB Fieldbus plug

E1/6 EP010 060198
9/60 ABB SACE

Ordering codes
Electronic releases and current sensors (for loose supplies)
PR121/P PR122/P PR123/P

1SDA......R1 1SDA......R1 1SDA......R1
Electronic releases
LI 058189 058196
LSI 058193 058197 058199
LSIG 058195 058198 058200
LSIRc 058201
1SDA.....R1
Rating plug
E1-E3 In=400A 058192
E1-E3 In=630A 058221
E1-E6 In=800A 058222
E1-E6 In=1000A 058223
E1-E6 In=1250A 058225
E1-E6 In=1600A 058226
E2-E6 In=2000A 058227
E3-E6 In=2500A 058228
E3-E6 In=3200A 058230
E4-E6 In=4000A 058232
E6 In=5000A 058233
E6 In=6300A 058234
ABB SACE 9/61

Ordering codes
Order examples
1) Extra codes
Instructions for ordering
Standard version Emax series circuit-breakers are identified by means of commercial codes
that can be altered by adding the following variables:
• Codes for Terminal Kits for fixed circuit-breakers (other than horizontal rear)
• Extra codes for Current Transformer Settings (for current values below rated)
• Extra codes for special Version for rated service voltages up to 1150V AC
The above types of variables can also be requested simultaneously on the same circuit-breaker.
The “Extra codes” indicate variables that are not in addition to, but in replacement of the those
found in the basic circuit-breaker.
For this reason, these commercial codes can only be ordered installed on the circuit-breaker
and not as loose parts.
For releases (which already include the Dialogue Unit) and Current Transformers for supplies as
spare parts for replacement by the customer, please see the coding section “Protection Re-
leases and Current Transformers which can be supplied separately”.
Numerical examples
• Terminal Kit Codes for fixed circuit-breaker (other than horizontal rear)
The codes indicate 3 or 4 pieces (for mounting on top or bottom terminals).
To convert a complete circuit-breaker, in the order specify 2 identical kits or 2 different kits for
mixed terminals.
For mixed solutions, the first code indicates the 3 or 4 terminals to be mounted above, while
the second indicates the 3 or 4 terminals to be mounted below.
Example no. 1
Emax E3N 3 poles fixed with Vertical Rear terminals (VR)
1SDA056148R1 E3N 3200 PR122/P-LSI-In=3200A 3p F HR
1SDA038054R1 KIT 1/2 3p F HR>F VR E3
Example no. 2
Emax E3N 3 poles fixed with top Vertical Rear (VR) and bottom Front (F) terminals
1SDA038064R1 KIT 1/2 3p F HR>F F E3
• Extra codes for Current Transformer Settings (for current values below rated)
Example no. 3
Emax E3N 3200 3 poles fixed In=2000A

1SDA058242R1 rating plug In=2000A E2-4IEC E3-4UL EX.C
• Extra codes for Special Version for rated service voltages up to 1150V AC
Example no. 4
Emax E3H/E 2000 3 poles fixed (version up to 1150V AC)
9 1SDA056432R1
1SDA048534R1
E3H 2000 PR121/P-LI-In=2000A 3p F HR
Special 1150V AC version Emax E3H/E20 circuit-breaker
9/62 ABB SACE

2) Mechanical
interlocks Instructions for ordering
All the mechanical interlocks for any type of SACE Emax circuit-breaker consist of various compo-
nents, each of which has been coded to ensure the greatest possible flexibility of the accessory.
The accessory components are described below

• Cables for interlock (Ref. 10.1 page 9/59)
One type of cable must be ordered for each interlock.
Flexible cables must be fixed to the fixed circuit-breakers and to the switchgear structures using
self-adhesive plates and self-locking bands.
• Interlock for fixed circuit-breaker/withdrawable circuit-breaker moving part (Ref. 10.2

page 9/59)
This is the accessory which must be installed on the moving part of the withdrawable circuit-
breaker or on the side of the fixed circuit-breaker.
This accessory must be ordered for each fixed circuit-breaker and for each moving part of the
withdrawable circuit-breaker.
• Interlock for fixed circuit-breaker/ withdrawable circuit-breaker fixed part (Ref. 10.3 page
9/59)
This is the accessory which must be installed on the fixed part of the withdrawable circuit-
breaker or on the interlock plate of the fixed circuit-breaker (which simulates the fixed part of the
withdrawable circuit-breaker).
This accessory must be ordered for each fixed circuit-breaker and for each fixed part of the
withdrawable circuit-breaker.
• I nterlock plate for fixed circuit-breaker (Ref. 10.4 page 9/59)

This must be requested for each fixed circuit-breaker present in the interlock.
For each circuit-breaker used in the interlock, depending on the type of circuit-breaker, the
accessories listed in the figures below must be ordered (see page 9/55).
A single group of cables (“Cables for interlock” ref. 10.1) must be ordered for each interlock.
In particular, either on a fixed circuit-breaker or on one of the fixed parts must be specified.
The examples beside show a general 1. Interlock between two fixed circuit-breakers 3. Interlock between three fixed circuit-breakers
guide to the types of accessories that
must be ordered for the various
versions of circuit-breakers and type
of interlock: 10.1 10.1
10.2 10.2 10.2 10.2 10.2
10.3 10.3 10.3 10.3 10.3
10.4 10.4 10.4 10.4 10.4
2. Interlock between two withdrawable circuit- 4. Interlock between three withdrawable circuit-
breakers breakers
10.1 10.1
FP FP FP FP FP
10.3 10.3 10.3 10.3 10.3
10.2 10.2 10.2 10.2 10.2

MP MP MP MP MP
9
ABB SACE 9/63

Guide to ordering
Order examples
Numerical examples
Example no. 5
An interlock is to be made between two type A circuit-breakers. In particular, the following are to
be interlocked:
– a SACE E3 3-pole fixed circuit-breaker
– with a SACE E4 4-pole withdrawable circuit-breaker;
the circuit-breakers are placed horizontally in the switchboard.
The codes to be used when ordering are listed below:
Pos Code Description

100 SACE E3 fixed circuit-breaker
1SDA038329R1 Type A interlock cables for fixed circuit-breakers or fixed parts - horizontal E1/6
1SDA038367R1 Interlock for fixed circuit-breaker/moving part of withdrawable circuit-breaker E3
1SDA038364R1 Interlock for fixed circuit-breaker/fixed part of withdrawable circuit-breaker
Interlock typeA / B / D E1/6
1SDA038358R1 Interlock plate for fixed circuit-breaker E1/6
200 SACE E4 moving part of withdrawable circuit-breaker

1SDA043466R1 Interlock for fixed circuit-breaker/moving part of withdrawable circuit-breaker
4p E4 / 3p E6
300 Fixed part SACE E4

Interlock TypeA / B / D E1/6
Example no. 6
Here an interlock is to be made between three Type C vertical circuit-breakers with the following
circuit-breakers:
– SACE E2 3-pole withdrawable circuit-breaker
– SACE E3 3-pole fixed circuit-breaker
– SACE E6 4-pole fixed circuit-breaker.
Pos Code Description

100 SACE E2 Moving Part of withdrawable circuit-breaker
1SDA038366R1 Interlock for fixed circuit-breaker/moving part of withdrawable circuit-breaker E1-E2
200 SACE E2 Fixed part

1SDA038335R1 Type C interlock cables for fixed circuit-breakers or fixed parts - vertical E1/6
Type C Interlock E1/6
300 SACE E3 Fixed circuit-breaker

Interlock E3
400 SACE E6 Fixed circuit-breaker

Interlock 4p E6
9/64 ABB SACE

1SDC200006D0202- 04/2005
Printed in Italy
6.000 - CAL
Due to possible developments of standards as well as of

materials, the characteristics and dimensions specified in the
present catalogue may only be considered binding after
confirmation by ABB SACE.
ABB SACE S.p.A.

An ABB Group company
L.V. Breakers
Via Baioni, 35
24123 Bergamo - Italy
Tel.: +39 035.395.111 - Telefax: +39 035.395.306-433
http://www.abb.com
NOV PART NO.:
1SDC200012D0201
Annex to the technical catalogue Emax DC
Low voltage switch-disconnectors
and automatic circuit-breakers for
Direct Current Applications
1SDC200012D0201
DC_copertina_A4.indd 1 16/03/2008 16.34.03

DC_copertina_A4.indd 3 16/03/2008 17.07.43
Index
SACE Emax DC automatic circuit-breakers . ........................................................................... 2
SACE Emax DC switch-disconnectors for applications up to 1000 V DC . ............................. 3
SACE Emax DC: Direct Current Applications .......................................................................... 4
Protection trip units and trip curves ......................................................................................... 8
Accessories ............................................................................................................................ 23
Overall dimensions ................................................................................................................. 24
Circuit diagrams ..................................................................................................................... 33
Ordering codes . ..................................................................................................................... 42
ABB SACE
DC_interno.indd 1 16/03/2008 16.49.31

SACE Emax DC automatic circuit-breakers
The SACE Emax range of low voltage automatic circuit-breakers is being enriched by the new series
SACE Emax DC of automatic circuit-breakers for direct current applications in compliance with the
international standard IEC60947-2.
Thanks to the exclusive technology of the new electronic SACE PR123/DC e PR122/DC the SACE Emax
DC range allows to cover all installation and automatic protection needs up to 1000V / 5000A DC.
By connecting three breaking poles in series it is possible to achieve a rated voltage of 750V DC,
while with four poles in series the limit rises 1000V DC.
The automatic circuit-breakers of SACE Emax DC range maintain the overall dimensions and fixing
points of the standard range circuit-breakers; they can be fitted with the various terminal kits and all
accessories common to the SACE Emax range.
The withdrawable circuit-breakers should be used together with the special version fixed parts for
applications at 750/1000 DC.
Common data
Voltages
Rated service voltage Ue [V–] 1000
Rated insulation voltage Ui [V] 1000
Rated impulse withstand voltage Uimp [kV] 12
Operating temperature [°C] -25....+70
1SDC200601F0001
Storage temperature [°C] -40....+70
Number of poles 3-4
Versions Fixed - Withdrawable

E2 E3 E4 E6
Performance levels B N N H S H H
Rated uninterrupted current (at 40 °C) Iu [A] 800 800
[A] 1000 1000
[A] 1250 1250
[A] 1600 1600 1600 1600 1600
[A] 2000 2000 2000
[A] 2500 2500 2500
[A] 3200 3200 3200
[A] 4000
[A] 5000
@ 500 V DC (III) [kA] 35 50 60 85 75 100 100
@ 750 V DC (III) [kA] 25 25 40 40 65 65 65
@ 750 V DC (IV) [kA] 25 40 50 50 65 65 65
@ 1000 V DC (IV) [kA] 25 25 35 40 50 65 65
Rated service breaking capacity under short-circuit Ics [%Icu] [kA] 100% 100% 100% 100% 100% 100% 100%
Rated short-time withstand current Icw (0.5s)
@ 500 V DC (III) [kA] 35 50 60 65 75 100 100
@ 750 V DC (III) [kA] 25 25 40 40 65 65 65
@ 750 V DC (IV) [kA] 25 40 50 50 65 65 65
@ 1000 V DC (IV) [kA] 25 25 35 40 50 65 65
Rated making capacity under short-circuit Icm [%Icu] [kA] 100% 100% 100% 100% 100% 100% 100%
Utilization category (according to CEI EN 60947-2) B B B B B B B
Isolation behaviour (according to CEI EN 60947-2) ■ ■ ■ ■ ■ ■ ■
Overcurrent protection
Electronic trip units for DC applications ■ ■ ■ ■ ■ ■ ■
Operating times
Closing time (max) [ms] 80 80 80 80 80 80 80
Breaking time for I<Icw (max) (1) [ms] 70 70 70 70 70 70 70
Breaking time for I>Icw (max) [ms] 30 30 30 30 30 30 30
Overall dimensions
Fixed: H = 418 mm - D = 302 mm - W (3/4 poles) [mm] 296/386 296/386 404/530 404/530 566/656 566/656 782/908
Withdrawable: H = 461 mm - D = 396.5 mm - W (3/4 poles) [mm] 324/414 324/414 432/558 432/558 594/684 594/684 810/936
Weights
Fixed 3/4 poles [kg] 50/61 50/61 66/80 66/80 97/117 97/117 140/160
Withdrawable 3/4 poles (including fixed part) [kg] 50/61 50/61 66/80 66/80 147/165 147/165 210/240
(1) Without intentional delays.
ABB SACE
SACE Emax Switch-disconnectors for
applications up to 1000V DC
ABB SACE has developed the SACE Emax/E MS range of switch-disconnectors for applications in
direct current up to 1000V in compliance with the international IEC 60947-3 Standard. These no-
automatic circuit-breakers are specially suitable for use as bus ties or main isolators in direct current
systems, such as in applications involving electric traction.
The range covers all installation needs up to 1000V DC /6300A.
They are available in fixed and withdrawable, three-pole and four-pole versions.
By connecting three breaking poles in series, it is possible to achieve a rated voltage of 750V DC,
while with four poles in series the limit rises to 1000V DC.
The switch-disconnectors of the SACE Emax/E MS range maintain the overall dimensions and fixing
points of the standard range circuit-breakers. They can be fitted with the various terminal kits and all
the accessories common to the SACE Emax range. They cannot, of course, be associated with the
electronic trip units, CSs and accessories for determining currents and for AC applications.
The withdrawable circuit-breakers should be used together with the special version fixed parts for
applications at 750/1000V DC.
E1B/E MS E2N/E MS E3H/E MS E4H/E MS* E6H/E MS*
[A] 1250 1600 1600 4000 6300
[A] 2000 2000
[A] 2500
[A] 3200
Poles 3 4 3 4 3 4 3 4 3 4
Rated service voltage Ue [V] 750 750 750 750 750 750 750 750 750 750
Rated insulation voltage Ui [V] 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
Rated impulse withstand voltage Uimp [kV] 12 12 12 12 12 12 12 12 12 12
Rated short-time withstand current Icw (1s) [kA] 20 20* 25 25* 40 40* 65 65 65 65
Rated making capacity Icm
750 V DC [kA] 42 42 52.5 52.5 105 105 143 143 143 143
1000 V DC [kA] 42 52.5 105 143 143
Note: the breaking capacity Icu, by means of external protection relay, with 500 ms maximum timing, is equal to the value of Icw (1s).
* The performances at 750 V are:
for E1B/E MS Icw=25kA
for E2N/E MS Icw=40kA
for E3H/E MS Icw=50kA
ABB SACE
DC_interno.indd 3 16/03/2008 16.49.32

SACE Emax DC: Direct Current Applications
The main applications of direct current are:
1. Emergency supply or auxiliary services: the use of direct current is due to the need to employ a
back-up energy source which allows the supply of essential services such as protection services,
emergency lighting, alarm systems, hospital and industrial services, data-processing centres etc.,
using accumulator batteries
2. Electrical traction: the advantages offered by the use of dc motors in terms of regulation and of
single supply lines lead to the widespread use of direct current for railways, underground railways,
trams, lifts and public transport in general
3. Particular industrial installations: there are some electrolytic process plants and applications which
have a particular need for the use of electrical machinery
4. Navy, Alternative Energy Conversion, …
ABB SACE
DC_interno.indd 4 16/03/2008 16.49.32

Direct Current Network Typology
Here below the typical distribution systems used in direct current are described:
Both Polarities Insulated from Earth
1SDC200602F0001
– Fault a: the fault, without negligible impedance, between the two polarities sets up a short-circuit
current to which both polarities contribute to the full voltage, according to which the breaking
capacity of the breaker must be selected.
– Fault b, c: the fault between the polarity and earth has no consequences from installation func-
tioning point of view.
One polarity connected to earth

1SDC200603F0001
– Fault a: the fault between the two polarities sets up a short-circuit current to which both polari-
ties contribute to the full voltage U, according to which the breaking capacity of the breaker is
selected.
– Fault b: the fault on the polarity not connected to earth sets up a current which involves the
over-current protection according to the resistance of the ground.
– Fault c: the fault between the polarity connected to earth and earth has no consequences from
the point of view of the function of the installation.
All the poles of the breaker necessary for protection must be connected in series on the non-earthed
polarity.
ABB SACE
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Direct Current Network Typology
Median Point connected to Earth
1SDC200604F0001
– Fault a: the fault between the two polarities sets up a short-circuit current to which both polari-
ties contribute to the full voltage U, according to which the breaking capacity of the breaker is
selected.
– Fault b: the fault between the polarity and earth sets up a short-circuit current less than that of
a fault between the two polarities, as it is supplied by a voltage equal to 0.5 U.
– Fault c: the fault in this case is analogous to the previous case, but concerns the negative polarity.
The breaker must be inserted on both polarities.
ABB SACE
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Circuit Breaker Selection
To correctly select the devices for the protection of a direct current network the following factors
must be considered:
• The type of network - earthing connection
• Rated Current
• Voltage Current
• The prospective short-circuit current at the point of installation
Here below the rating plate of an Emax DC air circuit-breaker for direct current application:
INCOMING POWER FROM UPPER TERMINALS
1SDC200605F0001
INCOMING POWER FROM BOTTOM TERMINALS
1SDC200606F0001
ABB SACE
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Protection trip units and trip curves
PR122/DC
Characteristics
The PR122/DC is the new electronic protection trip unit for the SACE Emax DC series suitable for
direct current installation wherein the basic protections are enough.
The PR122/DC offers the following protection functions:

• Overload (L);
• Selective short-circuit (S);
• Thermal memory for S and L (cable protection);
• Instantaneous short-circuit (I);
• Overtemperature protection (OT);
• Zone selectivity for S;
• Load Control (K).
1SDC200607F0001
ABB SACE
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Protection functions and setting values - PR122/DC
Overload I1= 0.4….1 x In 0.01 x In With current I = 3 x I1 3 s (1) – IEC60255-8 ■ –
protection t1= 3 s....102 s
Tolerance
(2)
Release between ± 10% If ≤ 6 x In
1.05 and 1.2 x I1 ± 20% If > 6 x In
Selective short- With current I > I2
circuit protection I2= 0.6….10 x In 0.1 x In t2= 0.05 s….0.35 s 0.01 s ■ t=k – ■
t2sel= 0.04 s…..0.2 s 0.01 s
Tolerance (2) ± 7% If ≤ 6 x In The better of the two figures:
± 10% If > 6 x In ± 10% or ± 40 ms
With current I = 10 x In
I2= 0.6….10 x In 0.1 x In t2= 0.05 s….0.35 s 0.01 s ■ t=k/I2 ■ –
Tolerance (2) ± 7% If ≤ 6 x In ± 15% If ≤ 6 x In
± 10% If > 6 x In ± 20% If > 6 x In
Instantaneous
short-circuit
overtemperature May not be set – Instantaneous – – temp=k – –
- fully powered release by voltage module and/or auxiliary power supply (without start-up)

S ± 10% ± 20%
I ± 15% ≤ 60ms
Others ± 20%
ABB SACE
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PR122/DC
Power Supply
The PR122/DC trip unit does not normally require an auxiliary power supply being self-supplied from
the measurement module PR120/V always supplied as standard in PR122/DC (only for power supply,
no voltage and power based protection/measurements available in PR122/DC).
On request it is possible to supply the PR122/DC with a special version of measurements module
suitable for very low DC rated voltage 24/48V DC, called PR120/LV, typically railway and mine in-
stallations.
An external auxiliary power supply is however required in case of the PR120/LV module is present.
Power supply from Minimum Voltage Threshold

Measurement Module Enabling Unit PR122/DC
PR120/V 70 V
When an auxiliary power supply is present, refer to the below table for the overall electronic power
consumption.
PR122/DC PR120/D-M PR120/K

Auxiliary power supply 24 V DC ± 20% from PR122/DC from PR122/DC
Maximum ripple 5%
Rated power @ 24V ~3 W +1 W +1 W
The Emax DC is supplied as standard for incoming power from the bottom terminals: PR120/V
- PR120/LV internal connection on bottom terminals – “U rear connection kit” mounted on upper
terminals.
Refer to Ordering Codes Section for incoming power from the upper terminals.
10 ABB SACE
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Functions L-S-I
t=k
1SDC200608F0001
Functions L-S-I
I2t = k
1SDC200609F0001
ABB SACE 11
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PR123/DC
Characteristics
The PR123/DC is the new electronic protection trip unit for the SACE Emax DC series; the complete
range of protection functions together with the wide combination of thresholds and trip times offered
make it suitable for protecting a wide range of direct current installation.
The PR123/DC offers the following protection functions:

• Overload (L);
• Selective short-circuit (S);
• Thermal memory for L and S (cable protection);
• Instantaneous short-circuit (I);
• Earth fault with adjustable delay (G);
• Poles unbalance (U);
• Overtemperature protection (OT);
• Load control (K);
• Undervoltage (UV);
• Overvoltage (OV);
• Reverse power (RP);
• Dual setting;
• Zone selectivity for S, G;
• Start-up thresholds for protection S and I.
1SDC200610F0001
12 ABB SACE
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Function Trip Threshold Trip Time Can be Relation Thermal Zone
threshold steps Time Step excluded t=f(I) memory selectivity
Overload With current I = 3xI1
protection I1= 0.4….1 x In 0.01 x In t1= 3 s....102 s 3 s (1) – IEC60255-8 ■ –
Tolerance (2) Release between ± 10% If ≤ 6 x In
1.05 and 1.2 x I1 ± 20% If > 6 x In
I1= 0.4….1 x In 0.01 x In With current I = 3xI1; t1= 3 s....144 s 3s – t=k(α)
Tolerance Release between ± 20% If > 5 x I1 α = 0.2-1-2
1.05 ... 1.2 x I1 ± 30% 2xI1≤ If ≤ 5 x I1
protection I2= 0.6….10 x In 0.1 x In t2= 0.05 s….0.35 s 0.01 s ■ t=k – ■
t2sel= 0.04 s…..0.2 s 0.01 s
± 10% If > 6 x In ± 10% or ± 40 ms
I2= 0.6….10 x In 0.1 x In With current I = 10xIn; t2= 0.05 s…0.35 s 0.01 s ■ t=k/I2 ■ –
Tolerance (2) ± 7% If ≤ 6 x In ± 15% If ≤ 6 x In
± 10% If > 6 x In ± 20% If > 6 x In
protection I2= 0.6….10 x In 0.1 x In t2= 0.05 s….0.35 s 0.01 s ■ t=k – ■
± 10% If > 6 x In ± 10% or ± 40 ms
Instantaneous
short-circuit
t4sel= 0.04 s…..0.2 s 0.01 s
Tolerance (2)
The better of the two figures:
± 7% ± 10% or ± 40 ms
I4= 0.2….1 x In 0.02 x In t4= 0.1 s…..1 s (with I=4xI4) 0.05 s ■ t=k/I2 – –
Tolerance (2) ± 7% ± 15%
U Phase unbalance I6= 5%….90% 5% t6= 0.5 s…..60 s 0.5 s ■ t=k – –
Tolerance (2) ± 10% ± 20% or ± 100 ms
Protection against
OT
overtemperature cannot be set – Instantaneous – – temp=k – –
Undervoltage I8= 0.5….0.95 x Un 0.01 x In With current U < U8; t8= 0.1 s….5 s 0.1 s ■ t=k – –
UV protection The better of the two figures:
Tolerance (2) ± 5% ± 20% or ± 40 ms
Overvoltage I9= 1.05….1.2 x Un 0.01 x In With current U > U9; t9= 0.1 s….5 s 0.1 s ■ t=k – –
OV protection The better of the two figures:
Tolerance (2)
± 5% ± 20% or ± 40 ms
RP Reverse With current P < P11
power P11= -0.3….-0.1 x Pn 0.02 Pn t11= 0.5 s…..25 s 0.1 s ■ t=k – –
Tolerance (2) ± 10% ± 10% or ± 100 ms
(2) These tolerances hold in the following conditions:
- fully powered release by voltage module and/or auxiliary power supply (without start-up)

S ± 10% ± 20%
I ± 15% ≤ 60ms
G ± 15% ± 20%
Others ± 20%
ABB SACE 13
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PR123/DC
Power Supply
The PR123/DC trip unit does not normally require an auxiliary power supply being self-supplied from
the measurement module PR120/V always supplied as standard in PR123/DC.
On request it is possible to supply the PR123/DC with a special version of measurements module
suitable for very low DC rated voltage 24/48V DC, called PR120/LV, typically railway and mine in-
stallations.
An external auxiliary power supply is however required in case of the PR120/LV module is present.
Power supply from Minimum Voltage Threshold

Measurement Module Enabling Unit PR123/DC
PR120/V 70 V
When an auxiliary power supply is present, refer to the below table for the overall electronic power
consumption.
PR123/DC PR120/D-M PR120/K

Auxiliary power supply 24 V DC ± 20% from PR122/DC from PR122/DC
Maximum ripple 5%
Rated power @ 24V ~3 W +1 W +1 W
The Emax DC is supplied as standard for incoming power from the bottom terminals: PR120/V
- PR120/LV internal connection on bottom terminals – “U rear connection kit” mounted on upper
terminals.
Refer to Ordering Codes Section for incoming power from the upper terminals.
14 ABB SACE
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Functions L-S-I
t=k
1SDC200608F0001
Functions L-S-I
I2t = k
1SDC200609F0001
ABB SACE 15
DC_interno.indd 15 16/03/2008 16.49.37

PR123/DC
Function G
k
t=
I2
t=k
1SDC200611F0001
Function U
1SDC200612F0001
16 ABB SACE
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Function RP
RP
1SDC200613F0001
Function UV
UV
1SDC200614F0001
ABB SACE 17
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PR123/DC
Function OV
OV
1SDC200615F0001
18 ABB SACE
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Override Protection
The automatic circuit-breakers of SACE Emax DC range are supplied of an internal back-up protection
called Override Protection made by the Module PR120/DC always supplied with the PR122/DC
and PR123/DC electronic trip units.
The Override Protection ensures the protection of the electrical plant against instantaneous short-
circuit in case of any loss of power supply of the protection unit PR122/DC and PR123/DC.
The Override protection threshold depends on the circuit breaker size; as standard neither connec-
tions nor settings are in user’ care.
1SDC200616F0001
ABB SACE 19
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PR123/DC
Optional Modules for Electronic Trip units

The electronic trip units PR122/DC and PR123/DC can be equipped with the same internal optional
modules already available on the electronic devices PR122/P and PR123/P for alternative current
application.
Code Internal Description PR123/DC

1SDA058255R1 PR120/K Internal signalling module ■
(4 output with independent terminals)
1SDA058256R1 PR120/K Internal signalling module ■
(4 output + 1 input with a common terminal)
1SDA058254R1 PR120/D-M Modbus RTU communication module ■
1SDA058252R1(1) PR120/LV Measurements module ■
1SDA065223R1(2) PR120/LV Measurements module - low voltage ■

(3)
PR120/DC Override protection module ■
(1) PR120/V Measurements Module always supplied with the trip units PR123/DC and PR122/DC
(2) Extracode to be specified with the circuit-breaker code to have the low voltage measuring module PR120/LV
(3) Not to be specified, always supplied with the electronic trip unit
Code External Description PR123/DC

1SDA058258R1 PR030/B Power supply unit ■
1SDA058259R1 BT030 External communication wireless unit ■
1SDA063143R1 HMI030 Interface from front of panel ■
1SDA048964R1 PR010/T External test unit ■
1SDA059146R1 PR021/K External signalling unit ■
1SDA052927R1 ATS010 Automatic transfer switch ■
1SDA060198R1 EP010 ABB Fieldbus plug ■
20 ABB SACE
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Measurements
PR122/DC
The following measurements are available
• Current;
• Instantaneous current value over a given time interval;
• Maintenance: number of operations, percentage of contact wears, opening data storage (latest
20 trips and 80 events);
• The protection records the historical data of the maximum current read.
PR123/DC
• Current;
• Maintenance: number of operations, percentage of contact wears, opening data storage (latest
20 trips and 80 events);
• Voltage;
• Instantaneous current/voltage value over a given time interval (data logger);
• Power;
• Energy;
• The protection records the historical data of the maximum current read, the maximum and minimum
voltage, the total maximum and mean value of power.
ABB SACE 21
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Measurements
Measurement Functions
The measurements available on electronic trip units PR122/DC and PR123/DC fitted by the Modbus
Communication module PR120/D-M and the protocol converter for Profibus and Devicenet FieldBus
EP010-FBP are listened on the following table.
PR122/DC PR123/DC PR122/DC-PR123/DC

+ PR120/D-M + PR120/D-M + PR120/D-M
and EP010
Communication functions
Protocol Modbus RTU Modbus RTU FBP
Physical layer RS-485 RS-485 Profibus-DP or
DeviceNet cable
Maximum baudrate 19200 bps 19200 bps 115 kbps
Measuring functions
Currents ■ ■ ■
Ground current ■ ■ ■
Voltage ■ on demand (1)
Power ■ on demand (1)
Energy ■ on demand (1)
Signalling from functions

LED: auxiliary power supply, warning, alarm ■ ■ ■
Temperature ■ ■ ■
Indication for L, S, I, G and other protection ■ ■ ■
Available data
Circuit-breaker status (open, closed) ■ ■ ■
Circuit-breaker position (racked-in, racked-out) ■ ■ ■
Mode (local, remote) ■ ■ ■
Protection parameters set ■ ■ ■
Load control parameters ■ ■ ■
Alarms
Protection L ■ ■ ■
Protection S ■ ■ ■
Protection I ■ ■ ■
Protection G ■ ■
Fault release mechanism failure ■ ■ ■
Undervoltage, overvoltage (timing and trip) protection ■ on demand (1)
Reverse power protection (timing and trip) ■ on demand (1)
Maintenance
Total number of operations ■ ■ ■
Total number of trips ■ ■ ■
Number of trip tests ■ ■ ■
Number of manual operations ■ ■ ■
Number of separate trips for each protection function ■ ■ ■
Contact wear (%) ■ ■ ■
Record data of last trip ■ ■ ■
Operating mechanisms
Circuit-breaker open/close ■ ■ ■
Reset alarms ■ ■ ■
Setting of curves and protection thresholds ■ ■ ■
Synchronize system time ■ ■ ■
Events
Status changes in circuit-breaker, protections and all alarms ■ ■ ■
(1) please ask ABB for further details
22 ABB SACE
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Accessories
Electrical and Mechanical Accessories
Accessories
The SACE Emax DC family can be fitted by the same electrical and mechanical accessories already
available on the standard alternative current family.
The ranges Automatic circuit-breakers Switch-disconnectors

Isolating Earthing Earthing
Circuit-breakers with Switch-disconnectors truck switch truck
full-size neutral for applications up to 1150V AC (CS) with (MT)
making
Circuit-breakers for Switch-disconnectors capacity
applications for applications up to 1000V DC (MPT)
up to 1150V AC
Circuit-breaker version Fixed Withdrawable Fixed Withdrawable Withdrawable Withdrawable Withdrawable
1a) Shunt opening/closing release (YO/YC)
and second opening release (YO2) ■ ■ ■ ■ ■ (YC)
1b) SOR test unit ■ ■ ■ ■
2a) Undervoltage release (YU) ■ ■ ■ ■
2b) Time-delay device for undervoltage release (D) ■ ■ ■ ■
3) Geared motor for the automatic charging
of the closing springs (M) ■ ■ ■ ■ ■
4a) Electrical signalling of electronic releases tripped ■ ■
4b) Electrical signalling of electronic releases tripped
with remote reset command ■ ■
5a) Electrical signalling of circuit-breaker open/closed (1) ■ ■ ■ ■ ■
5b) External supplementary electrical signalling
of circuit-breaker open/closed ■ ■ ■ ■ ■
5c) Electrical signalling of circuit-breaker racked-in/
test isolated/racked-out ■ ■ ■ ■ ■
5d) Contact signalling closing springs charged ■ ■ ■ ■ ■
5e) Contact signalling undervoltage release
de-energized (C. Aux YU) ■ ■ ■ ■
6a) Current transformer for neutral conductor
outside circuit-breaker ■ ■
6b) Homopolar toroid for the main power supply earthing
conductor (star center of the transformer) ■ ■
6c) Homopolar toroid for residual current protection ■ ■
7) Mechanical operation counter ■ ■ ■ ■ ■
8a) Lock in open position: key ■ ■ ■ ■ ■
8b) Lock in open position: padlocks ■ ■ ■ ■ ■
8c) Circuit-breaker lock in racked-in/racked-out/
test isolated position ■ ■ ■ ■ ■
8d) Accessories for lock in racked-out/test isolated position ■ ■ ■ ■ ■
8e) Accessory for shutter padlock device ■ ■ ■ ■ ■
8f) Mechanical lock for compartment door ■ ■ ■ ■ ■
9a) Protection for opening and closing pushbuttons ■ ■ ■ ■ ■
9b) IP54 door protection ■ ■ ■ ■ ■
10) Interlock between circuit-breakers (2) ■ ■ ■ ■
11) Automatic transfer switch - ATS010 (3) ■ ■ ■ ■
CAPTION
(1) For automatic circuit-breakers, four auxiliary contacts to electrically signal circuit-breaker
open/closed are included in the supply as standard.
■ Accessory on request for fixed circuit-breaker or moving part
(2) Incompatible with the E6/f versions with full-size neutral
■ Accessory on request for fixed part (3) Incompatible with the range of circuit-breakers for applications up to 1150V AC
■ Accessory on request for moving part
For Emax DC circuit-breakers accessories please refer to the same accessories codes of standard Emax AC circuit-breakers.
ABB SACE 23
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Overall dimensions
Basic version
with rear terminals INCOMING POWER FROM UPPER TERMINALS 6
4 POLES E2 - E4 E3 - E6
3 POLES
3 POLES
4 POLES
INCOMING POWER FROM BOTTOM TERMINALS 7
1SDC200617F0001
Caption

door
2 Segregation (when provided)
3 M10 mounting holes for
circuit-breakers (use M10 E2 III E2 IV
screws) View A View A
397
4 1xM12 screw (E1, E2, E3)
or 2xM12 screws (E4, E6) Iu=1250A 90 90 90 Iu=1250A
for earthing (included in Iu=1600A 145 100 Iu=1600A
the supply) 65
5 Insulating wall or
insulated metal wall
148
6 In case of incoming power 98 78
from UPPER terminals –
PR120/V internal connection
on upper terminals and 252
U rear connection kits on 242 177
bottom terminals M10

45
7 In case of incoming power 49
from BOTTOM terminals – Max. 40
PR120/V internal connection 330

on bottom terminals and U
rear connection kits on upper
terminals Iu=800A 100 145 Iu=800A
Iu=1000A 65
Iu=1000A
148
A B C D 98
78
E2 386 296 148 148 90 90 90
E3 530 404 202 202

1SDC200618F0001
E4 746 566 238 328
E6 1034 782 328 454
24 ABB SACE
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577
E4 III 180 180 325

View A
150 325 Iu=2500A 280
Iu=3200A
65 65
45
188
188
98 98
78 78
180 180
Iu=1600A
150 Iu=2000A
252
242 177
60
M10 10
45 10 10
49
50
Max. 40 98
78
510
757
E4 IV 180 180 180

Iu=2500A 325
View A Iu=3200A
280 325 280
65 65
45
188 188
98 98
78 78
180 180
Iu=1600A
252
242 177
150 Iu=2000A
60
M10 10
45 10 10
49
Max. 40 50
98
78
690
211
415
95
126 126
Iu=2000A
E3 III Iu=2500A 114
View A 96
168
148
98 78 98
78
126 126
177
Iu=800A
96
242 Iu=1000A
12
252 10
Iu=1250A
M10 10
12 12
Iu=1600A
1SDC200619F0001
49
50
Max. 40 98
78
348
ABB SACE 25
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Overall dimensions
Basic version
with rear terminals
541
Iu=2000A 126 126 126

E3 IV 126 126 126
Iu=2500A
View A 114 211
96 95
95
168 148
98 78 98 78
96
12
252
177 10 10 Iu=800A
242 Iu=1000A
M10 12 12 Iu=1250A
63
49
Iu=1600A
50
Max. 40 98
78
474
793
252 252
E6 III 410
View A
222 79,5 85
56
208
98 222
78 56 56
70
12
10 10
177 12 12
252
242
M10 50
98
78
49
Max. 40
63
726
1045
252 252 252

E6 IV
View A 182 410
56 85 85
208
222
98 56 70 56
78
12
10 10
177
12 12
252
242
M10 50
98
78
49
1SDC200620F0001
Max. 40
63
978
26 ABB SACE
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Compartment dimensions
A B
E2 400 490
E3 500 630
E4 700 880
E6 1000 1260
Depth
3 POLES
4 POLES
Through-holes for flexible cables for mechanical Drilling of compartment door

interlocks
N° 2 holes for IP54

protection cover
1SDC200621F0001
ABB SACE 27
DC_interno.indd 27 16/03/2008 16.49.54

Overall dimensions
Basic version with

rear terminals INCOMING POWER FROM UPPER TERMINALS 6
4 POLES
E2-E4 E3-E6
3 POLES
3 POLES
4 POLES
INCOMING POWER FROM BOTTOM TERMINALS 7
Caption
1SDC200622F0001
door
2 Segregation (when provided)
3 M10 mounting holes for E2 III E2 IV
circuit-breakers (use M10 View A View A
screws) 417
4 1xM12 screw (E1, E2, E3) 327 145
or 2xM12 screws (E4, E6) 100 100
for earthing (included in 90 90 90 90 90
the supply)
Iu=1250A 103
5 Insulating wall or 103
53 33 Iu=1600A 53 33
insulated metal wall
129 174
6 In case of incoming power
from UPPER terminals –
0
0
PR120/V internal connection 393,5 380

Ø1
Ø1
on upper terminals and 380

225 393,5 45 225
240
U rear connection kits on 240
bottom terminals
70 49
7 In case of incoming power 70 240
from BOTTOM terminals –
PR120/V internal connection 100 175 Iu=1250A
138 220 Iu=1600A
on bottom terminals and U
rear connection kits on upper 145 145
terminals Iu=800A 65 100
100
Iu=1000A
103 103
53 33 53 33
A B C D 65 90 90 90
90 90 Iu=800A
E2 414 324 162 162 Iu=1000A
E3 558 432 216 216 60 60
10 10
1SDC200623F0001
E4 774 594 252 342

10 10 10 10
E6 1062 810 342 468 53 33 50 53 33 50
28 ABB SACE
DC_interno.indd 28 16/03/2008 16.49.56

597
180 180
E4 III
325
View A 325
280
Iu=2500A 280
Iu=3200A
65 65
143 143
103
53 33 53 33
528 180 180

Ø10
33 10 10
40 45
393,5
7 10 10 10 10 Iu=1600A
380 84 400
530
53 50
Iu=2000A
33
122
120
E4 IV 777
View A 180 180 180
325 Iu=2500A 325

280
Iu=3200A
280
65 65
143 143
103
53 53 33
33
708
0 180 180 180
Ø1 45
33
10 10
393,5 40 700
7
10 10 10 10
Iu=1600A
380 580
84 Iu=2000A
53 33 50
122
120
435
126 126
211 211
E3 III 158 114
View A Iu=2000A
95 95
Iu=2500A
123 103
53 53
33 33
183
0
126 126
Ø1
33
393,5 40
7 240 12
380 225 10 10
84 183
12 12 Iu=800A
1SDC200624F0001
122 Iu=1000A
63 33 50
49 70 Iu=1250A
Iu=1600A
6 200
400
ABB SACE 29
DC_interno.indd 29 16/03/2008 16.49.59

Overall dimensions
Basic version with

rear terminals
561
E3IV 211
View A 95 Iu=2000A
158
Iu=2500A
211
95 114
123
53
33
103
126 126 126 63
246 33
10
Ø
126 126 126
33
393,5
380
40 7 225 Iu=800A
84 63 240 12 Iu=1000A
10 10 Iu=1250A
122 12 12
Iu=1600A
49 70
53 33 50
6 325
370
490
813
463
E6 III
410
View A
252 252 85
163
53 33
222
744 182
Ø10
33 12
393,5 40 10 10
380 7
84 12 12
750
53 50
33
122
63
620
1065
463
E6 IV
View A 410 410
252 252 252 85
163
53 222
33
182
12
10 10
33
393,5
40 12 12
380 7
84 53 50
33
122
1SDC200625F0001
63
866
30 ABB SACE
DC_interno.indd 30 16/03/2008 16.50.02

Compartment dimensions
A B
E2 400 490
E3 500 630
E4 700 880
E6 1000 1260
Depth
3 POLES
4 POLES
Through-holes for flexible cables for mechanical Drilling of compartment door

interlocks

protection cover
1SDC200626F0001
ABB SACE 31
DC_interno.indd 31 16/03/2008 16.50.02

Overall dimensions
Mechanical
compartment
door lock
Holes in compartment door Minimum distance between circuit-breakers and switchboard wall
1SDC200627F0001
A
3 POLES 4 POLES
E2 180 180
E3 234 234
E4 270 360
E6 360 486
32 ABB SACE
DC_interno.indd 32 16/03/2008 16.50.03

Circuit diagrams
Reading information
Warning
Before installing the circuit-breaker, carefully read note F on the circuit diagrams.

- releases not tripped
- motor operating mechanism with springs discharged.
Versions
Though the diagram shows a circuit-breaker in withdrawable version, it can be applied to a fixed version circuit-breaker
as well.
Fixed version
The control circuits are fitted between terminals XV (connector X is not supplied).
The control circuits are fitted between the poles of connector X (terminal box XV is not supplied).
Version with PR122/DC electronic trip unit
Version with PR123/DC electronic trip unit
Caption
* = See note indicated by letter
A1 = Circuit-breaker accessories
A3 = Accessories applied to the fixed part of the circuit-breaker (for withdrawable version only)
A4 = Example switchgear and connections for control and signalling, outside the circuit-breaker
D = Electronic time-delay device of the undervoltage release, outside the circuit-breaker
K51 = PR122/DC, PR123/DC electronic trip unit with the following protection functions:
- L overload protection with inverse long time-delay trip - setting I1
- S short-circuit protection with inverse or definite short time-delay trip - setting I2
- I short-circuit protection with instantaneous time-delay trip - setting I3
- G earth fault protection with inverse short time-delay trip - setting I4
K51/1...8 = Contacts of the PR021/K signalling unit
K51/GZin = Zone selectivity: input for protection G (only with Uaux. and PR123/DC trip unit)
K51/GZout = Zone selectivity: output for protection G (only with Uaux. and PR123/DC trip unit)
K51/IN1 = Digital programmable input (available only with Uaux and PR122/DC or PR123/DC trip unit with indicator
module PR120/K)
K51/P1...P4 = Programmable electrical signalling (available only with Uaux and PR122/DC or PR123/DC trip unit with
indicator module PR120/K)
K51/SZin = Zone selectivity: input for protection S (only with Uaux. And PR123/DC trip unit)
K51/SZout = Zone selectivity: output for protection S (only with Uaux. And PR123/DC trip unit)
K51/YC = Closing control from PR122/DC or PR123/DC electronic trip unit with communication module PR120/D-M
K51/YO = Opening control from PR122/DC or PR123/DC electronic trip unit with communication module PR120/D-M
Q = Circuit-breaker
Q/1...27 = Circuit-breaker auxiliary contacts
S51 = Contact for electrical signalling of circuit-breaker open due to tripping of the overcurrent release. The
circuit-breaker may be closed only after pressing the reset pushbutton, or after energizing the coil for
electrical reset (if available).
S75E/1...4 = Contacts for electrical signalling of circuit-breaker in racked-out position (only with withdrawable circuit-
breakers)
S75I/1...5 = Contacts for electrical signalling of circuit-breaker in racked-in position (only with withdrawable circuit-
breakers)
S75T/1..4 = Contacts for electrical signalling of circuit-breaker in test isolated position (only with withdrawable circuit-
breakers)
SC = Pushbutton or contact for closing the circuit-breaker
SO = Pushbutton or contact for opening the circuit-breaker
SO1 = Pushbutton or contact for opening the circuit-breaker with delayed trip
SO2 = Pushbutton or contact for opening the circuit-breaker with instantaneous trip
SR = Pushbutton or contact for electrical circuit-breaker reset
ABB SACE 33
DC_interno.indd 33 16/03/2008 16.50.03

Circuit diagrams
Reading information
W2 = Serial interface with the accessories of PR122/DC and PR123/DC trip units (internal bus)
X1...X7 = Connectors for the accessories of the circuit-breaker
XF = Delivery terminal box for the position contacts of the withdrawable circuit-breaker (located on the fixed
part of the circuit-breaker)
XK1 = Connector for power circuits of PR122/DC and PR123/DC trip units
XK2 - XK3 = Connectors for auxiliary circuits of PR122/DC and PR123/DC trip units
XK4 = Connector signalling open/closet contact
XK5 = Connector for PR120/V module
YO1 = Overcurrent shunt opening release
YR = Coil to electrically reset the circuit-breaker
Fig. 11 = Contact for electrical signalling of springs charged.
Fig. 12 = Contact for electrical signalling of undervoltage release energized (see notes B and S).
Fig. 13 = Contact for electrical signalling of circuit-breaker open due to tripping of the overcurrent release. The
circuit-breaker may be closed only after pressing the reset pushbutton.
Fig. 14 = Contact for electrical signalling of circuit-breaker open due to tripping of the overcurrent release and elec-
trical reset coil. The circuit-breaker may be closed only after pressing the reset pushbutton or energizing
the coil.
Fig. 21 = First set of circuit-breaker auxiliary contacts.
Fig. 22 = Second set of circuit-breaker auxiliary contacts (see note V).
Fig. 23 = Third set of supplementary auxiliary contacts outside the circuit-breaker.
Fig. 31 = First set of contacts for electrical signalling of circuit-breaker in racked-in, test isolated, racked-out position.
Fig. 32 = Second set of contacts for electrical signalling of circuit-breaker in racked-in, test isolated, racked-out
position.
Fig. 42 = Auxiliary circuits of PR122/DC and PR123/DC trip units (see notes F, M and V).
Fig. 45 = Circuits of the communication module PR120/D-M of the PR122/DC and PR123/DC trip units (optional,
see note E).
Fig. 46 = Circuits of the indicator module PR120/K of the PR122/DC and PR123/DC trip units - connection 1
(optional; see note V).
Fig. 47 = Circuits of the indicator module PR120/K of the PR122/DC and PR123/DC trip units - connection 2
(optional; see note V).
Fig. 62 = Circuits of the PR021/K signalling module (outside the circuit-breaker)
Incompatibilities
The circuits indicated in the following figures cannot be supplied simultaneously on the same circuit-breaker:
6-7-8
13 - 14
22 - 46 - 47
34 ABB SACE
DC_interno.indd 34 16/03/2008 16.50.03

Notes
A) The circuit-breaker is only fitted with the accessories specified in the ABB SACE order acknowledgement. Consult
this catalogue for information on how to make out an order.
B) The undervoltage release is supplied for operation using a power supply branched on the supply side of the circuit-
breaker or from an independent source. The circuit-breaker can only close when the release is energized (there is
a mechanical lock on closing).
If the same power supply is used for the closing and undervoltage releases and the circuit-breaker is required to
close automatically when the auxiliary power supply comes back on, a 30 ms delay must be introduced between
the undervoltage release accept signal and the energizing of the closing release. This may be achieved using an
external circuit comprising a permanent make contact, the contact shown in fig. 12 and a time-delay relay.
E) MODBUS map is available in the RE1134001 document
F) The auxiliary voltage Uaux allows actuation of all operations of the PR122/DC and PR123/DC trip units. Having
requested a Uaux insulated from earth, one must use “galvanically separated converters” in compliance with IEC
60950 (UL 1950) or equivalent standards that ensure a common mode current or leakage current (see IEC 478/1,
CEI 22/3) not greater than 3.5 mA, IEC 60364-41 and CEI 64-8.
N) With PR122/DC and PR123/DC trip units, the connections to the zone selectivity inputs and outputs must be made
with a two-pole shielded and stranded cable (see user manual), no more than 300 m long. The shield must be
earthed on the selectivity input side.
P) With PR122/DC and PR123/DC trip units with communication module PR120/D-M, the power supply for coils YO
and YC must not be taken from the main power supply. The coils can be controlled directly from contacts K51/YO
and K51/ YC with maximum voltages of 110-120 V DC and 240-250 V AC.
V) If fig. 22 is present (second set of auxiliary contacts) simultaneously as PR122/DC or PR123/DC release, the con-
tacts for the zone selectivity in fig. 42 (K51/Zin, K51/Zout, K51/Gzin and K51/Gzout) are not wired. In addition, the
indicator module PR120/K in figures 46 and 47 cannot be supplied.
ABB SACE 35
DC_interno.indd 35 16/03/2008 16.50.03

Circuit diagrams
Circuit diagram symbols (IEC 60617 and CEI 3-14 ... 3-26
Standards)

Delay Plug and socket Circuit-breaker-disconnector

(male and female) with automatic release
Mechanical connection Motor Switch-disconnector

(link) (general symbol) (on-load isolating switch)


relay

star characteritic
Equipotentiality Make contact Overcurrent relay with inverse

short time-lag characteritic
Converter with galvanic Break contact Overcurrent relay

separator with inverse long time-lag
characteritic

Twisted conductors (i.e., 3 Position switch (limit switch), Fuse

conductors shown) make contact (general symbol)
1SDC200628F0001
Connection of conductors Position switch (limit switch), Current sensing

break contact element
36 ABB SACE
DC_interno.indd 36 16/03/2008 16.50.04

Circuit diagrams
Circuit-breakers
Operating status
A1 C1 B1 A1 C1 D1 B1
K51 K51
Q Q
>
XK10 XK10
A1I 1 A1I 1
>> >>
2 2
A1E XO A1E XO
>> 1 >> 1
>>
> >>>
1
1
Y01 Y01
XO XO
2
2
>> 2 >> 2
PR122/DC PR122/DC
XK11 XK11
B1I 1 B1I 2
2 1
B1E B1E
PR123/DC PR123/DC
1SDC200629F0001
1SDC200630F0001
a1 c1 b1 a1 c1 d1 b1
Three-pole circuit-breaker with PR122/DC or PR123/DC electronic trip Four-pole circuit-breaker with PR122/DC or PR123/DC electronic trip
units units
A1 A2 C1 C2 D1 D2 B1 B2
K51
Q
>
>>
XK10 XO
A1I 1 >> 1
2 >>>
A1E
1
Y01
XO
2
>> 2
XK10
A2I 3
4
A2E
PR122/DC PR122/DC
XK11
B1I 1
B1E 2
XK11
B2I 3
4
B2E
1SDC200631F0001
1SDC200632F0001
PR123/DC
PR123/DC
a1 a2 c1 c2 d1 d2 b1 b2
Three-pole circuit-breaker with PR122/DC or PR123/DC electronic Four-pole circuit-breaker with PR122/DC or PR123/DC electronic trip
trip units units
ABB SACE 37
DC_interno.indd 37 16/03/2008 16.50.05

Circuit diagrams
Circuit-breakers
Motor operating mechanism, opening, closing and undervoltage

trip units
1SDC200633F0001
Signalling contacts
1SDC200634F0001
38 ABB SACE
DC_interno.indd 38 16/03/2008 16.50.05

Signalling contacts
1SDC200635F0001
1SDC200636F0001
ABB SACE 39
DC_interno.indd 39 16/03/2008 16.50.06

Circuit diagrams
Circuit-breakers
Auxiliary circuits of the PR122/DC and PR123/DC trip units
CAPTION: see note F.
PR122/DC
PR123/DC
1SDC200637F0001
Communication module PR120/D-M
PR122/DC
PR123/DC
1SDC200638F0001
40 ABB SACE
Signalling module PR120/K
(+)
(+)
(+)
PR122/DC PR122/DC
PR123/DC PR123/DC
(-)
(-)
(-)
1SDC200639F0001
PR122/DC
PR123/DC
1SDC200640F0001
ABB SACE 41
Ordering codes
SACE Emax DC automatic circuit-breakers for application
up to 1000 V DC
PR122/DC PR123/DC
1SDA......R1 1SDA......R1

E2 08 Iu (40 °C) = 800 A
VR = Vertical rear terminals
Fixed (F)
B 064580 064585 064668 064673

E2 10 Iu (40 °C) = 1000 A
Fixed (F)
B 064581 064586 064669 064674

E2 12 Iu (40 °C) = 1250 A
Fixed (F) B 064582 064587 064670 064675

E2 16 Iu (40 °C) = 1600 A
Fixed (F) B 064583 064588 064671 064676
N 064584 064589 064672 064677

E3 08 Iu (40 °C) = 800 A
Fixed (F)
N 064600 064609 064688 064697

E3 10 Iu (40 °C) = 1000 A
Fixed (F)
N 064601 064610 064689 064698

E3 12 Iu (40 °C) = 1250 A
Fixed (F)
N 064602 064611 064690 064699

E3 16 Iu (40 °C) = 1600 A
Fixed (F)
N 064603 064612 064691 064700
H 064606 064615 064694 064703

E3 20 Iu (40 °C) = 2000 A
Fixed (F)
N 064604 064613 064692 064701
H 064607 064616 064695 064704

E3 25 Iu (40 °C) = 2500 A
Fixed (F)
N 064605 064614 064693 064702
H 064608 064617 064696 064705
42 ABB SACE
DC_interno.indd 42 16/03/2008 16.50.07

PR122/DC PR123/DC
1SDA......R1 1SDA......R1

E4 16 Iu (40 °C) = 1600 A
Fixed (F)
S 064636 064641 064724 064729

E4 20 Iu (40 °C) = 2000 A
Fixed (F)
S 064637 064642 064725 064730

E4 25 Iu (40 °C) = 2500 A
Fixed (F) S 064638 064643 064726 064731

E4 32 Iu (40 °C) = 3200 A
Fixed (F) S 064639 064644 064727 064732
H 064640 064645 064728 064733

E6 32 Iu (40 °C) = 3200 A
Fixed (F)
H 064656 064659 064744 064747

E6 40 Iu (40 °C) = 4000 A
Fixed (F)
H 064657 064660 064745 064748

E6 50 Iu (40 °C) = 5000 A
Fixed (F)
H 064658 064661 064746 064749

1SDA......R1
Extracode
PR120/LV Low Voltage measuring module 24-48 V DC 065223*
PR120/V - PR120/LV Internal connection on upper terminals 058251**
* extracode to be specified with the circuit breaker code to have the low voltage measuring module PR120/LV
** The Emax DC is supplied ad standard for incoming power from the bottom terminals (PR120/V internal connection on bottom terminals – “U rear
connection kit” mounted on upper terminals).
In case of incoming power from the upper terminals an extracode must be specified: 1SDA058251R1 (PR120/V internal connection on upper
terminals – “U rear connection kit” mounted on bottom terminals).
ABB SACE 43
DC_interno.indd 43 16/03/2008 16.50.08

Ordering codes
SACE Emax DC automatic circuit-breakers for application
up to 1000 V DC
PR122/DC PR123/DC
1SDA......R1 1SDA......R1

E2 08 Iu (40 °C) = 800 A
Withdrawable (W) - MP
B 064590 064595 064678 064683

E2 10 Iu (40 °C) = 1000 A
B 064591 064596 064679 064684

E2 12 Iu (40 °C) = 1250 A
Withdrawable (W) - MP B 064592 064597 064680 064685

E2 16 Iu (40 °C) = 1600 A
Withdrawable (W) - MP B 064593 064598 064681 064686
N 064594 064599 064682 064687

E3 08 Iu (40 °C) = 800 A
N 064618 064627 064706 064715

E3 10 Iu (40 °C) = 1000 A
N 064619 064628 064707 064716

E3 12 Iu (40 °C) = 1250 A
N 064620 064629 064708 064717

E3 16 Iu (40 °C) = 1600 A
N 064621 064630 064709 064718
H 064624 064633 064712 064721

E3 20 Iu (40 °C) = 2000 A
N 064622 064631 064710 064719
H 064625 064634 064713 064722

E3 25 Iu (40 °C) = 2500 A
N 064623 064632 064711 064720
H 064626 064635 064714 064723
44 ABB SACE
DC_interno.indd 44 16/03/2008 16.50.09

PR122/DC PR123/DC
1SDA......R1 1SDA......R1

E4 16 Iu (40 °C) = 1600 A
S 064646 064651 064734 064739

E4 20 Iu (40 °C) = 2000 A
S 064647 064652 064735 064740

E4 25 Iu (40 °C) = 2500 A
Withdrawable (W) - MP S 064648 064653 064736 064741

E4 32 Iu (40 °C) = 3200 A
Withdrawable (W) - MP S 064649 064654 064737 064742
H 064650 064655 064738 064743

E6 32 Iu (40 °C) = 3200 A
H 064662 064665 064750 064753

E6 40 Iu (40 °C) = 4000 A
H 064663 064666 064751 064754

E6 50 Iu (40 °C) = 5000 A
H 064664 064667 064752 064755

1SDA......R1
Extracode
PR120/LV Low Voltage measuring module 24-48 V DC 065223*
PR120/V - PR120/LV Internal connection on upper terminals 058251**
* extracode to be specified with the circuit breaker code to have the low voltage measuring module PR120/LV
** The Emax DC withdrawable mobile part is supplied ad standard for incoming power from the bottom terminals (PR120/V internal connection on
bottom terminals).
In case of incoming power from the upper terminals an extracode must be specified: 1SDA058251R1 (PR120/V internal connection on upper
terminals).
ABB SACE 45
DC_interno.indd 45 16/03/2008 16.50.10

Ordering codes
750 V DC 1000 V DC
1SDA......R1
3 Poles 4 Poles
E2 FP = Fixed part
VR 059895 059906
Withdrawable (W) - FP
E3 FP = Fixed part
VR 059896 059907
E4 FP = Fixed part
VR 059897 059137
E6 FP = Fixed part
VR 059140 059143
1SDA......R1
Extracode*
U rear Connection kit FP E2-E6 DC on upper terminals 065169**
U rear Connection kit FP E2-E6 DC on bottom terminals 065619***
* extracode to be specified with the fixed part whenever used with Emax DC to include the mandatory U rear connection kits
** extracode to be specified for incoming power from the bottom terminals
*** extracode to be specified for incoming power from the upper terminals
46 ABB SACE
DC_interno.indd 46 16/03/2008 16.50.11

1SDC200012D0201 - 03/2008
Printed in Italy
6.000 - CAL
Due to possible developments of standards as well as of materials,

the characteristics and dimensions specified in the present
catalogue may only be considered binding after confirmation
by ABB SACE.
ABB SACE
A division of ABB S.p.A.
L.V. Breakers
Via Baioni, 35
24123 Bergamo - Italy
Tel.: +39 035.395.111 - Telefax: +39 035.395.306-433
http://www.abb.com
NOV PART NO.:
1SDC210004B0202
New Tmax T4-T5.
T Generation.
Preliminary - 1SDC210004B0202
BE FREE UP TO 630 A.
T ry to think of an installation which needs 630 A.
Have you done that?
Now think of sizing it, selecting the apparatus, the accessories and of installing it.
Right?
Now imagine being free to choose and free to work with much less, yes really much
less difficulty.
Are you there?
If you’ve managed to imagine this, you’re ready to enter a new generation.

You’re about to enter Tmax - the T Generation.
A NEW FREEDOM UP TO 630 A.
The new ABB SACE moulded-case circuit-breakers are called Tmax T4 and T5 and provide the performances
you’ve always wanted. High breaking capacity, Ics at 100% of Icu, high limitation of specific let-through energy -
performances which you were unable to find until today in circuit-breakers of these dimensions.
Designed up from the beginning to work together, they also offer you a complete series of thermomagnetic,
magnetic only and electronic protection releases, which are all interchangeable, as well as a new range of
accessories, among which are brand new residual current releases up to 630 A and the just as new stored
energy motor operator.
The new Tmax T4 and T5 are moulded-case circuit-breakers with the best performance/dimension ratios to be
found on the market, so can you imagine how much more space there is for cabling and how easily you can carry it
out, and, still further, the reduction in the switchgear dimension. But you’ll also find true allies for your job in the
terminals and accessories, with new, complete and standardised ranges.
Today with Tmax you’re even more free to choose: T1, T2, T3 up to 250A, and T4 and T5 up to 630 A.
Being free has never been so easy.
BE FREE TO RIDE THE MOST ADVANCED
T he Tmax circuit-breakers have been designed profiting by the experience which, for dozens of years,
has made ABB SACE recognised worldwide as a leader in constructing low voltage circuit-breakers.
It wasn’t easy to find the solutions which make it possible for the new Tmax T4 and T5 to achieve such high
performances in such limited dimensions. A high breaking capacity - Ics at 100% of Icu, and high limitation of
specific let-through energy, express the high technological level reached by these two new pieces of apparatus.
Thanks to latest generation electronics, T4 and T5 are born fitted with brand new electronic protection releases
with more functions, an integrated dialogue unit, a dedicated residual current release now up to 630 A and, for the
first time, the exclusive B type residual current release, sensitive to residual continuous and up 1000 Hz fault
currents.
Today more than yesterday, each installation, no matter what its type, has all the protection it needs.
Being free means this as well.

TMAX. BE FREE.
TECHNOLOGY.
BE FREE TO CHOOSE OPTIMAL SIZING.
M ore performance in less space. More applications, up to 630 A, with just two sizes. Easier selection of
the apparatus and the accessories. Optimal sizing of the installation and better protection of cables, busbar ducts
and supports. Less space needed in the metal structures. Less oversizing, i.e. lower costs. Less time for coordination
of installations. Fewer warehouse complications.
All the solutions needed can be selected with Tmax T4 and T5, even that of feeling more free to choose.
TMAX. BE FREE.
BE FREE TO DRIBBLE ROUND ALL INSTALLATI
H aving apparatus available with smaller dimensions than all the others on the market, undoubtedly
offers great advantages. More space for cabling operations, simpler installation, more compact and standardised
switchgear compartments. Surely it isn’t necessary to explain how much time you will save?
The new Tmax T4 and T5 then continue down the road taken by the first three sizes of the family - T1, T2 and
T3: they, too, offer a complete range of terminals for all installation requirements, and unified and standardised
accessories.
Can you imagine circuit-breakers with reduced dimensions with ample and optimised terminal slots?
Can you imagine the freedom of selecting the protection releases even with work under way?
Have you any idea of the reduction in stock provided by having standardised accessories?
Being free also means having much more time for yourself.
TMAX. BE FREE.
ON DIFFICULTIES.
THE HIGHEST BREAKING CAPACITIES.
○
○
The new Tmax T4 and T5 can be used in any application, even
○
○
the more unusual ones, thanks to their really exceptional
○
○
performances. Icu up to 200 kA at 415V, Ics = 100% of Icu, high
○
○
breaking capacities at 690V (80 kA), too, for the standard range,
○
○
as well as high Icu values for the range at 1000 V in direct current
○
and in alternating current, make T4 and T5 the ideal circuit-
○
○
breakers for all requirements.
○
○
○
○
JUST TWO SIZES UP TO 630 A.
○
ABB SACE introduces two sizes: Tmax T4 up to 320 A and Tmax
○
○
T5 up to 630 A. All of these have really high rated current/volu-
○
○
me ratios and are made of top quality materials using innovative
○
○
construction techniques which guarantee the same performances
○
○
for all their versions: fixed, plug-in and withdrawable.
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○
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○
○
○
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TMAX T4 AND T5.

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○
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ONLY THE MOST ADVANCED TECHNOLOGY

CAN ACHIEVE SUCH HIGH PERFORMANCE.
LATEST GENERATION ELECTRONICS. RESIDUAL CURRENT PROTECTION NOW REACHES 630 A.
○
○
The technology is of the latest generation: the electronic PR221DS The new Tmax T4 and T5 residual current release offers a com-
○
○
and PR222DS/P protection releases for distribution and the plete protection solution for both installations and people for all
○
○
PR222MP motor protection release are brand new. The dialogue types of installation and is very simple to use and install. In fact,
○
○
unit incorporated in the PR222DS/PD release is also absolutely residual current releases up to 630 A are available for all the fixed
○
new, and the dialogue function is added to its high protection

○
and plug-in versions. Moreover, only ABB makes the RC 223

○
performances. Furthermore, the basic versions of the releases have

○
(type B) residual current release, sensitive to residual continuous

○
been enriched with more functions. And then what about the and up to 1000 Hz fault currents, available for the market:
○
○
accessories for the electronic a most important innovation,

○
○
releases? The front display for and further witness to the

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○
showing current is one of the high quality and technological

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innovations along with auxiliary standard achieved by ABB

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contacts in electronic version, SACE circuit-breakers.

○
which communicate directly

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○
with the electronic release.

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HIGH LIMITATION MOTOR PROTECTION, FREEDOM OF
○
○
With the new Tmax T4 and T5, high limitation of both the specific CHOICE.
○
○
let-through energy and the short-circuit peak current is obtained, With Tmax T4 and T5, the best solution
○
for motor protection up to 250 kW at 400
○
thereby truly making it possible to size the installation in the best
○
V AC can be selected. Alongside the
○
possible way and obtain better cable, busbar duct and relative
○
support protection, as well as that of all the coordinated apparatus traditional solution, which uses a circuit-
○
○
on the load side. High values are also obtained for back-up, breaker with magnetic only release,
○
○
particularly useful contactor and external thermal relay, you
○
○
for sizing the can now find an integrated solution, with
○
○
final parts of the the circuit-breaker fitted with the new
○
PR222MP protection release and a
○
installation.
○
contactor. The PR222MP release is fitted
○
○
with all the protection functions, among
○
○
which are protection U against phase
○
○
unbalance and protection R against rotor
○
○
block.
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Freedom of choice is not only provided by
the protection release. Freedom of choice
○
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is also yours thanks to the high limitation

○
○
of Tmax T4 and T5, which allows optimal

○
sizing of the coordinated apparatus on the load side (contactor

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○
and thermal relay – when present) as well as the power supply

○
○
TMAX T4 AND T5. cables.

○
○
○
ABSOLUTE VERSATILITY FOR

OPTIMAL SIZING.
SELECTIVITY. ALL THE PROTECTION RELEASES.
○
○
For circuit-breakers with rated currents up to 630 A it is important Tmax T4 and T5 have a wide range of both thermomagnetic and
○
○
to reach high selectivity values and Tmax T4 and T5 guarantee electronic protection releases for all applications, even the most
○
○
these high performances. unusual ones. Along with the traditional thermomagnetic releases,
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Being free to count on high selectivity values simplifies selection there are also generator protection releases and magnetic only
○
○
of the circuit-breaker during the design of the installation, and ones recommended for motor protection.
○
The new generation of electronic releases has many new functions

○
facilitates optimal sizing of all the apparatus.

○
even in the basic version. Setting the neutral protection to 50%

○
○
or 100%, an LED for signalling pre-alarm and alarm for the

○
○
protection against overload, are just

○
some of the innovation within the new

protection releases. The wide and fine
setting range of the protection thresholds
○
are, furthermore, a guarantee

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of great flexibility of use and

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optimal protection in any

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installation.
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INCREASINGLY COMPACT DIMENSIONS. INTERCHANGEABLE
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○
The new Tmax T4 and T5 have the same height and depth, which PROTECTION RELEASES.
○
AT ALL TIMES.
○
facilitates positioning them in switchgear compartments and
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Thanks to ABB SACE’s design and
○
makes it possible to build increasingly compact and standardised
○
construction capacity, on the new
○
units.
○
Tmax T4 and T5, the protection
○
And that’s not all: the limited dimensions allow greater access to
○
releases of any type - magnetic
the terminals, and make all the connection and cabling operations
○
○
only, thermomagnetic or electronic
more convenient.
○
- can be replaced in complete
○
Available in all versions - fixed, plug-in and withdrawable - and
○
safety. The advantages?
○
provided with a conversion kit from fixed to plug-in/
○
Interchangeability of the releases
○
withdrawable, T4 and T5 are suited to constructing any
○
which therefore means terrific
○
installation solution. Selection flexibility is guaranteed.
○
versatility.
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UNIFIED ACCESSORIES.
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As with Tmax T1, T2, and T3, the new Tmax T4 and T5 have
a complete, standardised and unified range of electrical
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and mechanical
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accessories, which
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makes selection
○
○
easier, provides
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flexibility of use
○
○
and reduces stock.

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With Tmax you can

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select accessories
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with your eyes

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○
shut.
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TMAX T4 AND T5.

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ALL THE BENEFITS OF FLEXIBILITY AND

SIMPLE INSTALLATION.
CONVENIENTLY ACCESSIBLE CONNECTION
TERMINALS.
The terminal slots of the T4 and T5 circuit-breakers
are ample and optimised for all types of connection:
cables, busbars and cable lugs. A complete range of
connection terminals makes it possible to select those
most suited to the installation to be built. Standard
front (F), front extended (EF), front extended spread
(ES); front for copper cables (FC Cu), for
copper-aluminium cables (FC CuAl) and
multi-cable (MC) terminals, as well as rear
terminals (R), make all configurations possible.
With T4 and T5 you can build the exact
switchgear you had in mind.
T1, T2, T3, T4 AND T5. THE TMAX PROJECT. INDUSTRIALIT. BORN TO INTEGRATE.
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○
That’s right: with the arrival of Tmax T4 and T5, designing and IndustrialIT is the solution developed by ABB to integrate the
○
○
building an installation up to 630 A has never been so simple. company activities at all levels, collecting together automation
○
○
All the Tmax apparatus starts out life distinguished by very high and control systems, installation running and production
○
○
construction quality, recognised over the years for all ABB SACE processes, design, marketing and sales, as well as the financial
○
○
products. The whole Tmax project, from T1 to T5, has basic and administrative activities, under a single management system
○
characteristics common to all the apparatus, such as double (AIP: Aspect Integrator Platform).
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insulation, the possibility of use in heavy-duty environments, and The products and technologies are certified according to the
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a complete set of international certifications. IndustrialIT standard and grouped into about thirty functional
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There are two depths up to 630 A: 70 mm for T1, T2 and T3, categories.
○
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103.5 mm for T4 and T5. Quality means this as well. As well as interaction between certified products, each certified
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○
product ensures easy traceability of all the information useful for
○
○
its operation - technical characteristics, instructions for
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installation, use and maintenance, environmental certificates and
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○
declarations, updated to the latest version … a great advantage
○
The Tmax T4 and T5 circuit-
○
breakers have obtained the
for the user.
○
prestigious “INTEL Design 2003 The whole range of Tmax moulded-case circuit-breakers, together
○
– Augusto Morello award” in the

○
Product Technologies and with Isomax and the Emax air circuit-breakers, is IndustrialIT
○
○
Production processes section.

enabled and is part of the suite of ProtectIT products – apparatus
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○
for protection of installations and people. Morover, T4 and T5

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will feature e-plug communication interface which will allow

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○
integration to IndustrialIT systems.

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○
TMAX MOULDED-CASE CIRCUIT-BREAKERS.

AN INCREASINGLY WIDE CHOICE.
Today you have a family of circuit-breakers available for various Tmax, Isomax and Emax operate in an integrated way with the
○
○
different fields of application. A power distribution range for the ABB products which can be configured in a system: this intention
○
○
protection of installations in direct and alternating current, has always been behind ABB SACE’s design process. Mass
○
○
transformer and capacitor protection and a generator protection customisation, i.e. producing customised products in series
○
○
range; a motor protection range for protecting asynchronous according to the requirements of each customer, is already possible,
○
as the IndustrialIT certification demonstrates.

○
motors up to 250 kW by means of circuit-breakers with currents

○
up to 400 A. And then, a range of circuit-breakers for protecting Once again, ABB SACE is to the fore in offering you better service!
○
○
installations up to 1000V in direct and alternating current for

○
○
applications such as road or railways tunnels, traction or mines.

○
○
And finally, the switch-disconnectors derived from the

○
○
corresponding circuit-breakers.
○
○
That’s really great freedom of choice, isn’t it?

○
Overview of the Tmax family
T1 1p T1 T2 T3 T4 T5
Circuit-breakers for distribution AC-DC
Iu [A] 160 160 160 250 250/320 400/630
In [A] 16…160 16…160 1.6…160 63…250 20…320 320…630
Poles [Nr] 1 3/4 3/4 3/4 3/4 3/4
Ue [V] (AC) 50 - 60 Hz 240 690 690 690 690 690
[V] (DC) 125 500 500 500 750 750
Icu (380-415 V AC) [kA] B 25* (220/230 V AC) 16
[kA] C 25
[kA] N 36 36 36 36 36
[kA] S 50 50 50 50
[kA] H 70 70 70
[kA] L 85 120 120
[kA] V 200 200
Circuit-breakers for motor protection T2 T3 T4 T5

Iu [A] 160 250 250 400
Poles [Nr] 3 3 3 3
Ue [V] (AC) 50 - 60 Hz 690 690 690 690
Magnetic only release, IEC 60947-2 ■ ■ ■
PR221DS-I electronic release, IEC 60947-2 ■ ■ ■
PR222MP electronic release ■ ■
Circuit-breakers for applications up to 1000 V T4 T5

Iu [A] 250 400/630
Poles [Nr] 3/4 3/4
Icu max [kA] 1000 V AC 20 20
[kA] 1000 V DC 4 poles in series 40 40
Switch-disconnectors T1D T3D T4D T5D

Ith [A] 160 250 320 400/630
Ie [A] 125 200 320 400/630
Poles [Nr] 3/4 3/4 3/4 3/4
Ue [V] (AC) 50 - 60 Hz 690 690 690 690
(DC) 500 500 750 750
Icm [kA] 2.8 5.3 5.3 11
Icw [kA] 2 3.6 3.6 6
* For In 16 A and In 20 A: Icu @ 220/230 V AC = 16 kA
Note: ABB SACE’s moulded-case circuit-breakers are also available in versions according to UL Standards (see
catalogue “ABB SACE molded case circuit breakers - UL 489 and CSA C22.2 Standard”).
Accessories
T1 T2 T3 T4 T5
Rated service current 160 A 160 A 250 A 250-320 A 400-630A
Rated voltage Ue (AC) 50-60 Hz [V] 690 690 690 690 690
Service releases
Shunt opening release - SOR
Undervoltage release - UVR
Delayed undervoltage release - UVD
Electrical signals
Contacts:
1 on changeover open/closed + 1 on changeover
for signalling release trip - AUX
3 on changeover open/closed + 1 on changeover
for signalling release trip - AUX
2 on changeover open/closed - AUX
1 signalling electronic release trip
(with PR222DS/PD) - AUX-SA
1 signalling state of the motor operator - AUX-MO
2 early auxiliary contacts for
undervoltage release - AUE
3 auxiliary position contacts for signalling
circuit-breaker racked-in/out - AUP
Electrical operators
Solenoid operator with front assembly - MOS
Solenoid operator with side-by-side assembly - MOS
Stored energy operating mechanism - MOE
Stored energy operating mechanism
for PR222DS/PD release - MOE-E
ATS010
Operating mechanisms and locks

Direct rotary handle operating mechanism - RHD
Transmitted rotary handle operating mechanism - RHE
Lever lock with padlocks - PLL
Key lock on the circuit-breaker - KLC
Key lock for rotary handle and front operating mechanism -
RHL/KL D/KL S
Key lock for stored energy operating mechanism - MOL
Front for locks - FLD
Key locks for fixed part of withdrawable KL D FP/KL S FP
Padlock for fixed part of withdrawable - PLL FP
Thermomagnetic release anti-tampering lock
Compartment door lock
Front interlock - MIF
Rear interlock - MIR
Electronic residual current releases

Dedicated:
RC221
RC222 "L" shape
RC222 underneath
For switchgear compartment: RCQ
Overcurrent releases
Thermomagnetic TMD and TMA
Thermomagnetic release for generator protection
Magnetic only MA and MF
Electronic PR221DS
Electronic PR222DS/P - PR222DS/PD - PR222MP
Interchangeability of protection releases
Connection terminals
FC Cu - EF F - FC Cu F - FC Cu
Terminals for fixed or plug-in version FC Cu Al 95 mm2 FC Cu Al FC Cu Al
HR EF - ES - R EF - ES - R
FC Cu Al 185 mm2
Terminals for fixed version F - EF - ES F - EF - ES
FC Cu - FC CuAI FC Cu
MC - R FC CuAI - R
Terminals for plug-in / withdrawable version EF - ES - FC Cu EF - ES - FC Cu
FC CuAl - HR - VR FC CuAl - HR - VR
High and low terminal covers
Circuit-breakers for power distribution
Electrical characteristics
Tmax T1 1P Tmax T1
Rated uninterrupted current, Iu [A] [A] 160 160
No. Poles [No.] 1 3/4
Rated service voltage, Ue (AC) 50-60 Hz [V] 240 690
(DC) [V] 125 500
Rated impulse withstand voltage, Uimp [kV] 8 8
Rated insulation voltage, Ui [V] 500 800
Test voltage at industrial frequency for 1 min. [V] 3000 3000
Rated ultimate short-circuit breaking capacity, Icu B B C N
(AC) 50-60 Hz 220/230 V [kA] 25(*) 25 40 50
(AC) 50-60 Hz 380/415 V [kA] – 16 25 36
(AC) 50-60 Hz 440 V [kA] – 10 15 22
(AC) 50-60 Hz 500 V [kA] – 8 10 15
(AC) 50-60 Hz 690 V [kA] – 3 4 6
(DC) 250 V - 2 poles in series [kA] 25 (at 125 V) 16 25 36
(DC) 250 V - 3 poles in series [kA] – 20 30 40
(DC) 500 V - 2 poles in series [kA] – – – –
(DC) 500 V - 3 poles in series [kA] – 16 25 36
(DC) 750 V - 3 poles in series [kA] – – – –
Rated service short-circuit breaking capacity, Ics
(AC) 50-60 Hz 220/230 V [%Icu] 75% 100% 75% 75%
(AC) 50-60 Hz 380/415 V [%Icu] – 100% 100% 50% (25 kA)
(AC) 50-60 Hz 440 V [%Icu] – 100% 75% 50%
(AC) 50-60 Hz 500 V [%Icu] – 100% 75% 50%
(AC) 50-60 Hz 690 V [%Icu] – 100% 75% 50%
Rated short-circuit making capacity, Icm
(AC) 50-60 Hz 220/230 V [kA] 52.5 52.5 84 105
(AC) 50-60 Hz 380/415 V [kA] – 32 52.5 75.6
(AC) 50-60 Hz 440 V [kA] – 17 30 46.2
(AC) 50-60 Hz 500 V [kA] – 13.6 17 30
(AC) 50-60 Hz 690 V [kA] – 4.3 5.9 9.2
Opening time (415 V) [ms] 7 7 6 5
Category of utilisation (EN 60947-2) A A
Isolation behaviour ■ ■
Reference standard IEC 60947-2 IEC 60947-2
Releases: thermomagnetic
T fixed, M fixed TMF ■ –
T adjustable, M fixed TMD – ■
T adjustable, M adjustable (5…10 x In) TMA – –
T adjustable, M fixed (3 x In) TMG – –
T adjustable, M adjustable (2.5…5 x In) TMG – –
magnetic only MA – –
electronic PR221DS-LS/I – –
PR221DS-I – –
PR222DS/P-LSI – –
PR222DS/P-LSIG – –
PR222DS/PD-LSI – –
PR222DS/PD-LSIG – –
PR222MP – –
Interchangeability – –
Versions F F
Terminals fixed FC Cu FC Cu-EF-FC CuAl -HR
plug-in – –
withdrawable – –
Fixing on DIN rail – DIN EN 50022
Mechanical life [No. operations] 25000 25000
[No. hourly operations] 240 240
Electrical life @ 415 V AC [No. operations] 8000 8000
[No. hourly operations] 120 120
Basic dimensions - fixed version L [mm] 25.4 (1 pole) 76
4 poles L [mm] – 102
P [mm] 70 70
H [mm] 130 130
Weight fixed 3/4 poles [kg] 0.4 (1 pole) 0.9/1.2
plug-in 3/4 poles [kg] – –
withdrawable 3/4 poles [kg] – –
TERMINAL CAPTION EF = Front extended FC Cu = Front for copper cables R = Rear orientated VR = Rear in vertical flat bar
F = Front ES = Front extended spread FC CuAl = Front for CuAl cables HR = Rear in horizontal flat bar MC = Multicable
Tmax T2 Tmax T3 Tmax T4 Tmax T5
160 250 250/320 400/630
3/4 3/4 3/4 3/4
690 690 690 690
500 500 750 750
8 8 8 8
800 800 1000 1000
3000 3000 3500 3500
N S H L N S N S H L V N S H L V
65 85 100 120 50 85 70 85 100 200 300 70 85 100 200 300
36 50 70 85 36 50 36 50 70 120 200 36 50 70 120 200
30 45 55 75 25 40 30 40 65 100 180 30 40 65 100 180
25 30 36 50 20 30 25 30 50 85 150 25 30 50 85 150
6 7 8 10 5 8 20 25 40 70 80 20 25 40 70 80
36 50 70 85 36 50 36 50 70 100 150 36 50 70 100 150
40 55 85 100 40 55 – – – – – – – – – –
– – – – – – 25 36 50 70 100 25 36 50 70 100
36 50 70 85 36 50 – – – – – – – – – –
– – – – – – 16 25 36 50 70 16 25 36 50 70
100% 100% 100% 100% 75% 50% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
100% 100% 100% 75% (70 kA) 75% 50% (27 kA) 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
100% 100% 100% 75% 75% 50% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
100% 100% 100% 75% 75% 50% 100% 100% 100% 100% 100% 100% 100% 100% 100%(1) 100%(2)
100% 100% 100% 75% 75% 50% 100% 100% 100% 100% 100% 100% 100% 100%(1) 100%(2) 100%(2)
143 187 220 264 105 187 154 187 220 440 660 154 187 220 440 660
75.6 105 154 187 75.6 105 75.6 105 154 264 440 75.6 105 154 264 440
63 94.5 121 165 52.5 84 63 84 143 220 396 63 84 143 220 396
52.5 63 75.6 105 40 63 52.5 63 105 187 330 52.5 63 105 187 330
9.2 11.9 13.6 17 7.7 13.6 40 52.5 84 154 176 40 52.5 84 154 176
3 3 3 3 7 6 5 5 5 5 5 6 6 6 6 6
A A A B (400 A)(3) - A (630 A)
■ ■ ■ ■
IEC 60947-2 IEC 60947-2 IEC 60947-2 IEC 60947-2
– – – –
■ ■ ■ (up to 50 A) –
– – ■ ■
– ■ – –
– – – ■
■ (MF up to In 12.5 A) ■ ■ –
■ – ■ ■
■ – ■ ■
– – ■ ■
– – ■ ■
– – ■ ■
– – ■ ■
– – ■ ■
– – ■ ■
F-P F-P F-P-W F-P-W
F-FC Cu-FC CuAl-EF-ES-R F-FC Cu-FC Cu Al-EF-ES-R F-FC Cu-FC CuAl-EF-ES-R-MC F-FC Cu-FC CuAl-EF-ES-R
F-FC Cu-FC CuAl-EF-ES-R F-FC Cu-FC Cu Al-EF-ES-R EF-ES-HR-VR-FC Cu-FC CuAl EF-ES-HR-VR-FC Cu-FC CuAl
– – EF-ES-HR-VR-FC Cu-FC CuAl EF-ES-HR-VR-FC Cu-FC CuAl
DIN EN 50022 DIN EN 50022 – –
25000 25000 20000 20000
240 240 240 120
8000 8000 8000 (250 A) - 6000 (320 A) 7000 (400 A) - 5000 (630 A)
120 120 120 60
90 105 105 140
120 140 140 184
70 70 103.5 103.5
130 150 205 205
1.1/1.5 2.1/3 2.35/3.05 3.25/4.15
1.5/1.9 2.7/3.7 3.6/4.65 5.15/6.65
– – 3.85/4.9 5.4/6.9
(1)
F = Fixed circuit-breakers W = Withdrawable circuit-breakers (*) The breaking capacity for settings 75% for T5 630
(2)
P = Plug-in circuit-breakers In=16 A and In= 20 A is 16 kA 50% for T5 630
(3)
Icw = 5 kA
1SDC210004B0202 - 11/2003
Printed in Italy
Tipografia
Due to possible developments of standards as well as

of materials, the characteristics and dimensions
specified in the present catalogue may only be
considered binding after confirmation by ABB SACE.
NOV PART NO.:
1SDH000436R0.001-L0501
Tmax T4
DOC. N.° 1SDH000436R0.001- L0501
1 1,5÷ 10 mm2
200
50
A
Tm
a
25 25
In x T4
=25 7-2
Ue 0 A H 2 94
50 IEC
60
Icu (V)
Ics (kA) Ue ly
23 V Ita
205
(% 0 =6 8k in CE
Ca
t. A Icu) 100 40 90V p= 0 de SA
0 /4 Uim 7 5 MaABB
Ma 10
0 15 36 by
70 V 0
de 00 10 ries
by in 10 44 Ui= 10 500 se
AB Italy 0 0 Ui= 50 in
BS 50 1000 3P
AC AC 65 0 V 69
0
10
0
C E V
50 100 90
SO E S
50 69 IEC =6 500 40
SO -60 0
Ue 0 2P
R 10 6 50 10
RIE
Hz 0 40 U 09 4 0
UV
50 imp 7-2 44 0
AU
R S 10
0 0 =8 0A
25 /415 65 10
S Nr. 50 kV
In= 400
0
10 Hz
MO (SY - 10 70 -60
S + 0 50
1Q 0 75 0 23 10
0
25
0 0
+ 100
4H
K5 2P 36
xT 10
1)
in se 10 a
rie 3 P 0
s Tm (V)
)
Ue (kA Icu
Icu =%
FC Ics . A
Cu W ir T
e ra CA
6-1 ng
e
85
mm
2 To
rqu
B
e
10
Nm
50
200
16÷ 185 mm2
Ue A B C
< 440 V 30 25 0
_> 440 V
60 45 0
< 500 V
_> 500 V 60 45 40
2 _
Ue >500V
3
CLACK
OFF ON TRIPPED
4 F-F
140
52,5 105 112,5
Y Y
35 35 35 35 35 103,5 Y
70
17,5 17,5 20 max 8 35
ø5 ø5 17,5
,5 ,5 ,5 - = = ,5 -
ø8 ø8 M5 M5
max 9,5
max 9,5
102,5
102.,5
105
84,75
88
148,2 113,2
88
59,5
2,7 5,5 2,7 5,5
105
205
176
X X
176
X X X X X
169,5
205
Y Y
Y max 25 _
<2
_>3 139
5 F- FC Cu
140 105 112,5

Y Y
Y 52,5 35 35 103,5 70
35 35 35 20 18x18 ø5 35 ø5
,5 - = = ,5 - 17,5
M5 M5
19
102,5
102,5
105
84,75
88
148,2
88
113,2
59,5
2,7 5,5 2,7 5,5
176
205
105
X X X X X X X X
176
205
169,5
Y _
<2 Y Y
_>3 139
6 30
45
165
45
Y
45
130
F - ES
50 50 112,5
Y 30 103,5
ø 10
,5 ø 10,5 26 6
Y
57,25
57,25
Y
ø5 70
,5 - 35 ø5
M5 ,5 - 17,5
= = M5
144,75
102,5
102,5
84,75
105 105
88
88
148,2
59,5
113,2
2,7 5,5 2,7 5,5
289,5
169,5
X X X X X X X
176
205
205
176
105
Y Y
200
200
Y _
<2
52,5
140 _>3 139
7 35
140
35
Y
FC CuAl
35 35
105
Y
35
28 24 24
112,5
103,5
F - FC CuAl/FC MC
28
Y Y
44,25
60
ø 18
60
ø5 ø5 70
21
,5 - 35 ,5 -
M5 M5 17,5
114,75
102,5
102,5
105 105
88
88
148,2 113,2
59,5
2,7 5,5 2,7 5,5
105
205
176
X X X X X X
176
X X X X
205
325
117,75
ø8
Y Y
39,25
15
60
60
18 41,5 19,5
Y 18 _
Y 52,5 FC MC 30 _>3 139
<2
8 105
139
F - EF
Y 112,5
35 35 35 35 35
103,5
100
17,5 17,5
100
Y 26 6
Y Y
ø10 ø10 70
39,2
39,2
ø5 35 ø5
.5 - .5 - 17,5
M5 = = M5
102,5
127,75
102,5
84,75
105
88
88
148,2 113,2
59,5
205
2,7 5,5 2,7 5,5

105
176
X
176
X X X X X X
169,5
205
255,5
Y
Y
60
60
Y 52,5 Y 103,5
140 _>3 _
<2
112,5
9 F - FC CuAl
140 105 Y Y
103,5
Y 52,5 35 35 70
35 35 35 Y 25,9 ø 18 ø5 35 ø5
,5 - = = ,5 - 17,5
M5 M5
20,8
102,5
102,5
84,75
88
105
88
59,5
148,2 113,2
2,7 5,5 2,7 5,5
176
205
105
X
176
X X X X X X
169,5
205
15,5
Y 26 ø 10 _
<2 Y Y
Y
_>3 139
10 ø 5,5 - M5
Y
ø 5,5 - M5 Y F-R
Y Y
18,8 18,8
84,75
70 35
84,75
ø 8,25 ø 8,25
88
88
17,5
X 35 35 35 35 35
105
X
176
X X
169,5
169,5
105
176
92,5
92,5
25
25
42,5
55
42,5
55
35 35
35 35 35
Y ø 25 Y 112,5
ø 25
140 105 103,5
52,5 35 35
35 35 35 20
Y
104,5
104,5
105
84,75
148,2 113,2
59,5
2,7 5,5 2,7 5,5
169,5
105
X X X X X
209
209
4,5
Y 20
Y _
<2
>3
_ 139
11 140
105 162,5
P - EF
Y 52,5
35 35 35 35 35 153,5
17,5 Y 17,5 25 5
ø8 Y Y
31
31
ø8
96
61 ø 5, 30,5
5-M
5
104,5
104,5
125
105 105
59,5
148,2 113,2
65
2,7
65
5,5 2,7 5,5
X X X X X X X
130
209
130
209
105
250
ø5
,5
-M Y
Y 5
_
<2
Y Y
_>3 189
12 Fc Cu P - FC Cu/FC Cu Al
140
52,5 105 162,5
153,5
35 35 35 35 35 84
30 18x18
Y Y
20,8
48
61 96
Y
Y
104,5
104,5
125
105 105 30,5

59,5
148,2 113,2
5,5
65
2,7 2,7
65
5,5
X
105
X X X X X X X
209
250
130
130
209
ø5
ø5 ,5
Y ,5 Y -M
-M 5
5
20,8
48
48
Y Y 36 ø18 _
<2
Fc Cu Al _>3 189
13 P - VR
Y Y
27
35 35
27
35 35 35
4 4
30,5 61 11
11
96
72,25
62,75
62,75
72,25
47,25
47,25
Y
37,75
37,75
Y
142,5
130
X X X
142,5
132
130
48,5 97
ø5 ø5,
,5 - 5-M
27
27
M5 Y Y
5
Y 162,5
140
105 153,5
52,5
Y Y
104,5
104,5
105 105
84,75
148,2 113,2
59,5
2,7 5,5 2,7 5,5
209
105
X X X X X X
209
169,5
0
ø1
19
Y Y _
<2
_>3 189
14
Y Y
Y Y P - HR
27
27
35 35 35 35 35
19 19
30,5 61
10
10
96 ø
ø
72,25
62,75
72,25
62,75
142,5
47,25
47,25
X X
37,75
37,75
X
142,5
130
130
132
48,5 97
ø 5, ø5,
5-M 5-M
27
5
27
5
Y Y
Y Y 162,5
140
105 153,5
52,5
104,5
104,5
91,8
105 113,2
148,2
59,5
2,7 5,5 2,7 5,5

183,5
X X X
209
X X
105
209
Y Y _
<2
_>3 189
15 140 W - EF
10,5
105
10,5
5 25 _>3
Y Y 52,5
27,5
96
** ø 5,5 - M5
61 30,5
Y Y
125
140,5
140,5
250
89
125
166
89
59,5
2,7 2,7
105,5
X X X X X X X
130
12
130
ø 5,5
144,8
144,8
209
250
209
5
-M Y
,5
ø5
ø4
80°
ø8 ø8
_
<2 190,5 17,5 17,5
10,5
196 35 35 35 **
35 35
10,5
55,2 84 90,2 84
139,2 174,2
Y Y
16 Fc Cu
84
18x18 30 105
Y
140
Y 52,5 W - FC Cu/FC Cu Al
10,5
27,5
96
**
61 30,5
19
Y Y
ø 5,5 - M5
104,5
104,5
125
166
89
89
59,5
2,7 2,7
130
105,5
305
X X
12
X X X X X X
ø 5,5
250
144,8
144,8
305
130
209
- M5
209
ø 5,5
Y
20,8
80°
ø4
**
ø18 36 90,2 84
10,5
35 35
84 174,2
_
<2 190,5 _>3 55,2 84
139,2 Y
196
Fc Cu Al Y
17 W - HR
Y Y
35 35 ø1 35 35 35 Y
0 19 Y
19
27
27
ø1
0 62,75
61 30,5
62,75
37,75
37,75
96
142,5
142,5
130
X X X X
130
132
97 48,5
ø5 ø5
,5 -
27
27
M5 ,5
-M
105 140 5
Y Y Y Y
62,75 140
27,5 37,75 105 52,5
Y Y
80°
ø4
104,5
104,5
91,75
89
89
59,5
2,7 2,7
105,5
X X X X X
12
209
ø 5,5
209
144,8
183,5
144,8
4
166 47,25 55,2 84 90,2 84

_
<2 190,5 72,25 139,2 174,2
196 Y Y
18 W - VR
Y Y
35 35 35 35 35
27
27
11 11
61 30,5
Y
72,25
72,25
4 Y 96
47,25
47,25
X X X X
130
142,5
130
142,5
132
97
48,5
ø5
,5 ø
27
27
-M 5,
5 5
Y -M
105 140 Y 5
140
Y Y 105
27,5 52,5
Y
80°
ø4
104,5
ø 10
104,5
84,75
59,5
2,7 2,7
105,5
X X
12
X
209
X
169,5
ø 5,5
209
19
166 37,75 55,2 84 90,2 84

2 190,5 62,75 139,2 174,2
196
19 F- FC CuAl
16 Nm 16 Nm
F - EF
F- ES
10 Nm 9 Nm 31 Nm
2 Nm
F-FC Cu F - FC CuAl 18 Nm 18 Nm 18 Nm
F-F F - FC CuAl
18 Nm
F - FC MC
F-R
18 Nm 6 Nm
18 Nm
7 Nm
9 Nm 5,6 Nm
18 Nm P/W-FC CuAl
P/W- EF 7 Nm
10 Nm
18 Nm 9 Nm 31 Nm P/W - HR
18 Nm
18 Nm 4,5 Nm
P/W - ES P/W -VR
P/W - FC Cu 4,5 Nm
20 165 116
27 14
61,25
Y Y
75,75
96
65
72
116,5
138
X X X X
190,5
13,5
18
Y
Y R= 200min
117
B
= =
Y Y
76
X X X X
138
Y
Y
A A B C D
RIMOVIBILE
PLUG-IN
FISSO
FIXED
WITH FLANGE 107 157 115 115 64,5

CON MOSTRINA A
WITHOUT FLANGE 107 157 107 107 60,5
SENZA MOSTRINA
21 I3 TMD
TMA
In M IN (Inx5) M ED (Inx7,5) M AX (Inx10)
Tmax T4H 250
320 1600 2.400 3200

In=250A Ue=690V Ui=1000V Uimp=8kV IEC 60947-2
Ue (V) 230 400/415 440 500 690 500 750
Icu (kA) 100 70 65 50 40 50 36
Ics=% Icu 100 100 100 100 100 100 100 Made in Italy Tm
MA
CAT. A 50-60Hz 2P 3P in series by ABB SACE ax
250 T4H
In= 2
250 1250 1.875 2500

47-
Ue A 25 609
Icu (V)
0 IEC
Ics (kA) Ue=
230 Italy
(% 690 8kV in E
Cat Icu 100 p= de SAC
.A ) 400 V Uim 750 MaABB
100 /41 36
Ma 5 by
de 70 0V 100 ies
by in 100 440 Ui= 100 500 ser
ABB Ital Ui= in
SAC y 500 1000V 50
AC 65
690 100
3P
CE E
V
200 1000 1.500 2000

50- 100 50 690 690 40
SO SS 60H
IEC
Ue= 500 2P
R OR z
100 40 609 50 100
UV
R IES 100 500
Uim 47-
p= 2 A
440
100
AU
S Nr. 8kV 250 /415 65
50 100 z
MO (SY - 100
In= 400
70 60H
S +
0
1Q 750 230 50-
100
+ 25
K51 2P 36 H 100
) T4 100
in ser 100 ax
ies3 P Tm (V)
)
TM A 160 800 1.200 1600

Ue (kA Icu
Icu =%
FC Ics . A
Cu Wir
1
e ran CAT
6-1 ge
85
mm
2 Tor
que
10
Nm
125 625 938 1250

100 500 750 1000
80 400 600 800 CLACK
TM D 50 - - 500
32 - - 320
20 - - 320
I1
T4 MA I3
In MIN (0,63) MIN (0,7) MED (0,815) MED (0,85) MAX (1xIn)
In MIN (Inx6) MED (Inx10) MAX (Inx14)
320 - 224 - 272 320
200 1200 2.000 2800 250 - 175 - 213 250
160 960 1.600 2240 TMA 200 - 140 - 170 200
125 750 1.250 1750 160 - 112 - 136 160
100 600 1.000 1400 125 - 88 - 106 125
80 480 800 1120 100 - 70 - 85 100
80 50 - 65 - 80
52 312 520 728 2 TMD 50 32 - 41 - 50
25 150 250 350 32 20 - 26 - 32
10 60 100 140 20 13 - 16 - 20
22 PR221DS
Esempio:
In=100A
I2 =100 x (1,5+2)=350A
t2= 0,1 s @800 A (8In)
Example:
Tm
ax
250 T4H
In= 2
47-
Ue A 25 609
Icu (V)
0 IEC
Ics (kA) y
Tmax T4H 250

230 Ue Ital
(% =6 8kV in E
Ca
t. A Icu) 100 400 90V p=
Ma 100 /41
70
5
0V
Uim 750
36 by
de SAC
MaABB In=250A Ue=690V Ui=1000V Uimp=8kV IEC 60947-2
de 100 ies
by in 440 Ui= 100 500 ser
100
Ue (V)
1
ABB Ital
AC SACE
CE
y 65 500 1000V
V
Ui=
690
50
100
3P
in
230 400/415 440 500 690 500 750
50- 100 50 690 690 40
SO SS IEC 2P
UV
R
R
OR
IES
60H
z
100 40
100 500
609
Uim 47-
p= 2 A
Ue= 500
440
50
100
100 Icu (kA) 100 70 65 50 40 50 36
AU
Nr. 8kV 250 /415 65
I3=OFF
S
MO (SY
S +
-
50
100
In= 400
70
100 z
60H Ics=% Icu 100 100 100 100 100 100 100 Made in Italy
0
1Q 750 230 50-
100
25
+
H 100
CAT. A 50-60Hz 2P 3P in series by ABB SACE
t
K51 2P 36
) T4 100
in ser 100 ax
ies3 P Tm (V)
)
Ue (kA Icu
Icu =%
FC Ics . A
Cu Wir
e ran CAT
6-1 ge
85
mm
2 Tor
que
10
Nm
t1
CLACK S
t2
I1 I2
I
t
L
Esempio: t I1 I3
I
Example:
L Esempio: In=100 A
Example: I =100 x (1,5+2)=350A
In = 100 A 3
t1
I1 = 100 x (0,4+0,08+0,32)= 80A
t1= 12 s @480 A (6I1) I2=OFF
I Esempio:
2 Example:
I1 I3 Ne=ON ; 50%
I
23 Preset-
Trip
ready 4
RE PO+
AD
Y
LARI
TY -
SA
CE
3 TRIP
TES
TT1
1 T
TH
THE IS TE PR
BR ST C
EA
KE AUSE
ESE
R TR S
IP
T
TRIP TEST REA

DY
+
POL
SA
ARIT
Y
-
CE
TRIP TT1
TEST
THE
THIS
BREA
TEST
KER
CAU
TRIP
SES
PR
ESET
CLACK
2
ABB SACE S.p.a.

Via Baioni, 35
24123 Bergamo Italy
Tel. +39 035 395.111 - Telefax +39 035 395.306-433
http://www.abb.com
NOV PART NO.:
1SDH000460R0002-L2234
Technical Manual
ABB-EMAX - Low Voltage Air Circuit
Breaker - Installation, Service &
Maintenance Manual
ADDITIONAL CODE SDRL CODE TOTAL PGS This document contains proprietary and confidential information
161 which belongs to National-Oilwell Varco, L.P., its affiliates or National Oilwell Varco
subsidiaries (all collectively referred to hereinafter as "NOV"). It is Rig Solutions
REMARKS loaned for limited purposes only and remains the property of NOV.
Reproduction, in whole or in part or use of this design or distribution 11000 Corporate Centre Drive
MAIN TAG NUMBER DISCIPLINE of this information to others is not permitted without the express Suite 200
written consent of NOV. This document is to be returned to NOV Houston, Texas 77041 USA
upon request and in any event upon completion of the use for which
CLIENT PO NUMBER it was loaned. This document and the information contained and Phone + 281 854 0400
represented herein is the copyrighted property of NOV. Fax + 281 854 0607
© National Oilwell Varco
ISDH000460R0002-L2234 02
www.nov.com
Document number 1SDH000460R0002-L2234
Revision 02
Page 2
REVISION HISTORY
02 12.04.2010 Updated Address on Cover Sheet MSL BSD BSD

01 27.08.2008 For Information - - -
www.nov.com
Installation and service Installation, service and
instructions maintenance instructions
for low voltage air circuit-breakers
1SDH000460R0002 L2234 Emax

Dwg. Resp.Off. Title
Language
Installation, service and maintenance
App. Take-over Off. instructions for low voltage air
circuit-breakers
en
Model L2234 Apparatus Scale
Emax
Doc. N°
ABB SACE 1SDH000460R0002
Index 11.2.1 Abbreviations ......................................................... page 30
11.2.2 Notes ............................................................................. « 30
1. Description ..................................................... page 6
1.1 General characteristics ................................................. « 6 12. SACE PR121/P Release - Identification ............ « 31
1.2 External front view of the circuit-breaker ..................... « 6 12.1 Standard ....................................................................... « 31
1.3.1 Circuit-breaker rating plate .......................................... « 6 12.2 Specifications ................................................................ « 31
1.3.2 Disconnector rating plate ............................................. « 6 12.2.1 General .......................................................................... « 31
1.4 Moving part construction characteristics ..................... « 6 12.2.2 Electrical characteristics ............................................... « 31
1.5 Fixed part construction characteristics ........................ « 7 12.2.2.1 Self-supply .................................................................... « 31
12.2.2.2 Auxiliary power supply ................................................. « 31
2. Checking on receipt ............................................ « 7 12.2.3 Environmental characteristics ....................................... « 32
12.2.4 Communication bus ...................................................... « 32
3. Storage, lifting and weights ................................. « 7 12.2.5 Protection functions ...................................................... « 32
12.2.5.1 Calculating the RMS and peak .................................... « 32
4. Installation ............................................................ « 8 12.2.5.2 Watchdog ..................................................................... « 32
4.1 Installation room ............................................................ « 8 12.2.6 Description of the protection functions ........................ « 32
4.2 Installation of the fixed circuit-breaker .......................... « 8 12.2.6.1 Protection “L” ................................................................ « 32
4.3 Installation of the fixed part of the withdrawable 12.2.6.2 Protection “S” ............................................................... « 32
circuit-breaker ................................................................ « 8 12.2.6.3 Protection “I” ................................................................. « 33
4.3.1 Preparation of the fixed part .......................................... « 8 12.2.6.4 Protection “G” ............................................................... « 33
4.3.2 Installation of the fixed part ........................................... « 9 12.2.6.5 Protection against instantaneous short-circuits "Iinst" .. « 33
4.3.3 Installation of the fixed part on board a ship ................. « 9 12.2.7 Summary table of protections ...................................... « 33
4.4 Installation of the flange on the compartment door ...... « 10 12.2.8 Measurements ............................................................... « 33
12.2.9 Trip curves .................................................................... « 34
5. Electrical connections ......................................... « 10 12.2.9.1 Trip curves for functions L-I .......................................... « 34
5.1 Connections to the power circuit .................................. « 10 12.2.9.2 Trip curves for functions L-S(t=k/I2)-I ........................... « 34
5.1.1 Shapes of the terminals ................................................. « 10 12.2.9.3 Trip curves for functions L-S(t=k)-I .............................. « 35
5.1.2 Examples of positioning the connection busbars 12.2.9.4 Trip curves for function G ............................................. « 35
according to the types of terminal ............................... « 11 12.3 Other functions .............................................................. « 36
5.1.3 Assembly procedure for the connection busbars ....... « 12 12.3.1 Indication of the cause of the trip and trip test button . « 36
5.2 Earthing ......................................................................... « 12 12.4 Putting into service ........................................................ « 36
5.3 Wiring the circuit-breaker auxiliary circuits .................. « 12 12.4.1 Connections .................................................................. « 36
5.3.1 Interfacing elements for fixed circuit-breakers ............ « 12 12.4.2 CS and TC connection check ...................................... « 36
5.3.2 Withdrawable circuit-breaker ....................................... « 13 12.4.3 Current sensor connection for external neutral ............ « 36
5.4 Conversion of the auxiliary contacts or of the signalling 12.5 User interface ................................................................ « 36
contacts (disconnected - test isolated - connected) from
12.5.1 Trip Test ......................................................................... « 37
normally closed (opening) to normally open (closing)
or vice versa .................................................................. « 14 12.5.2 Initial settings ................................................................. « 37
12.5.3 Changing protection functions ..................................... « 37
6. Putting into service .............................................. « 15 12.5.3.1 Example of settings ....................................................... « 37
6.1 General procedures ...................................................... « 15 12.5.4 PR121/P default settings ............................................... « 38
12.6 Operating instructions / Operation in service .............. « 38
7. Instructions for use .............................................. « 16 12.6.1 Adjusting the neutral ..................................................... « 38
7.1 Operating and signalling parts ...................................... « 16 12.6.2 Table of neutral adjustments ........................................ « 38
7.2 Circuit-breaker closing and opening procedures ......... « 17 12.6.3 Replacing an electronic release ................................... « 38
7.3 Racking-in/out operation ............................................... « 18 12.7 Definition of the alarms and signals for the
PR121/P unit .................................................................. « 39
8. Maintenance ........................................................ « 19 12.7.1 Optical signals ............................................................... « 39
8.1 Warning ......................................................................... « 19 12.7.2 Troubleshooting ............................................................ « 39
8.2 Maintenance program ................................................... « 20 12.7.3 In the case of a fault ...................................................... « 40
8.3 Maintenance operations ................................................ « 20 12.8 Accessories ................................................................... « 40
8.3.1 Preliminary operations ................................................... « 20 12.8.1 ABB SACE PR010/T test and configuration unit .......... « 40
8.3.2 General inspection of the circuit-breaker ...................... « 21 12.8.2 BT030 communication unit ............................................ « 40
8.3.3 Checking contact wear .................................................. « 21 12.8.3 PR021/K and HMI030 units ........................................... « 40
8.3.4 Operating mechanism maintenance ............................. « 22 12.9.4 PR030/B power supply unit .......................................... « 40
9. Measures to be taken for any operating 13. SACE PR122/P Release - Identification ............ « 41
anomalies ............................................................. « 23 13.1 Standard ....................................................................... « 41
13.2 Specifications ................................................................ « 41
10. Accessories .......................................................... « 24 13.2.1 General .......................................................................... « 41
10.1 Electrical accessories .................................................... « 24 13.2.2 Electrical characteristics ............................................... « 42
10.2 Mechanical locks ........................................................... « 27 13.2.2.1 Self-supply .................................................................... « 42
10.3 Spare parts and retrofitting ............................................ « 28 13.2.2.2 Auxiliary power supply ................................................. « 42
13.2.2.3 Powered by PR120/V module ...................................... « 42
11. Protection releases - General notes .................... « 29 13.2.3 Environmental characteristics ....................................... « 42
11.1 Safety notes ................................................................... « 30 13.2.4 Description of inputs/outputs ........................................ « 42
11.1.1 Notes for dielectric stiffness tests .................................. « 30 13.2.4.1 Binary opto-insulated inputs ......................................... « 42
11.2 Abbreviations and notes ................................................ « 30 13.2.4.2 Binary opto-insulated outputs ....................................... « 42

Emax
Doc. No. Page No.
1SDH000460R0002 1/155
13.2.5 Communication bus ............................................ page 42 13.4.3.1 Modification of basic configuration .................... page 61
13.2.6 Protection functions ................................................... « 42 13.4.4 Default settings .......................................................... « 62
13.2.6.1 Calculating the RMS and peak ................................. « 43 13.5 Operating instructions / Operation in service .......... « 63
13.2.6.2 Mains frequency ....................................................... « 43 13.5.1 Menu .......................................................................... « 63
13.2.6.3 Harmonic distortion ................................................... « 43 13.5.2 Protections Menu ...................................................... « 64
13.2.6.4 Circuit-breaker state ................................................. « 43 13.5.2.1 Protections Menu table ............................................. « 64
13.2.7 Measurement functions ............................................. « 43 13.5.3 Measurements Menu ................................................. « 67
13.2.8 Watchdog .................................................................. « 43 13.5.3.1 Measurements Menu table ....................................... « 67
13.2.9 Description of the protection functions ..................... « 44 13.5.4 Settings Menu ........................................................... « 67
13.2.9.1 Protection “L” ............................................................ « 44 13.5.4.1 Settings Menu table .................................................. « 67
13.2.9.1.1 Thermal memory “L” ................................................. « 44 13.5.4.2 Neutral adjustments .................................................. « 68
13.2.9.2 Protection “S” ........................................................... « 44 13.5.4.2.1 Neutral adjustments table ......................................... « 68
13.2.9.2.1 Thermal memory "S" .................................................. « 44 13.5.4.3 Mains frequency settings .......................................... « 68
13.2.9.2.2 Start-up threshold "S" ................................................ « 44 13.5.4.4 Modules ..................................................................... « 68
13.2.9.2.3 Zone selectivity "S" .................................................... « 45 13.5.4.4.1 PR120/V MEASURING module ................................. « 68
13.2.9.3 Protection “I” ............................................................. « 45 13.5.4.4.2 PR120/D-M - COM module ....................................... « 69
13.2.9.3.1 Start-up threshold "I" ................................................. « 45 13.5.4.4.3 PR120/K - SIGNALLING module .............................. « 69
13.2.9.4 Protection “G” ........................................................... « 45 13.5.4.4.4 PR120/D - WL-COM module ..................................... « 69
13.2.9.4.1 Start-up threshold "G" ................................................ « 46 13.5.4.4.5 Settings for the Local Bus unit .................................. « 69
13.2.9.4.2 Zone selectivity "G" .................................................... « 46 13.5.5 Test Menu .................................................................. « 69
13.2.9.5 Protection against phase unbalance "U" .................. « 46 13.5.5.1 Test Menu table ......................................................... « 69
13.2.9.6 Protection against overtemperature inside 13.5.6 Information Menu ...................................................... « 70
the relay "OT" ............................................................. « 46 13.5.6.1 Information on the trip and opening data ................ « 70
13.2.9.7 Load control function ................................................. « 47 13.6 Definition of alarms and signals in the PR122/P unit « 70
13.2.9.8 Voltage protections "UV", "OV", "RV" ........................ « 47 13.6.1 Optical signals ........................................................... « 70
13.2.9.8.1 Protection "UV" .......................................................... « 47 13.6.2 Electrical signals ........................................................ « 70
13.2.9.8.2 Protection "OV" .......................................................... « 47 13.6.3 Table of error and warning messages ..................... « 71
13.2.9.8.3 Protection "RV" .......................................................... « 47 13.6.4 Error messages displayed in pop-up windows ....... « 72
13.2.9.9 Reverse active power protection "RP" ...................... « 47 13.7 Troubleshooting PR122/P unit .................................. « 73
13.2.9.10 Frequency protections "UF", "OF" ............................ « 47 13.7.1 In the case of a fault .................................................. « 73
13.2.9.11 Summary table of the protection function setting 13.8 Accessories ............................................................... « 74
for the PR122/P .......................................................... « 48 13.8.1 ABB SACE PR010/T test and configuration unit ...... « 74
13.2.9.11.1 Summary of the additional protection functions 13.8.2 ABB SACE PR030/B power supply unit ................... « 74
for the PR122/P with the optional PR120/V module .. « 49 13.8.3 BT030 wireless communication unit .......................... « 74
13.2.9.11.2 Table of measurements ............................................ « 49
13.2.10 Trip curves .................................................................. « 50 14. SACE PR123/P Release Identification ............. « 75
13.2.10.1 Trip curves for functions L-I ........................................ « 50 14.1 Standard .................................................................... « 75
13.2.10.2 Trip curves for functions L-S(t=k/I2)-I ......................... « 50 14.2 Specifications ............................................................ « 75
13.2.10.3 Trip curves for functions L-S(t=k)-I ............................ « 51 14.2.1 General ...................................................................... « 75
13.2.10.4 Trip curves for function L in accordance with 14.2.2 Electrical characteristics ............................................ « 76
IEC-60255-3 (type A) ................................................. « 51 14.2.2.1 Self-supply ................................................................. « 76
13.2.10.5 Trip curves for function L in accordance with 14.2.2.2 Auxiliary supply .......................................................... « 76
IEC-60255-3 (type B) ................................................. « 52 14.2.2.3 Powered by the PR120/V module ............................. « 76
13.2.10.6 Trip curves for function L in accordance with 14.2.3 Environmental characteristics ................................... « 76
IEC-60255-3 (type C) ................................................. « 52 14.2.4 Description of inputs/outputs .................................... « 76
13.2.10.7 Trip curves for function G ........................................... « 53 14.2.4.1 Binary opto-insulated inputs ...................................... « 76
13.2.10.8 Trip curves for function U ........................................... « 53 14.2.4.2 Binary opto-insulated outputs ................................... « 76
13.2.10.9 Trip curves for function UV ........................................ « 54 14.2.5 Communication bus .................................................. « 76
13.2.10.10 Trip curves for function OV ........................................ « 54 14.2.6 Protection functions ................................................... « 76
13.2.10.11 Trip curves for function RV ........................................ « 55 14.2.6.1 RMS and peak calculation ......................................... « 77
13.2.10.12 Trip curves for function RP ........................................ « 55 14.2.6.2 Mains frequency ........................................................ « 77
13.3 Putting into service .................................................... « 56 14.2.6.3 Harmonic distortion ................................................... « 77
13.3.1 Connections ............................................................... « 56 14.2.6.4 Circuit-breaker state .................................................. « 77
13.3.1.1 Current sensor connection for external neutral ........ « 56 14.2.7 Measurement functions ............................................. « 77
13.3.2 VT connections .......................................................... « 56 14.2.8 Watchdog .................................................................. « 77
13.3.3 CS and TC connection test ....................................... « 56 14.2.9 Description of the protection functions ..................... « 78
13.3.4 Test ............................................................................ « 56 14.2.9.1 Protection "L" ............................................................. « 78
13.3.5 Initial settings ............................................................. « 57 14.2.9.1.1 Thermal memory "L" .................................................. « 78
13.3.6 Password management ............................................ « 57 14.2.9.2 Protection "S" ............................................................. « 78
13.3.7 Changing the electronic release .............................. « 57 14.2.9.2.1 Thermal memory "S" .................................................. « 78
13.3.7.1 Installation .................................................................. « 57 14.2.9.2.2 Start-up threshold "S" ................................................ « 78
13.3.7.2 Uninstalling ................................................................ « 57 14.2.9.2.3 Zone selectivity "S" .................................................... « 79
13.4 User interface ............................................................ « 58 14.2.9.3 Double S .................................................................... « 79
13.4.1 Use of pushbuttons ................................................... « 58 14.2.9.4 Directional Protection "D" ........................................... « 79
13.4.2 Read and Edit modes ............................................... « 58 14.2.9.4.1 Start-up threshold "D" ................................................ « 80
13.4.3 Changing parameters ............................................... « 59 14.2.9.4.2 "D" (directional) zone selectivity ................................ « 80

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14.2.9.5 Protection "I" ....................................................... page 81 14.5.4.4.3 PR120/K module ................................................ page105
14.2.9.5.1 Start-up threshold "I" ................................................. « 81 14.5.4.4.4 PR120/D - WL-COM module ..................................... « 105
14.2.9.6 Protection "G" ............................................................ « 81 14.5.4.4.5 Settings for the Local Bus unit .................................. « 105
14.2.9.6.1 Start-up threshold "G" ................................................ « 82 14.5.5 Test Menu .................................................................. « 105
14.2.9.6.2 Zone selectivity "G" .................................................... « 82 14.5.5.1 Test Menu table ......................................................... « 106
14.2.9.7 Protection against phase unbalance "U" .................. « 82 14.5.6 Informations Menu ..................................................... « 106
14.2.9.8 Protection against overtemperature inside the 14.5.6.1 Information on the trip and openig data .................. « 106
relay "OT" ................................................................... « 82 14.6 Definitions of alarms and signals in the PR123/P unit« 107
14.2.9.9 Load control function ................................................. « 83 14.6.1 Optical signals ........................................................... « 107
14.2.9.10 Voltage protections "UV", "OV", "RV" .......................... « 83 14.6.2 Electrical signals ........................................................ « 107
14.2.9.10.1 Protection "UV" .......................................................... « 83 14.6.3 Table of error and warning messages ..................... « 107
14.2.9.10.2 Protection "OV" ......................................................... « 83 14.6.4 Error messages dispalyed in pop-up windows ....... « 108
14.2.9.10.3 Protection "RV" .......................................................... « 83 14.7 Troubleshooting PR123/P unit .................................. « 109
14.2.9.11 Protectiona against reverse active power "RP" ......... « 83 14.7.1 In the case of a fault .................................................. « 109
14.2.9.12 Frequency protections "UF", "OF" ............................. « 83 14.8 Accessories ............................................................... « 110
14.2.9.13 Double protections setting ........................................ « 83 14.8.1 ABB SACE PR010/T test and configuration unit ...... « 110
14.2.9.14 Summary table of the protection function settings 14.8.2 ABB SACE PR030/B power supply unit ................... « 110
for the PR123/P .......................................................... « 84 14.8.3 BT030 wireless communication unit .......................... « 110
14.2.9.15 Table of measurements .............................................. « 85
14.2.10 Trip curves ................................................................. « 86 15 Modules ............................................................ « 111
14.2.10.1 Trip curves for functions L-S(t=k/I2)-I ........................ « 86 15.1 PR120/V - MEASURING Module ............................... « 111
14.2.10.2 Trip curves for functions L-S(t=k)-I ........................... « 86 15.1.1 General characteristics .............................................. « 111
14.2.10.3 Trip curves for function G .......................................... « 87 15.1.2 Front view .................................................................. « 111
14.2.10.4 Trip curves for function L in accordance with 15.1.3 Releases complete with the module ......................... « 111
IEC 60255-3 (type A) ................................................ « 87 15.1.4 Powering the PR122/P and PR123/P units via the
14.2.10.5 Trip curves for function L in accordance with PR120/V module ........................................................ « 111
IEC 60255-3 (type B) ................................................. « 88 15.1.5 Operating instructions / Operation in service ............ « 112
14.2.10.6 Trip curves for function L in accordance with 15.1.5.1 Using the Measurement submenus with the PR120/V«112
IEC 60255-3 (type C) ................................................. « 88 15.1.5.2 Table of submenus for the PR120/V module ............ « 114
14.2.10.7 Trip curves for function D .......................................... « 89 15.1.5.3 Measurements Menu table ........................................ « 114
14.2.10.8 Trip curves for function U .......................................... « 89 15.1.5.4 Measurements Menu ................................................. « 115
14.2.10.9 Trip curves for function UV ........................................ « 90 15.1.5.4.1 Historicals .................................................................. « 115
14.2.10.10 Trip curves for function OV ........................................ « 90 15.1.5.4.2 Openings ................................................................... « 115
14.2.10.11 Trip curves for function RV ........................................ « 91 15.1.5.4.3 Events ........................................................................ « 115
14.2.10.12 Trip curves for function RP ........................................ « 91 15.1.5.4.4 Measurements ........................................................... « 115
14.3 Putting into service .................................................... « 92 15.1.5.4.5 Power factor ............................................................... « 115
14.3.1 Connections ............................................................... « 92 15.1.5.4.6 Energy ....................................................................... « 116
14.3.1.1 Current sensor connection for external neutral ........ « 92 15.1.5.4.7 Peack factor ............................................................... « 116
14.3.2 VT connections .......................................................... « 92 15.1.5.4.8 Mains frequency ........................................................ « 116
14.3.3 CS and TC connection test ....................................... « 92 15.1.5.4.9 Contact wear .............................................................. « 116
14.3.4 Test ............................................................................ « 92 15.1.5.4.10 Waveforms ................................................................ « 116
14.3.5 Initial settings ............................................................. « 93 15.1.6 Data Logger ............................................................... « 116
14.3.6 Password management ............................................ « 93 15.1.7 Electrical characteristics of the transformers ............ « 117
14.3.7 Changing the electronic release .............................. « 93 15.2 PR120/D-M - COM COMMUNICATION Module ........ « 118
14.3.7.1 Installation .................................................................. « 93 15.2.1 General characteristics .............................................. « 118
14.3.7.2 Uninstalling ................................................................ « 93 15.2.2 Front view .................................................................. « 118
14.4 User interface ............................................................ « 94 15.2.3 Releases complete with the module ......................... « 118
14.4.1 Use of pushbuttonsUtilizzo dei pulsanti .................... « 94 15.2.4 Power supply ............................................................. « 118
14.4.2 Read and Edit modes ............................................... « 94 15.2.5 Connection ................................................................ « 118
14.4.3 Changing parameters ............................................... « 95 15.2.6 Communication functions available .......................... « 118
14.4.3.1 Modification of basic configuration ........................... « 97 15.2.7 PR120/D-M - COM module menu ............................. « 118
14.4.4 Default settings .......................................................... « 98 15.3 PR120/K - SIGNALLING Module .............................. « 119
14.5 Operating instructions / Operation in service .......... « 99 15.3.1 General characteristics ............................................. « 119
14.5.1 Menu .......................................................................... « 99 15.3.2 Front view .................................................................. « 119
14.5.2 Protections Menu ...................................................... « 100 15.3.3 Releases complete with the module ......................... « 119
14.5.2.1 Protections Menu table ............................................. « 100 15.3.4 Characteristics of the digital input ............................ « 119
14.5.3 Measurements Menu ................................................. « 103 15.3.5 Characteristics of the signalling contacts ................. « 119
14.5.3.1 Measurements Menu table ....................................... « 103 15.3.6 Power supply ............................................................ « 120
14.5.4 Settings Menu ........................................................... « 103 15.3.7 PR120/K module menu ............................................. « 120
14.5.4.1 Settings Menu table .................................................. « 103 15.3.8 Programming contacts K51/p1, K51/p2, K51/p3
14.5.4.2 Adjusting the neutral ................................................. « 104 and K51/p4 ................................................................ « 121
14.5.4.2.1 Neutral adjustments table ......................................... « 104 15.3.9 Configurable input .................................................... « 121
14.5.4.3 Mains frequency settings .......................................... « 104 15.3.9.1 Input configuration settings ...................................... « 121
14.5.4.4 Modules ..................................................................... « 105 15.3.9.2 Input function settings (ACTION) ............................. « 121
14.5.4.4.1 PR120/V module ....................................................... « 105 15.3.9.3 Setting the input enabling delay .............................. « 121
14.5.4.4.2 PR120/D-M - COM module ....................................... « 105 15.3.10 PR120/K module menu layout .................................. « 122

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15.4 PR120/D-WL - COM module ............................. page122
15.4.1 General characteristics ................................................. « 123
15.4.2 Front view ..................................................................... « 123
15.4.3 Releases complete with the module ............................ « 123
15.4.4 Power supply ............................................................... « 123
15.4.5 Connection ................................................................... « 123
16 Appendices ......................................................... « 124

16.1 PR021/K outside signalling unit ................................... « 124
16.1.1 General information ...................................................... « 124
16.1.2 Power supply ............................................................... « 124
16.1.3 General characteristics of the signalling relays ........... « 124
16.1.4 Relay functions ............................................................. « 124
16.1.5 PR021/K signalling unit menu ...................................... « 124
16.1.5.1 PR021/K unit menu table ............................................. « 125
16.1.5.2 Important note .............................................................. « 125
16.2 SD-Pocket .................................................................... « 126
16.3 SD-Testbus ................................................................... « 126
16.4 Data Logger (recorder) ................................................ « 127
16.4.1 General characteristics ................................................ « 127
16.4.2 Description of the Data Logger menu .......................... « 127
16.4.2.1 Data Logger enabled ................................................... « 127
16.4.2.2 Setting the sampling frequency ................................... « 127
16.4.2.3 Setting the standard (trigger) stop sources ................. « 127
16.4.2.4 Setting and viewing customized trigger points ............ « 128
16.4.2.5 Setting the stopping delay ........................................... « 128
16.4.2.6 Restart/Stop Data Logger ............................................ « 128
16.4.3 Recording time windows .............................................. « 128
16.4.4 Description of the information given by the Data
Logger system ............................................................. « 129
16.4.4.1 Combination of devices for reading/setting data from the
Data Logger system .................................................... « 129
16.4.4.2 Access to the saved data from the system ................. « 129
16.4.4.3 Information from the system on the configuration and status
of the Data Logger ...................................................... « 130
16.4.5 Data Logger commands from the systems ................ « 130
16.5 Table showing lists of events ....................................... « 131
16.5.1 "Standard" events for PR120/K and for PR121/K
selectable from the relay ............................................. « 131
16.5.2 "Standard" events for the Data Logger function ..........
selectable from the relay ............................................. « 131
16.5.3 Examples of "Custom" events for the Data Logger
function for PR120/K and PR121/K ............................. « 131
16.5.4 Combining the devices needed to customize settings« 131
17. Overall dimensions ............................................ « 132
18. Circuit diagrams ................................................. « 146

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1. Description
1.1 General characteristics
The SACE Emax series of circuit-breakers and disconnectors consists of a steel sheet structure which houses the operating mechanism, the poles
and the auxiliary parts. Each pole, insulated from the others, contains the circuit-breaking parts and the current transformer of the corresponding
phase.
The structure of the poles differs according to whether the circuit-breaker is selective or current-limiting.
The fixed version circuit-breaker has its own terminals for connection to the power circuit; in the withdrawable version the circuit-breaker comprises
the moving part of the apparatus, which is completed with a fixed part fitted with the terminals for connection to the power circuit of the installation.
The moving part and the fixed part coupled by means of special contacts installed in the fixed part.
1.2 External front view of the circuit-breaker 1.3.1 Circuit-breaker rating plate
1 PR121, PR122 or PR123

electronic microprocessor- Fig. 2a
3 based release
2 Trade mark 1.3.2 Disconnector rating plate
3 Operating and control parts
4 of the operating mechanism
and release tripped signals
4 Rating plate
Fig. 1 Fig. 2b
1.4 Moving part construction characteristics
7 7
9 8 9 8
6b 6a
6a
5b
10 5a
5a 10
12 12
4 15 4 15
2 2
3 3
11 1 12 13 14 11 1 12 13 14
Selective circuit-breaker Current-limiting circuit-breaker
1 Supporting structure made of steel sheet

2 Current transformer for protection release 8 Terminal box for the fixed version-Sliding contacts for the withdrawable version
3 Terminal supporting molded case /insulating box 9 Protection release
4 Horizontal rear terminals 10 Circuit-breaker closing and opening mechanism
5a Main fixed contact plates 11 Closing springs
5b Fixed arcing contact plates 12 Spring loading geared motor (on request)
6a Main moving contact plates 13 Lever for manually loading the closing springs
6b Moving arcing contact plates 14 Racking-out device (only for withdrawable circuit breakers)
7 Arcing chamber 15 Service releases (shunt closing release, shunt opening release, under-
voltage release)(on request)
Fig. 3

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1.5 Fixed part construction characteristics
1 5 1 Steel sheet supporting structure

2 Earthing contacts (a: for all versions; b: for
E4, E6)
9 3 Safety shutters (IP20 degree of protection)
4 4 Insulating terminal support base
5 Terminals
8 6 Contacts for signalling connected/test
3 isolated/disconnected (on request)
7 Sliding contacts
8 Padlock for safety shutters (on request))
9 Anti-racking-in lock for circuit-breakers of
2b different size
2a 10 Fixing holes (qty 4 for E1, E2, E3, 6 for E4,
10 E6)
Fig. 4
2. Checking on receipt
Examine the state of the material received and its consistency with the content of the order. Should any damage or errors be found on unpacking,
which must be carried out carefully, make the relative notification within and not over 5 days from the receipt of the material. The notification must
indicate the number of the shipping note.
3. Storage, lifting and weights

The circuit-breaker, protected by an external wooden crate, is fixed by means of screws to the transport pallet or to the bottom of the packing case.
If the circuit-breaker has to remain in the warehouse even for a short time before being put into service, after checking it on receipt, it must be put
back in its container and covered with a waterproof sheet.
Caution
– Use a dry, dust-free room free of aggressive chemical agents as a storage room
– Position the circuit-breaker and any fixed part on a horizontal surface, not in direct contact with the floor, but on a suitable support surface
(Fig. 5)
– The maximum number of stackable circuit-breakers is indicated in figure 6.
– Keep the circuit-breaker in the open position and with the closing springs unloaded to avoid unnecessary stresses and the risk of accidents to
the personnel.
Fig. 5 Fig. 6

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With regard to lifting, follow the instructions: the circuit-breakers must be placed on a sturdy supporting surface and lifted, preferably, by means of
a special fork-lift truck. However, the use of ropes is allowed. In this case, the lifting ropes must be hooked up as shown in the figures (the lifting
plates are always supplied with the circuit-breaker).
Fig. 7
Table of the circuit-breaker weights (Kg.)
Selective Fixed version Withdrawable version Current-limiting Fixed version Withdrawable version
circuit-breaker circuit-breaker
3 poles 4 poles 3 poles 4 poles 3 poles 4 poles 3 poles 4 poles
E1 45 54 70 82 E2L 52 63 80 95
E2 50 61 78 93 E3L 72 83 110 127
E3 66 80 104 125
E4 97 117 147 165
Notes
E4/f 120 170
The weights indicated in the table are intended for circuit-breakers complete with PR121,
E6 140 160 210 240 PR122 or PR123 releases and relative current sensors, excluding the accessories.
The withdrawable version includes the moving part in the same conditions as above, and the
E6/f 165 250 fixed part with horizontal rear terminals.
4. Installation
4.1 Installation room
Install the circuit-breaker in a dry, dust-free, non-corrosive room, and in
such a way that it is not subject to shocks or vibrations. Where this is not
possible, install it inside a switchboard with a suitable degree of
protection.
For the preparation of the installation room, please refer to the "Overall
dimensions" paragraph, which gives information on the following points:
– minimum installation volumes of the circuit-breakers and derived
versions
– distances to be respected for circuit-breakers in compartments
– overall dimensions of the circuit-breakers
– fixing drillings
– compartment door drillings
The installation, commissioning and any ordinary and extraordinary
maintenance have to be done by skilled personnel, with a detailed
knowledge of the apparatus.
4.2 Installation of the fixed circuit-breaker

Fix the circuit-breaker to a horizontal surface using the screws (M10 x
12 min.). Fig. 8
4.3 Installation of the fixed part of the withdrawable circuit-breaker
4.3.1 Preparation of the fixed part
Assembly of the anti-racking-in lock

Before installing the fixed part, it is necessary to check the presence of the anti-racking-in lock for circuit-breakers with different electrical
characteristics from those of the fixed part. If the anti-racking-in lock has been supplied separately, proceed to assemble it as follows:
– On the self-adhesive plate (4), find the assembly position of the stop bolts in relation to the circuit-breaker which has to be housed in the fixed
part
– Insert the hexagonal-head screws (1) in the holes found in the previous item as shown in the figure
– Fix the screws with the washers (2) and the hexagonal stops (3).
– Make sure that the anti-racking-in lock corresponding to the one installed on the fixed part is present on the circuit-breaker (moving part).
– Anti-racking-in plate on the moving part (5).

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Example for E1B 08 according to the nameplate diagram
2
3
1
4
3
Fig. 9 Fig. 10
4.3.2 Installation of the fixed part (Fig. 12)

Attach the fixed part by means of the screws (1), washers (2) and nuts (3) (M8 x 16), supplied by ABB SACE. if other screws are used, make sure
that the head of the screws does not extend more than 5.5 mm from the base of the fixed part.
4.3.3 Installation of the fixed part on board a ship (Fig. 11)

Regarding the fixing points of the SACE Emax withdrawable version air circuit-breakers, for applications on board a ship, additional fixing on the
sides of the fixed part itself is recommended (the M12 screws and the spacers are not provided in the supply).
E1 - E2 - E3 Spaces
E4 - E6 Spaces
Fig. 11

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4.4 Installation of the flange on the compartment door (Fig. 13)
– Make the compartment door drillings specified in the "Overall dimensions" paragraph.
– Attach the flange (1) on the front of the compartment door, fixing it from the inside by means of the self-tapping screws (2).
1 2
Notes
(*) For the E1-E2-E3 fixed parts,
there are four fixing points, whereas
there are six for E4-E6.
Fig. 12 Fig. 13
5. Electrical connections
5.1 Connections to the power circuit
5.1.1 Shapes of the terminals
Fixed circuit-breaker Fixed part for withdrawable circuit-breaker
Horizontal rear terminals Vertical rear terminals Horizontal rear terminals Vertical rear terminals
Front terminals Front terminals Flat terminals
Fig. 14 Fig. 15
Note
The drawings are provided to show the type of terminal in graphic form. The exact shape of the terminals is given in the "Overall dimensions" chapter.
Different terminals can be installed between the top and bottom parts (inlet and outlet).

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5.1.2 Examples of positioning the connection busbars according to the types of terminals
The connection busbars enable the connection between the terminals of the circuit-breakers and the busbars of the switchgear. Their sizing must
be carefully studied by the switchgear designer. Some examples of possible constructions in relation to the shape and size of the circuit-breaker
terminals are given in this paragraph. The various types of terminals are of constant dimensions for each size of circuit-breaker: it is normally advisable
to exploit the whole contact surface of the terminal, so the width of the connection busbars should be the same as that of the terminal. Different
connection capacities can be obtained by adjusting the thickness and number of busbars in parallel. In some cases, reductions in the width of the
connection in relation to that of the terminal are allowable as shown in the following examples.
Vertical terminals Horizontal and front terminals
Sections Iu [A] Continuous current-carrying Busbar cross-section Continuous current-carrying Busbar cross-section
capacity [A][mm2] capacity [A][mm2]
35°C 45°C 55°C 35°C 45°C 55°C
E1B/N 08 800 800 800 800 1x(60x10) 800 800 800 1x(60x10)
E1B/N 10 1000 1000 1000 1000 1x(80x10) 1000 1000 1000 2x(60x8)
E1B/N 12 1250 1250 1250 1250 1x(80x10) 1250 1250 1200 2x(60x8)
E1B/N 16 1600 1600 1600 1500 2x(60x10) 1550 1450 1350 2x(60x10)
E2S 08 800 800 800 800 1x(60x10) 800 800 800 1x(60x10)
E2N/S 10 1000 1000 1000 1000 1x(60x10) 1000 1000 1000 1x(60x10)
E2N/S 12 1250 1250 1250 1250 1x(60x10) 1250 1250 1250 1x(60x10)
E2B/N/S 16 1600 1600 1600 1600 2x(60x10) 1600 1600 1530 2x(60x10)
E2B/N/S 20 2000 2000 2000 1800 3x(60x10) 2000 2000 1750 3x(60x10)
E2L 12 1250 1250 1250 1250 1x(60x10) 1250 1250 1250 1x(60x10)
E2L 16 1600 1600 1600 1500 2x(60x10) 1600 1500 1400 2x(60x10)
E3H/V 08 800 800 800 800 1x(60x10) 800 800 800 1x(60x10)
E3S/H 10 1000 1000 1000 1000 1x(60x10) 1000 1000 1000 1x(60x10)
E3S/H/V 12 1250 1250 1250 1250 1x(60x10) 1250 1250 1250 1x(60x10)
E3S/H/V 16 1600 1600 1600 1600 1x(100x10) 1600 1600 1600 1x(100x10)
E3S/H/V 20 2000 2000 2000 2000 2x(100x10) 2000 2000 2000 2x(100x10)
E3N/S/H/V 25 2500 2500 2500 2500 2x(100x10) 2500 2450 2400 2x(100x10)
E3N/S/H/V 32 3200 3200 3100 2800 3x(100x10) 3000 2880 2650 3x(100x10)
E3L 20 2000 2000 2000 2000 2x(100x10) 2000 2000 1970 2x(100x10)
E3L 25 2500 2500 2390 2250 2x(100x10) 2375 2270 2100 2x(100x10)
E4H/V 32 3200 3200 3200 3200 3x(100x10) 3200 3150 3000 3x(100x10)
E4S/H/V 40 4000 4000 3980 3500 4x(100x10) 3600 3510 3150 6x(60x10)
E6V 32 3200 3200 3200 3200 3x(100x10) 3200 3200 3200 3x(100x10)
E6H/V 40 4000 4000 4000 4000 4x(100x10) 4000 4000 4000 4x(100x10)
E6H/V 50 5000 5000 4850 4600 6x(100x10) 4850 4510 4250 6x(100x10)
E6H/V 63 6300 6000 5700 5250 7x(100x10) - - - -
Fig. 16
Positioning the first anchoring baffle of the busbars according to the short-circuit current
Anchoring to the switchgear
HORIZONTAL FRONT
VERTICAL
FLAT
P E1-E2 E3-E4-E6 E1-E6

HORIZONTAL 250 150 –
VERTICAL 250 150 –
FRONT – – 250
FLAT – – 250
Fig. 17
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5.1.3 Assembly procedure for the connection busbars
Check the state of the contact surfaces of the connections very carefully: they must be very clean with no burrs, dents or traces of rust which must
be eliminated using a fine file or an emery cloth to prevent localized increases in temperature. On completion of the operation, remove all traces
of grease or dust with a cloth soaked in a suitable solvent. When copper connections are used, it is advisable to tin-plate the contact surfaces. When
aluminium connections are used, it is advisable to apply a thin layer of Vaseline over the contact surfaces.
The connections must not exert any strain on the terminals in any direction.
Always insert a large-diameter flat washer and a spring washer between them (to spread the tightening pressure over a greater area).
Make the contact between connection and terminal and tighten the fixing screws completely.
Always use two wrenches (so as not to strain the insulating parts excessively), applying the tightening torque indicated in Fig. 18. Check tightness
after 24 hours.
M12 high strenght screws

Tightening torque of the main terminals: 70 Nm
Fixed part terminals No. of screws for phase No. of screws for neutral Fixed circuit-breaker terminals No. of screws for phase No. of screws for neutral
2 2 2 2
3 3 3 3
4 2 4 2
4 4 4 4
6 3 6 3
6 6 6 6
Fig. 18
5.2 Earthing
The fixed circuit-breaker and the fixed part of the withdrawable circuit-breaker have one or two terminals on the rear, marked with the special symbol,
for connection to earth (Fig. 9 and Fig. 12b).
Each terminal is complete with a bolt for fixing the connection. A conductor with a cross-section conforming to current standards must be used for
the connection.
Before assembling the connection, clean and degrease the area around the screw.
After the assembly, tighten the bolt with a torque of 70 Nm.
5.3 Wiring the circuit-breaker auxiliary circuits

5.3.1 Interfacing elements for fixed circuit-breakers
A special terminal box is provided, fitted with screw terminals for connecting the auxiliary circuits.
The terminals are marked with alphanumerical identification codes as for the electrical circuit diagram.
The terminal box is identified by code XV on the electrical circuit diagram.
The terminal box is immediately accessible when the compartment door is open.
XV
Fig. 19

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5.3.2 Withdrawable circuit-breaker
For connection of the moving part to the auxiliary circuits, a connection with sliding contacts is available on the fixed part (see figure), identified by
code X on the electrical circuit diagram.
The terminals of the fixed connector are immediately accessible when the compartment door is open.
Furthermore a terminal box identified by code XF is available for connecting the position contacts of the moving part in relation to the fixed part.
The connector and terminal box have screw terminals.
E1 - E2 - E3
10 contacts in position
1
1 3
2
E1 - E2 - E3 - E4 - E6 E4 - E6
5 contacts in position 10 contacts in position
Caption
1 Sliding contacts(X)
2 Terminal box for position contacts (XF)
3 Position contacts
Fig. 20

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5.4 Conversion of the auxiliary contacts or of the signalling contacts (disconnected - test isolated - connected), from normally
closed (opening) to normally open (closing) or vice versa
The contacts are wired at the factory as shown on the electrical circuit diagram. If it is necessary to change their state for installation requirements,
proceed as follows.
a) Auxiliary contacts
To access the auxiliary contacts, carry out the following operations.

– remove the front protection (3) of the release by taking action on the blocks (1) as shown in the figure
– remove the protection release (4) removing the side nuts (2) and then sliding the release out from the front of the circuit-breaker.
Fig. 21
Being of the two-way type (changeover contacts), the auxiliary contacts can be modified from break contacts to make contacts and vice versa simply
by moving the output conductor from one position to the other, as shown in the figure (example for PR121).
N.C. contact Sliding contacts N.O. contact Terminal box
Fig. 22
b) Position contacts disconnected - test isolated - connected
To change the state of the position contact, proceed in the same way as explained for the auxiliary contacts.

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6. Putting into service
6.1 General procedures
– Check tightness of the power connections at the circuit-breaker terminals
– Carry out all the preparatory operations on the release
– Make sure that the value of the auxiliary circuit power supply voltage is between 85 and 110% of the rated voltage of the electrical appplications
– Make sure that there is an adequate air circulation in the place of installation to avoid overheating
– Also carry out the checks specified in the following table
Item inspected Procedure Positive check
1 Manual operating mechanism Carry out some opening and closing operations The spring loading lever moves correctly.
(see the chapter 7.2).
CAUTION
When there is an undervoltage release, the
circuit-breaker can only be closed after the
release has been electrically energized.
2 Geared motor (if any) Supply the spring loading geared motor at the The springs are loaded correctly.
corresponding rated voltage. The signals are correct.
The geared motor stops with the springs loaded.
Carry out some closing and opening operations. The geared motor recharges the springs after
each closing operation.
Note. Supply the undervoltage release at the
corresponding rated voltage (if any)
3 Undervoltage release Supply the undervoltage release at the The circuit-breaker closes correctly. The signals
(if any) corrsponding rated voltage and carry out the are correct.
circuit-breaker closing operation.
Disconnect voltage to the release. Supply the The circuit-breaker opens. The signal changes
undervoltage release at the corresponding over.
rated voltage and carry out the circuit-breaker
closing operation.
4 Shunt opening release (if any) Close the circuit-breaker. The circuit-breaker opens correctly. The
Supply the shunt opening release at the signals are correct.
corresponding rated voltage
5 Shunt closing release (if any) Open the circuit-breaker. Supply the shunt The circuit-breaker closes correctly. The signals
closing release at its rated voltage. are correct.
6 Circuit-breaker lock in the open position Open the circuit-breaker, turn the key and
remove it from its seat. Attempt the circuit- Both manual and electrical closing are
(with key or padlocks) prevented.
breaker closing operation.
7 Auxiliary contacts of the circuit-breaker Insert the auxiliary contacts in suitable signalling The signals are given correctly.
circuits. Carry out some circuit-breaker closing
and opening operations.
8 Auxiliary contacts for signalling circuit- Insert the auxiliary contacts in suitable signalling The signals due to the relative operations are
breaker connected, test isolated and circuits. Then put the circuit-breaker in the given correctly.
disconnected connected, test isolated and disconnected
position.
9 Lock devices for circuit-breakers Carry out the operating tests. The locks function correctly.
connected and disconnected. Interlocking
devices between circuit-breakers side by
side and one on top of another (if any)
Racking-in operation: the circuit-breaker racks
10 For withdrawable circuit-breakers: racking Carry out some racking-in and out operations. in correctly. The first turns of the crank handle
-in/out device do not meet with particular resistance.

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7. Instructions for use
7.1 Operating and signalling parts
1 Pushbutton for the manual opening operation

2 Lever for manual loading of the closing springs
3 Mechanical indicator for circuit-breaker open “O” and closed “I”
4 Mechanical indicator for protection release tripped (on request)
5 Pushbutton for the manual closing operation
6 Signalling device for springs loaded - unloaded
7 Operation counter (on request)
8 Key lock on the closing operation
9 Mechanical indicator for circuit-breaker connected, test isolated and disconnected
10 Seat for the racking-in/out lever
11 Lever releasing the racking-in/out operation
12 Key lock on the racking-in/out operation (on request)
13 Padlock on the manual closing operation (on request)
14 Padlock on the racking-in/out operation (on request)
Fixed circuit-breaker Withdrawable circuit-breaker
4
4
13
8 8
5 5
1 1
6
2 6 2
7
3 3
11
7
10
12
9
14
Fig. 23
Note
On request, a transparent cover can be installed on the front of the circuit-breaker to increase the degree of protection to IP54. The cover has a locking
key.
As an alternative to the transparent cover, a protection can be mounted on the manual closing and opening controls, which only allows operation
of the pushbuttons by means of a special tool.
Fig. 24

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7.2 Circuit-breaker closing and opening procedures
The operation of the circuit-breaker can be either manual or electrical.

a) Manual loading of the closing springs
– Make sure that the indicator (3) shows "O" (circuit-breaker open)
– Make sure that the indicator (6) is WHITE (springs unoaded)
– Repeatedly activate the lever (2) until the indicator (6) changes its
color to YELLOW
b) Electrical loading of the closing springs

The electrical loading of the circuit-breaker is possible when the
following accessories (supplied on request) are present:
– geared motor for automatic loading of the closing springs 2
– shunt closing release
– shunt opening release.
The geared motor automatically reloads the springs after each closing
operation until the yellow indicator appears (6, Fig. 25). When the power
is cut off during loading, the geared motor stops and automatically starts
reloading the springs again when the power returns. It is, in any case,
always possible to complete the reloading operation manually.
3 6
Fig. 25
c) Closing the circuit-breaker

The operation can only be carried out with the closing springs fully loaded. For manual closing, press the pushbutton (5) marked with the letter “I”.
When there is a shunt closing release, the operation can be carried out remotely by means of the special control circuit. The special indicator (3)
changes to indicate "I" to signal that the circuit-breaker has closes. Furthermore, the indicator of the state of the springs (6) goes to the WHITE
position. Even with the closing springs unloaded, the operating mechanism retains enough energy for the opening operation. The geared motor,
if any, immediately starts the automatic spring reloading operation.
5
Press
3 6
Fig. 26
d) Opening the circuit-breaker

For manual opening of the circuit-breaker, press pushbutton“O” (1). When there is a shunt opening release, the operation can also be carried out
remotely by means of the special control circuit. Opening having taken place is signaled by the letter “O” appearing in the indicator (3).
Press
3
Fig. 27

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7.3 Racking-in/out operation
WARNING
A) Open the circuit-breaker before carrying out any racking-in/out operation.
B) The circuit-breaker (moving part) and fixed part are fitted with a lock which prevents the fixed part from being racked into the circuit-breakers
with a different rated current: the congruence of the anti-racking-in lock must be checked by the operator before carrying out the racking-in
operation to avoid any unnecessary stress.
C) Before the racking-in operation, remove any padlock on the segregation shutter of the isolation terminals on the fixed part.
Press
B C
Fig. 28
NOTES
In relation to the fixed part, the circuit-breaker (moving part) can take up
different positions, identified as follows:
– DISCONNECTED: the moving part is inserted in the fixed part
WITHOUT any connection between the terminals and WITHOUT
coupling the sliding contacts for the auxiliary circuits: in this position
all electrical operation of the circuit-breaker is prevented. On the front
the indicator (9, Fig. 23) indicates DISCONNECTED. The switchgear
compartment door can be closed.
– TEST ISOLATED: the moving part is inserted in the fixed part WITHOUT
any connection between the power terminals, but WITH the sliding
contacts coupled for the auxiliary circuits. In this position, the circuit-
breaker can be operated for the offline tests. The indicator (9, Fig. 23)
indicates TEST ISOLATED.
– CONNECTED: the moving part is fully inserted in the fixed part WITH
the connection of both the power terminals and the sliding contacts
for the auxiliary circuits. The circuit-breaker is operational. The
indicator (9, Fig. 23) indicates CONNECTED.
a) Positioning the moving part in the fixed part in the

DISCONNECTED position
Lift the moving part as shown in the paragraph (3) and insert it in the fixed
part guide, tilting it as shown in figure 29.
The manual connection must allow the edge (E) of the circuit-breaker
guide to slide under the blocks (D) of the fixed part. Remove the lifting
devices.
The position reached is stable and allows for any inspections of the
circuit-breaker.
Push the moving part as far as the stop in the fixed part.
Close the compartment door.
Fig. 29

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b) Passing from the DISCONNECTED to the TEST ISOLATED position
Make sure that the indicator (9) is in the DISCONNECTED position.
For the connection procedure, make sure that the key (12) is in the correct position and/or the padlock (14), if any, has been removed.
Make sure that the circuit-breaker is open.
Push the moving part right into the fixed part.
Lower the releasing lever (11).
Insert the crank handle in the corresponding coupling (10).
Proceed to turn the crank handle clockwise until the TEST ISOLATED indication appears on the indicator (9). During the initial turns, the crank handle
must oppose no any particular resistance to rotation.
Should it be necessary to carry out offline circuit-breaker operations, the crank handle must be removed.
12 14 11 10 9
Fig. 30
c) Passing from the TEST ISOLATED position to the CONNECTED position

Make sure that the circuit-breaker is open.
Lower the releasing lever (11).
Insert the crank handle in the corresponding coupling (10).
Proceed to turn the crank handle clockwise until the CONNECTED indication appears on the indicator (9).
Remove the crank handle to enable the circuit-breaker to close.
11 10 9
Fig. 31
d) Passing from the CONNECTED position, to the TEST ISOLATED position, to the DISCONNECTED position
Repeat the connection procedures changing the direction for turning the crank handle to anti-clockwise. Open the door in the disconnected position.
8. Maintenance
8.1 Warning
Before carrying out any maintenance work, it is necessary to complete the following procedure:
– open the circuit-breaker and check that the operating mechanism springs are unloaded
– in the case of withdrawable circuit-breakers, work with the circuit-breaker racked-out of the fixed part
– for action on fixed version circuit-breakers or on fixed parts of withdrawable circuit-breakers, disconnect the supply to the power circuit and to
the auxiliary circuits. Furthermore, visibly earth the terminals both on the power supply side and on the load side.
During normal service, the circuit-breakers require limited maintenance.
The table of the maintenance program is given in the following paragraph, indicating the corresponding periodic intervals for action. In particular,
with regard to the time intervals, it is advisable to follow the raccomendations in the table, at least for the first year of service.
On the basis of the results obtained during the routine checks, establish the best time intervals for the maintenance operations.
It is also advisable to refer to the following rules:

– circuit-breakers which rarely operate, or which remain closed for long periods, must be operated from time to time to avoid any tendency to stick
– during service, routinely inspect the circuit-breaker from the outside to check for any dust, dirt or damage of any kind.
For circuit-breakers with SACE PR122 and SACE PR123 releases, check the percentage of wear on the contacts.
– For circuit-breakers fitted with SACE PR121 releases, installation of the mechanical operation counter (supplied on request) is recommended.
The SACE PR122 and SACE PR123 releases allow for the number of operations performed by the circuit-breaker in service to be displayed at all
times on the special display.

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With regular maintenance, SACE Emax circuit-breakers, either with or without a geared motor, can withstand the following operation without
replacement of parts.
Rated uninterrupted current Mechanical life (*) Electrical life
Iu (40°C) N° of operations Frequency 440 V ~ 690 V ~ Frequency
[A] x 1000 operations/hour N° of operations x 1000 N° of operations x 1000 operations/hour
E1 B-N 800 25 60 10 10 30
1000-1250 25 60 10 8 30
1600 25 60 10 8 30
E2 B-N-S 800 25 60 15 15 30
1000-1250 25 60 15 15 30
1600 25 60 12 10 30
2000 25 60 10 8 30
E2 L 1250 20 60 4 3 20
1600 20 60 3 2 20
E3 N-S-H-V 800 20 60 12 12 20
1250 20 60 12 12 20
1600 20 60 10 10 20
2000 20 60 9 9 20
2500 20 60 8 7 20
3200 20 60 6 5 20
E3 L 2000 15 60 2 1,5 20
2500 15 60 1,8 1,3 20
E4 S-H-V 3200 15 60 7 7 10
4000 15 60 5 4 10
E6 H-V 3200 12 60 5 5 10
4000 12 60 4 4 10
5000 12 60 3 2 10
6300 12 60 2 1,5 10
(*) With regular ordinary maintenance
8.2 Maintenance program
Maintenance operations Interval
Installation in normal rooms Installations in dusty or polluted rooms
General inspection (see par. 8.3.2) One year or after a short-circuit trip Six months or after a short-circuit trip
External visual check and inspection One year Six months
of the power section
Operating mechanism maintenance (par. 8.3.4) One year or 10000 operations Six months or 10000 operations
Checking trip of the release One year Six months
8.3 Maintenance operations
8.3.1 Preliminary operations

– Remove the flange (1) of the release, turning the screws (2) as shown in the figures
– Remove the front escutcheon plate (3) by removing the four screws (4)
– Remove, if present, one or both side guards (5) by removing the front (6) and lateral (7) screws
– Remove the arcing chambers (8) by removing the screws (9).
9 9
8 8
7
7
5
2
2
1
1
4 3
4 3
E1-E3 E4-E6
Fig. 32

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8.3.2 General inspection of the circuit-breaker
Item to be inspected Problem found Remedy
1 Operating mechanism/Electrical accessories – Presence of dust on the internal parts – Clean with brushes or dry cloths
– Springs deformed or rusty – Replace damaged springs
– Safety rings out of place, nuts or screws loose – Put the rings back in place and tighten screws and
nuts appropriately
– Wires and straps detached – Replace the straps and connect the detached
wires correctly
2 Arcing and main contacts – Traces of wear – Smooth the contacts with emery cloth
– Incorrect adjustments: distance A - Fig. 33 is less – Adjust according to the paragraph 8.3.3
than 1mm for E1-E2-E3 or less than 0.8 mm for E4-
E6
3 Arcing chambers – Presence of fumes or dust – Remove with compressed air and remove the
– Presence of cracks in the external plastic structure fumes and any slag with a brush
– Excessive difference in wear between the first and – Replace the arcing chamber
last arc extinguishing plate
– Replace the arcing chamber
4 Main circuit - Busbars - Insulating contacts – Presence of dust or dirt on the insulating parts – Clean with a brush or dry cloths
– Safety rings out of place, screws or nuts loose – Put the rings back in place and tighten screws and
– Deformation or cracks of the insulating parts nuts appropriately
– Ask ABB SACE to replace the damaged parts
– Insulating contacts oxidized (only for withdrawable – Remove the shutters and clean with a rough
circuit-breaker) clothsoaked in a suitable solvent and lubricate
– Screws loose on the connections to the terminals moderately with neutral grease
of the circuit-breaker (only for fixed circuit-breaker) – Tighten the screws suitably
5 Earthing contacts (only for withdrawable circuit- Presence of rust or loose nuts Clean with a rough cloth soaked in a suitable solvent
breaker) and lubricate moderately with neutral grease. Tighten
the nuts completely
6 Earth connection (only for fixed circuit-breaker) Presence of rust and/or loose nuts Clean with a rough cloth soaked in a suitable solvent,
fully tighten the earth connection and cover with
neutral grease again
7 Auxiliary circuit power supply voltage Check the power supply voltage of the electrical The releases and locking devices must operate
accessories of the operating mechanism normally for values between 85% and 110% of the
corresponding rated voltage
8 Operating and control parts The operating tests, which must be carried out as Replace the defective parts or those with a faulty
shown in paragraph 6.1 have shown defects in the operation (if necessary, ask ABB SACE)
components
8.3.3 Checking contact wear
In order to ensure the gap A indicated in the table, you can adjust the
position of the shaft and of the operating mechanism.
1) Open the circuit-breaker
2) Remove the arcing chamber
3a) Adjust the distance of the moving contacts for E1-E2-E3:
- loosen the screws in pos.1 and the nuts in pos. 3 (FIG 33 a)
- proceed in the same way on the screws in pos. 2
- bring the bushes of the operating mechanism (pos. 5) to rest on the
shaft, tacking action on the nuts in pos. 4
- tighten the screws in pos.1 and the nuts in pos. 3 and 4
- close the circuit-breaker and check the gap A
3b) Adjust the distance of the moving contacts detachment for E4-E6:
- loosen the screws in pos.1 and 6, the nuts in pos 3. and 8 (FIG 33
a and 33 b)
- proceed in the same way on the screws in pos. 2
- bring the bushes of the operating mechanism (pos. 5) and the
bushes of the intermediate abutments ( pos. 9) to rest on the shaft,
Circuit-breaker
tacking action on the nuts in pos.4 and the screws in position 7 A
- tighten the screws in pos.1 and 6, and the nuts in pos. 3, 4 and 8
- close the circuit-breaker and check the gap A E1 - E2 - E3 1 ÷ 1.9 mm
4) If the gap A is not correct, open the circuit-breaker again and repeat E4 - E6 0.8 ÷ 1.5 mm
the procedure indicated in item 3a or 3b
5) If the gap A is correct, open the circuit-breaker again, seal with Fig. 33
yellow paint and reinstall the arcing chambers.

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Fig. 33a
Fig. 33b Fig. 33c
8.3.4 Operating mechanism maintenance
– Carry out the checks and take the action listed under item 1 of the table in paragraph 8.3.2.
– Lubricate the bearings of the drive shaft with MU-EP1 (AGIP) grease, including those on the sides of the circuit-breaker. Equivalent greases: ESSO
Beacon EP1 - BP LTX1 - SHELL AVANIA GREASE R1 - KLUBER LUBRIFICATION CENTO PLEX 2P
– Lubricate the small opening and closing shafts and the hooks with 5 RX MOLY (OLEOTECNICA) grease (Fig. 33c). Equivalent grease: KLUBER
LUBRIFICATION GRAFLOSCON A-G 1 ULTRA.

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9. Measures to be taken for any operating anomalies
Pressing the i Test pushbutton on the PR122/PR123 does not cause circuit-breaker opening
The WARNING or ALARM led on the PR121/PR122/PR123 release lights up
Release coils interrupted or burnt out, geared motor winding interrupted
The shunt opening release or shunt closing release does not energize sufficiently
The shunt opening release or shunt closing release remains energized Anomalies
The moving part does not rack into the fixed part
The moving part does not rack out of the fixed part
The circuit-breaker does not close
The circuit-breaker does not open
Possible causes Checks and remedies
• Connector XO not inserted correctly Check and insert connector XO correctly
• Coil of the opening release YO1 interrupted Replace theYO shunt opening release
• Defect in the electronic circuits of the electronic release Put the circuit-breaker out of service and check the release
with the test apparatus
• The possible causes of tripping are listed in the part of the

manual relating to the releases
Take action according to the cause: in particular, if contact
wear is higher than 80% (WARNING led lit up), the circuit-
breaker can remain in service, but replacement of the circuit-
breaking parts must be scheduled within a short time. If
contact wear reaches 100%, the circuit-breaker must be put
out of service immediately. Ask ABB SACE about replacement
procedures for the circuit-breaking parts.
• Protections not reset Press the mechanical pushbutton for signalling protection
tripping
• Operating mechanism or consent contacts blocked in

closing position
Check the state of the contacts in series with the release circuit
• • •• Auxiliary circuit power supply voltage too low Measure the voltage: it must not be less than 85% of the rated
voltage
• •• Different power supply voltage from the one indicated on

the rating plate of the releases
Check the rating plate voltage of the releases
• •• Operating circuit faulty Check connections, fuses, interlock, protection circuit-

breakers and consent contacts
• •• Wire tightening screws loose Check tightness of the screws connecting the wires
• •• Incorrect electrical connections in the power supply circuit Check the connections with the corresponding circuit diagram
•• Release coils interrupted Replace the coils
• •• Operating mechanism blocked Operate by hand. If the fault persists contact ABB SACE
• Key not inserted in the opening mechanism lock Insert and turn the key
• Circuit-breaker in intermediate position between connected

and disconnected
Complete the operation
• Undervoltage release not energized Check the corresponding power supply circuit
• Shunt opening release remains energized Check the power supply circuit
•• Racking-in or out operation not carried out correctly See paragraph 7.3

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10. Accessories
10.1 Electrical accessories

Shunt opening/closing (YO/YC) and second shunt opening release (Y02)
This allows remote opening or closing control of the apparatus. Given the characteristics ot the circuit-breaker operating mechanism, opening (with
the circuit-breaker closed) is always possible, whereas closing is only possible when the closing springs are loaded. Most of the releases can operate
with either direct or alternating current. This release carries out an instantaneous service (*), but can be supplied permanently (**).
In uses where the shunt closing release is supplied permanently, to carry out the circuit-breaker reclosing operation after opening, it is necessary
to momentarily de-energize the shunt closing release (the circuit-breaker operating mechanism reclosing is, in fact, fitted with an antipumping
device).
In some versions it is necessary to have a very high degree of safety for the remote opening control of the circuit-breaker, and, in particular, the
duplication of the control circuit of the shunt opening release is required. In order to achieve this, you can fit the SACE Emax circuit-breakers with
a second shunt opening release. The second shunt opening release is located in the undervoltage release and its technical caracteristics are the
same as the standard shunt opening release.
(*) In the case of instantaneous service, the minimum duration of the current impulse must be 100 ms.
(**) In the case of permanent power supply to the shunt opening release, you must wait for at least 30 ms before giving the opening control to the shunt closing release.
Reference figures in the electrical circuit diagrams: YO (4) - YC (2) - YO2 (8)
Power supply (Un) 24 V DC Operating limits (YO-YO2) : 70…110% Un

30 V AC/DC (CEI EN 60947-2 Standards) (YC) : 85…110% Un
48 V AC/DC Inrush power consumption (Ps) DC = 200 W
60 V AC/DC Inrush power time ~100 ms AC = 200 VA
110-120 V AC/DC Continuous power (Pc) DC = 5 W
120-127 V AC/DC AC = 5 VA
220-240 V AC/DC Opening time (YO - YO2) (max) 60 ms
240-250 V AC/DC Closing time (YC) (max) 80 ms
380-400 V AC Insulation voltage 2500V 50Hz (for 1 min.)
440 V AC
Undervoltage release (YU)

The undervoltage release opens the out circuit-breaker in the case of a considerable drop or lack of its power supply voltage. It can be used for remote
tripping (by means of normally closed type pushbuttons), as a lock on closing or to control the voltage in the primary and secondary circuits. The
release power supply is therefore branched on the supply side of the circuit-breaker from an independent source. Circuit-breaker closing is only
allowed with the release powered (the closing lock is carried out mechanically). Most of the releases can operate with either direct or alternating
current.
Power supply (Un) 24 V DC

30 V AC/DC
48 V AC/DC
60 V AC/DC
110-120 V AC/DC
120-127 V AC/DC
220-240 V AC/DC
240-250 V AC/DC
380-400 V AC
440 V AC
Operating limits: (YO-YO2): 70% ... 110% Un
(CEI EN 60947-2 Standards) (YC): 85% ... 110% Un
Circuit-breaker opening takes place with power supply voltage values of the release equivalent to 35 - 70% Un.
Circuit-breaker closing is possible with power supply voltage of the release equivalent to 85-110% Un.
It can be fitted with a signalling contact for undervoltage release energized (C. aux YU).
Reference figures in the electrical circuit diagram: YU (6)
Inrush power consumption (Ps): DC = 200 W

AC = 200 VA
AC = 5 VA
Opening time (YU): 30 ms
Insulation voltage 2500V 50 Hz (for 1 min.)

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Time delay device for undervoltage release (D)
The undervoltage release can be combined with an electronic time-delay device for installing outside the circuit-breaker, which enables a delay in
the tripping of the release with preset, adjustable times. The use of the delayed undervoltage release is recommended when the power supply
network of the release can be subject to power cuts or short-lived voltage drops, in order to avoid trips.
When it is not supplied, circuit-breaker closing is prevented.
The time-delay device has to be combined with an undervoltage release with the same voltage as the time-delay device.
Reference figures in the electrical circuit diagrams: YU + D;(7)
The characteristics of the time-delay device are:
Power supply (D): 24-30 V AC/DC

48 V AC/DC
60 V AC/DC
110-127 V AC/DC
220-250 V AC/DC
Adjustable opening time (YU+D): 0,5-1-1,5-2-3 s
Geared motor for automatic closing spring loading (M)

This automatically loads the circuit-breaker operating mechanism closing springs. After circuit-breaker closing, the geared motor immediately sees
to reloading the closing springs.
When there is no power supply or during maintenance work, the closing springs can still be loaded manually (by means of the special lever on the
operating mechanism).
Power supply 24-30 V AC/DC
48-60 V AC/DC
100-130 V AC/DC
220-250 V AC/DC
Operating limits: 85…110% Un(CEIEN 60947-Standards)
Inrush power consumption (Ps): DC = 500 W

AC = 500 VA
Rated power (Pn): DC = 200 W
AC = 200 VA
Inrush time 0,2 s
Loading time: 4-5 s
Insulation voltage 2500V 50 Hz (for 1 min.)
It is always supplied with limit contacts and microswitch for signalling closing springs loaded.
Reference figure in the electrical circuit diagrams: M (1)

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Mechanical and electrical trip signalling for overcurrent releases
The following signals are available following tripping of the overcurrent release:
a) Mechanical trip signalling for overcurrent releases
This enables a visual signalling on the operating mechanism by pushing the trip pushbutton in when the circuit-breaker has been opened following
tripping of an overcurrent release. The circuit-breaker can only be closed again by putting the pushbutton back into its normal position included
in the standard configuration.
Reference figure in the electrical circuit diagram: S51 (13).
b) Electrical and mechanical trip signalling for overcurrent releases

This enables a visual signalling on the operating mechanism (mechanical) and remotely (electrically by means of a changeover switch) of the circuit-
breaker being opened following a trip of the overcurrent releases. To reset the circuit-breaker, it is necessary to reset the mechanical indicator
pushbutton.
Reference figure in the electrical circuit diagram: S51 (13).
c) Coil for resetting the mechanical release trip indicator
This enables a visual signalling on the operating mechanism (mechanical) and remotely (electrically by means of a changeover switch) of the circuit-
breaker being opened following a trip of the overcurrent releases.With this accessory, you can reset the mechanical indicator with an electronic
relay using a remote control and this enables the circuit-breaker to be reset.
Power supply: 24-30 V AC/DC

220-240 V AC/DC
110-130 V AC/DC
Reference figure in the electrical circuit diagrams: S51 (14)
Auxiliary contacts
Auxiliary contacts installed on the circuit-breaker are available to enable an indication of the circuit-breaker's status. A special version of the auxiliary
contacts is also available (gold plated contacts) for a rated voltage under 24 V (digital signal).
Un In max T Un In max cosϕ

ϕ
125 V DC 0.3 A 10 ms 250 V AC 5A 0.3
250 V DC 0.15 A 10 ms
The versions available are:
a) Electrical signalling for circuit-breaker open/closed

It is possible to have electrical signalling of the circuit-breaker status (open/closed) 4, 10 or 15 auxiliary contacts.
The auxiliary contacts can have the following configurations:
– 4 break/make contacts for PR121 (2 normally open + 2 normally closed)
– 4 break/make contacts for PR122/ PR123 (2 normally open + 2 normally closed + 2 for the release)
– 10 break/make contacts for PR121 (5 normally open + 5 normally closed);
– 10 break/make contacts for PR122/ PR123 (5 normally open + 5 normally closed + 2 for the release)
– 15 supplementary break/make contacts which can be mounted outside the circuit-breaker.
The basic configuration described above can be modified by the user to indicate normally open or normally closed by repositioning the rapid
connector on the microswitch. When 10 contacts for PR122/ PR123 are required, zone selectivity and the PR120/K module are not available.
Reference Fig. in the electrical circuit diagrams: Q/1÷10 (21-22)
b) Electrical signalling for circuit-breaker connected/test isolated/disconnected

In addition to mechanical signalling of the position of the circuit-breaker, it is possible to have electrical signalling by means of 5 or 10 auxiliary
contacts which are installed on the fixed part.
Only available for circuit-breakers in withdrawable versions for installing on the fixed part.
The auxiliary contacts can have the following configurations:
Reference figure in the electrical circuit diagrams: S75I (31-32) - S75T (31-32) - S75E (31-32)
– 5 contacts; group consisting of 2 connected signalling contacts, 2 disconnected signalling contacts and 1 test position signalling contact (main
contacts isolated, but sliding contacts connected)
– 10 contacts; group consisting of 4 connected signalling contacts, 4 disconnected signalling contacts and 2 test position signalling contacts (main
contacts isolated, but sliding contacts connected).
c) Contact for signalling closing springs loaded

This consists of a microswitch which allows remote signalling of the state of the circuit-breaker operating mechanism closing springs. The contact
is always supplied with the spring loading geared motor.
Reference figure in the electrical circuit diagrams: S33 M/2 - (11)
d) Contact for signalling undervoltage release energized (C.aux YU)

The undervoltage releases can be fitted with a contact (by choise, preferably closed or open) for signalling undervoltage energized for remote
signalling of the state of the undervoltage release.
Reference figure in the electrical circuit diagrams: (12)
Transformers and operation counters

a) Current sensor for the neutral conductor outside the circuit-breaker
The sensor allows neutral protection by means of connection to the overcurrent release and is available only for three-pole circuit-breakers. It is
supplied on request.
Reference figure in the electrical circuit diagram: UI/N

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b) Homopolar toroid for the main power supply earthing conductor (star center of the transformer)
PR122 and PR123 microprocessor-based electronic releases may be used in combination with an external toroid located on the conductor, which
connects the star center of the MV/LV transformer (homopolar transformer) to earth: in this case, the earth protection is defined as Source Ground
Return.
The In of the toroid can be regulated to 100 A, 250 A, 400 A, 800 A by using different combinations of the connections.
Reference figure in the electrical circuit diagrams: UI/0.
c) Homopolar toroid for residual current protection
The toroid enables the residual current protection to be activated and can be combined with the PR122/P LSIRc, PR122/P LSIG releases (with
PR120/V) and PR123/P. The accessory is fitted with a dip-switch multiple selectors which is reset according to the required sensitivity (up to 3A or
30A) . The accessory is for installation on the busbars and is available in different sizes: up to 3200A for three- and four-pole circuit-breakers, up
to 4000A for three-pole circuit-breakers.
d) Mechanical operations counter
This is connected to the operating mechanism by means of a simple lever mechanism. It indicates the number of circuit-breaker mechanical
operations. The indication is visible on the front of the circuit-breaker from the outside.
10.2 Mechanical locks

a-b) Lock in open position
Different mechanisms are available which enable the circuit-breaker to be locked in the open position.
These devices can be controlled by:
– a key (a): a special circular lock with different keys (for a single circuit-breaker) or with the same keys (for several circuit-breakers). In the latter
case, up to four different key code numbers are available.
– padlocks (b): up to 3 padlocks (not supplied): Ø 4 mm.
c) Circuit-breaker lock in connected - test isolated - disconnected position

This device can be controlled by a special circular lock with different keys (for a single circuit-breaker) or with the same keys (for several circuit-
breakers available up to four different key code numbers) and by padlocks (up to 3 padlocks, not supplied - Ø 4 mm).
Only available for circuit-breakers in withdrawable versions for installing on the moving part.
d) Accessories for lock in test isolated - disconnected position

In addition to the circuit-breaker lock in the connected - test isolated - disconnected position, this allows locking only in the disconnected or test
isolated positions. Only available for circuit-breakers in withdrawable versions for installing on the moving part.
e) Accessories for shutter padlocks

They enable the shutters to be padlocked (installed on the fixed part) in the closed position.
Only available for circuit-breakers in withdrawable versions for installing on the fixed part.
f) Mechanical lock on compartment door

This prevents the compartment door from being opened when the circuit-breaker isclosed (and connected in the case of withdrawable circuit-
breakers) and prevents circuit-breaker closing with the compartment door open.
Transparent protection covers
a) Protection covers for opening and closing pushbuttons

These protection covers, applied over the opening and closing pushbuttons, prevent the corresponding circuit-breaker operations except by using
a special tool.
b) IP54 door protection

This is provided by means of a transparent plastic escutcheon plate which fully protects the front of the circuit-breaker and ensures a degree of
protection to IP54. Mounted on hinges, it is fitted with a key lock.

This mechanism makes the mechanical interlock between two or three circuit-breakers (even of different sizes and in any fixed/withdrawable version)
by means of a flexible cable. The electrical circuit diagram for the electrical changeover by means of a relay (to be provided by the customer) is
supplied with the mechanical interlock. The circuit-breakers can be installed vertically or horizontally.
4 types of interlocks are available:
type A: between 2 circuit-breakers (power supply + emergency)
type B: between 3 circuit-breakers (2 power supplies + emergency)
type C: between 3 circuit-breakers (2 power supplies + bus-tie)
type D: between 3 circuit-breakers (3 power supplies / a single closed circuit-breaker)
The emergency power supply is generally supplied in order to substitute the normal power supply in two cases.
- to supply safety services for people.
- to supply essential parts of the installation, other than the safety services.
The change over from the normal supply to the emergency supply, can be done manually (with a local or remote control) or automatically. For the
change over, the circuit-breakers must be supplied with the necessary accessories for the electrical remote control and for electrical and mechanical
interlocks provided for the changing over.
The accessories can be for example:
- the shunt opening release
- the shunt closing release
- the motor operator
- the auxiliary contacts.

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For the change over, the customer can use a suitable electronic relay, whose diagram is supplied by ABB SACE. The mechanical interlocks between
two or three circuit-breakers are made by means of cables that can be used for circuit-breakers installed, either side-by-side or one over the other.
Table of feasible mechanical interlocks between two or three circuit-breakers

Type of Number of Type of circuit-breaker Possible interlocks
interlocks circuit-breakers
A TWO a normal power supply unit the first circuit-breaker can be closed only if
and an emergency unit the second (emergency) breaker is open
B THREE a normal power supply unit and the first and third circuit-breakers can be
an emergency unit closed only if the second (emergency) breaker
is open. The latter can be closed only if
the first and third are open.
C THREE a unit of 2 supplies and a bus-tie. one or two circuit-breakers out of three can be
The two half-busbars can be supplied closed at the same time
by a single transformer (bus-tie closed)
or simultaneously by both
(bus-tie open)
D THREE a unit of 3 supplies / a single only one of the three circuit-breakers can be
closed circuit-breaker. Three supplies closed
(generators or transformers) on the same
busbar for which parallel operation is
not allowed
10.3 Spare parts and retrofitting

Spare parts
The spare parts available are:
– Shields and front escutcheon plate
– Opening solenoid for the PR121 / PR122 / PR123 overcurrent release
– Arcing chamber
– Closing springs
– Jaw-type isolating contact for fixed part of the withdrawable circuit-breaker
– Sliding earth contact (for withdrawable version)
– Fixed part shutters
– Complete pole
– Operating mechanism
– Current sensor and connection cables with the release
– Transparent protection for SACE PR 030/B power supply unit
– Tool case
– Front escutcheon plate for Ronis-type key lock
For further details, ask for the ABB SACE spare parts catalogue.
Retroffitting kit
The kits enable SACE Otomax and Novomax G30 circuit-breakers to be replaced, coupling the new circuit-breaker in the old switchboard.

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11. Protection releases - General notes
Emax, the range of ABB air circuit breakers, now has a new range of electronic relays.
These are called PR121, PR122 and PR123, and they substitute the previous range PR111, PR112 and PR113.
The new protection releases integrate all the functions of their predecessors, adding new and interesting technical features that are useful
for satisfying every current and future system installation need.
Every operational requirement is now met thanks to the different performance levels of the new relays and of the additional modules that
can be fitted inside them (PR120/V, PR120/K, PR120/D-M, PR120/D-BT).
A table can best illustrate the technical features and the mix and matchability of the three relays.
Function/Unit PR121 PR122 PR123

Current protections (L, S, I, G) S S S
Additional protections (U, OT) - S S
Voltage protections (D, UV, OV, RV, RP, UF, OF) - S (4) S
Harmonics analysis - - S
Temperature protection - S S
Local bus for separate auxiliary units S S S
Serial wire communication (RS485) - S (3) S (3)
Radio communication (wireless Bluetooth) S (1)
S (1,2)
S (1,2)
Data Logger - S S
Compatibility with SD.Pocket S S S
Compatibility with SD.Testbus S S S
Compatibility with PR010/T S S S
PR120/V Measuring (internal voltages module) - O S
PR120/K Signalling (internal signalling module) - O O
PR120/D-M Com (internal communication module) - O O
PR120/D-BT WL-Com (internal Bluetooth communication module) - O O
PR021/K (separate signalling unit) O O O
HMI030 (separate graphics interface) O O O
PR030/B (separate power supply unit) O S S
BT030 (separate Bluetooth communication unit) O O O
Key:
S : standard function/unit,
O : optional function/unit,
- : function/unit unavailable.
Notes:
1. : with separate BT030 unit (for temporary connections),
2. : with internal PR120/D-BT module,
3. : with PR120/D-M module,
4. : with PR120/V module.
The main features and improvements of the new relay PR12x with respect to the earlier PR11x are (depending on the combination of relay-
modules):
1. High current reading accuracy (1.5%) and numerous other functions.
2. The PR120/V module for measuring line voltages up to 690 V, is integrated in the relay, making a separate voltage transformer
unnecessary.
3. Double settings for the protection functions (PR123/P).
4. Input can be combined with actions selectable by the user (with PR120/K).
5. Four power outputs fully-configurable by the customer in terms of status, delay and type (with PR120/K).
6. Wireless Bluetooth connection to PDA and/or PC (with PR120/D-BT).
7. Freely available software for relay testing and maintenance.
8. High-performance data logger with 8 analogue signals and 4 digital signals, which can be synchronized with hundreds of events/
situations of the user’s choice.
9. Relay powered even with the circuit-breaker open, using the busbar voltages (with PR120/V).
10. New residual-current function (Rc).
11. Double protection G function, with simultaneous reading from two sensors (PR123).
12. Continuous control of the connection of the current sensors and trip coil (all relays).
13. Analysis up to the 40th harmonic.
14. Cause of trip is memorized even in self-powered mode (all relays).
15. PR121 with serial link for separate PR021/K and HMI030 module.
16. Extended neutral selection.
17. Double protection S (PR123).
18. Date and time in “real time” (all relays).

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11.1 Safety notes
WARNING: this symbol gives information about operations, actions or circumstances that can cause injuries to the personnel, damage
to the unit or economic losses.
Read this manual carefully and completely.

The use of this device should be reserved for qualified and expert personnel only.
If in doubt, about its safe usage, the unit must be put out of service to prevent any accidental use.
You must assume that safe usage is impossible if:

1. the unit shows visible signs of damage.
2. the unit does not function (for example with autotest or with the trip test unit).
3. the unit has been damaged in transit.
11.1.1 Notes for dielectric stiffness tests
Dielectric stiffness tests on the releases, inputs and outputs,

are not permitted.
11.2 Abbreviations and notes

11.2.1 Abbreviations
Abbreviations Meaning
BA Opening coil
BC Closing coil
CB Circuit Breaker (for example Emax)
BT030 Wireless communication unit
CS Current Sensor (current transformer)
PDA Pocket Pc with Bluetooth
Emax Series of ABB SACE air circuit-breakers
HMI030 Human Machine Interface
HW Hardware
In Rated current of the Rating Plug installe in the circuit-breaker
MT Thermal memory
Pn Circuit-breaker rated power
Pn phase Phase rated power
PR120/K Internal signalling unit of alarms and trips on the circuit-breaker
PR120/V Measuring module
PR120/D-M Communication module
PR120/D-BT Wireless communication module
BT030 Wireless communication unit
PR010/T ABB SACE unit test
PR121/P Protection relay for CB Emax
PR030/B ABB SACE power supply unit
Relay also called “protection unit” or “protection release”
RMS Root mean square value
TC Trip Coil (opening solenoid)
SdZ Zone selectivity
SGR External toroid
SW Software
i Test "i Test" button on the fron of relay
Trip CB opening, generated by the release
VT Voltage transformer (see also VS)
Un Rated voltage of the voltage transformers installed (phase voltage)
Vaux Auxiliary power supply
VS Voltage Sensor (see also VT)
11.2.2 Notes
A. Use the “Belden 3105A”- type two-wire cable for instance (not supplied by ABB SACE).
B. Use the “Belden 3106A”- type three-wire cable for instance (not supplied by ABB SACE).
C. The unit has a “backup-protection” function; if the first command to the opening solenoid does not open immediately the circuit-breaker (TC
partially fault), TRIP commands are repeatedly sent until the circuit-breaker opens (providing a Vaux is present) or the current disappears (if self-
power supplied). The “backup” condition can be signalled by configuring the unit relays; using the “YO back” selection, it is possible to command
the "opening coil(YO)" accessory as another opening device if TC does not work.

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12. SACE PR121/P Release - Identification
The PR121/P units available, in accordance with the IEC Standards, with the various default and optional protections and modules, are illustrated
in the figure below.
PR121/P PR121/P PR121/P

Protections
Optional modules available

BT030 Opt
12.1 Standard
The PR121/P has been designed to work in accordance with the following international standard:
IEC 60947-2 Low voltage apparatus. Circuit-breakers.
12.2 Specifications
12.2.1 General
The PR121/P unit is a high-performance self-supplied protection unit with Protection functions for the ABB SACE 'Emax' range of 3-pole and 4-
pole low voltage air circuit-breakers. The unit's user interface also enables parameter setup and complete pre-alarm and alarm management with
LED warning/alarm indicators for the protection and watchdog functions.
Depending on the version, the protections available are as follows:
Symbol Protection against

L overload with inverse long time delay
S short-circuit with adjustable delay
I instantaneous short-circuit
G earth fault with adjustable delay
The PR121/P can be installed on 3-pole CBs with and without an external neutral, or on 4-pole CBs.
It should be noted that the reference current for the PR121/P is the In (the rated current defined by the Rating Plug) and not the Iu (the uninterrupted
rated current of the CB itself).
Example: the CB E1B800 with a 400A Rating Plug has an Iu of 800A and an In of 400A.
The unit opens the circuit breaker in which it is installed by means of the TC, which takes effect directly on the device's mechanical leverism.
The unit is made using digital microprocessor technology and interfaces with the user by means of DIP switches. The unit's protection parameters
and general operating mode can be set entirely by the user.
12.2.2 Electrical characteristics

Rated operating frequency 50/60 Hz ±10%
Pass band 3000 Hz max
Peak factor 6.3 max @ 2 In
MTBF (MIL-HDBK-217E) 15 years @ 45°C
12.2.2.1 Self-supply
The unit requires no outside power source for the protection and alarm signal functions. It is self-supplied by the current sensors installed on the
circuit breaker. For it to function, it simply needs the current defined below to be flowing in at least one phase. An outside power source can, however,
be connected to enable other functions and particularly for its connection to the separate devices: HMI030 and PR021/K.
The characteristics of the busbar current are given in the table below:
Characteristics E1 - E2 - E3 E4 - E6
Single-phase minimum busbar current for enabling relay 70 A 140 A
12.2.2.2 Auxiliary power supply

The outside auxiliary power supply is provided using a galvanically-separated power pack.
Since the auxiliary voltage needs to be isolated from the ground, "galvanically separated converters" in accordance with
the IEC standard 60950 (UL 1950) or the equivalent IEC 60364-41 and CEI 64-8 have to be used to guarantee a current in
common mode or leakage current (as defined in IEC 478/1 and CEI 22/3) no greater than 3.5 mA.

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The presence of the auxiliary power supply enables the relay unit to be used even with the circuit breaker open.
The characteristics of the power pack are given in the table below.
Characteristics Version PR121/P

Auxiliary voltage
(galvanically separated) 24V DC ±20%
Maximum ripple 5%
Inrush current @ 24 V ~10A for 5ms
Rated power @ 24 V ~2W
12.2.3 Environmental characteristics

Operating temperature -25°C ... +70°C
Storage temperature -40°C ... +90°C
Relative humidity 0% ... 98% with condensation
Degree of protection (with PR121/P installed in the circuit-breaker) IP 30
12.2.4 Communication bus

Local internal bus on rear connector; RS485 physical interface, ABB SACE protocol.
12.2.5 Protection functions

The PR121/P unit provides 5 independent protection functions, i.e.:
1. protection against overload with inverse time “L”;
2. protection against short-circuit with adjustable delay "“S”;
3. protection against instantaneous short-circuit “I”;
4. protection against earth fault with adjustable delay “G”;
5. protection against instantaneous short circuit at high currents “Iinst”.
The PR121/P unit allows the neutral pole's current signal to be processed using different relationships with the value of the phases.
N.B.: Beyond 15.5xIn of current on the Ne, the protection is considered as being set to 100%.
A timing indication ("alarm" LED) is provided on the front of the unit, which is enabled during an alarm for each protection; it is disabled when the
alarm condition ceases or when the protection has been tripped.
The unit also has a "backup protection" function. If the circuit breaker does not open immediately the first time the Trip Coil is hit (partial TC failure),
TRIP commands are sent repeatedly until the circuit breaker opens.
For the inverse-time protections, the relationship between trip time and overcurrent is given by the formula: t=k/I2.
For the fixed-time protections with an adjustable delay, the relationship adopted is as follows: t=k.
12.2.5.1 Calculating the RMS and Peak

All the protection functions do their respective processing on the basis of the real rms value of the currents (the protection G is disabled for current
values greater than 8 In [where I4≥0.8In], greater than 6In [where 0.5In ≤ I4<0.8In] and greater than 4 In [where I4<0.5In]).
For currents higher than 6xIn, and for the "I" function, processing takes into account the peak value divided by 2 (so the sinusoidal wave form
is considered); this is due to incompatibility between the trip time and the rms value calculation time.
If the waveform has a deformation beyond the declared limit (6.3@2In), the tolerance for the calculation of the true rms value will increase.
12.2.5.2 Watchdog
The PR121/P unit provides some watchdog functions to guarantee the proper management of relay malfunctions. These functions are as follows:
Rating PLUG validity
Watchdog for proper current sensor connection (CS). Any anomalies are indicated by the LED coming on, as explained in par. 12.7.1.
Watchdog for proper opening solenoid connection (TC). Any anomalies are indicated by the LED coming on, as explained in par. 12.7.1.
Watchdog for protection against Hw Trip. If the sensors are disconnected or there is a Rating Plug error, a CB opening command is issued
due to the TC being activated.
12.2.6 Description of the protection functions
12.2.6.1 Protection “L”

The "L" is the only protection that cannot be disabled because it is for self-protection against overloading of the relay itself.
The type of curve that can be set is t=k/I2.
The inverse-time protection trip time is given by the expression
⎡ 9 ⋅ t1 ⎤
max ⎢ ,1 ⎥ where lf ≤ 12ln, 1 s where lf > 12ln
⎣ (lf / l1 )2 ⎦
If is the fault current and I1 the protection threshold, established by the user.
NB: Time expressed in seconds.
12.2.6.2 Protection “S”

This protection can be disabled; it can be of the fixed time (t=k) or inverse time (t=k/I2) type; in the latter case, the trip time is given by the expression
⎡ 100 ⋅ t 2 ⎤
max ⎢ , t 2 ⎥ where lf > l2
⎣ (lf )2
⎦

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12.2.6.3 Protection “I”
This protection can be disabled; it is of the fixed time (t=k) type, and is designed for a nil intentional delay.
12.2.6.4 Protection “G”

This protection can be disabled; it can be of the fixed time (t=k) or inverse time (t=k/i2) type; in the latter case, the trip time is given by the expression:
⎡ 2 ⎤
max ⎢ , t4 ⎥ where l = lf / l4
⎣ l2 ⎦
The PR121/P unit can provide earth fault protection, achieved inside the relay by vectorially adding together the phase and neutral currents. The
fault current is defined by the following formula:
r r r r r
I G = I1 + I 2 + I 3 + I N
If the circuit reveals no faults, the module of the sum of these currents is always nil; vice versa, the value of the fault current takes on a larger and
larger value depending on the entity of the fault.
12.2.6.5 Protection against instantaneous short-circuit "Iinst"

This function has a single fixed-time protection curve.
When the protection is tripped, the circuit breaker is opened by the opening solenoid (TC).
12.2.7 Summary table of protections

Disabling
Protection Trip threshold Trip time Trip Trip

threshold time
tolerance tolerance
L I1 = 0.4 - 0.425 - 0.45 - 0.475 - 0.5 - Release between

(t=k/I2) 0.525 - 0.55 - 0.575 - 0.6 - 0.625 - t1 = 3 - 12 - 24 - 36 - 48 - 72 1.05 and 1.2 x I1 ± 10% If ≤ 6 x In
0.65 - 0.675 - 0.7 - 0.725 - 0.75 - 108 - 144 s (1) ± 20% If > 6 x In
0.775 - 0.8 - 0.825 - 0.85 - 0.875 - @ 3 I1
0.9 - 0.925 - 0.975 - 1 x In
S I2 = 1 - 1.5 - 2 - 2.5 - 3 - 3.5 - 4 - 5 - where I > I2 ± 7% If ≤ 6 x In The best of the two data:
(t=k) 6 - 7 - 8 - 8.5 - 9 - 9.5 - 10 x In t2 = 0.1 - 0.2 - 0.3 - 0.4 - 0.5 - 0.6 ± 10% If >6 x In ± 10% or ± 40 ms
0.7 - 0.8 s
S I2 = 1 - 1.5 - 2 - 2.5 - 3 - 3.5 - 4 - 5 - t2 = 0.1 - 0.2 - 0.3 - 0.4 - 0.5 - 0.6 ± 7% If ≤ 6 x In ± 15% If ≤ 6 x In
(t=k/I2) 6 - 7 - 8 - 8.5 - 9 - 9.5 - 10 x In 0.7 - 0.8 s ± 10% If >6 x In ± 20% If >6 x In
@ 10 In
I I3 = 1.5 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 - 10 - ≤ 30 ms ± 10%
(t=k) 11 - 12 - 13 - 14 - 15 x In
G I4 = 0.2 - 0.3 - 0.4 - 0.6 - 0.8 - 0.9 - where I > I4 ± 7% The best of the two data:
(t=k) 1 x In t4 = 0.1 - 0.2 - 0.4 - 0.8 s ± 10% or ± 40 ms
G I4 = 0.2 - 0.3 - 0.4 - 0.6 - 0.8 - 0.9 - t4 = 0.1 - 0.2 - 0.4 - 0.8 s ± 7% ± 15%
(t=k/I2) 1 x In @ 4 I4
I inst Automatic, defined by SACE Instantaneous ± 5% +1ms

(1)
The minimum value of this trip is 1s regardless of the type of curve set For all cases not covered by the above hypotheses, the following tolerances apply:
(self-protection).
(2)
These tolerances apply in the following conditions:
- self-powered relay at full power (without start-up) Protections Trip threshold Trip time
- two-phase or three-phase power supply L Release between 1.05 and 1.25 x I1 ± 20%
- trip time setting ≥ 100ms S ± 10% ± 20%
I ± 15% ≤ 60ms
G ± 10% ± 20%
12.2.8 Measurements Others ± 20%
The PR121/P protection unit can take the various types of measurement shown in the following table with the corresponding tolerances.
Type of measurement Tolerance

Range %
Phase and neutral current 0.3 ... 6 In 1.5

Earth fault current 0.3 ... 4 In 1.5
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12.2.9 Trip curves
The trip curves provided are merely for guidance and only show a sub-group of the possible selections (see par. 12.2.7).
12.2.9.1 Trip curves for functions L-I
12.2.9.2 Trip curves for functions L-S(t =k/I2)-I
k
t=
I2

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12.2.9.3 Trip curves for functions L-S(t=k)-I
t=k
12.2.9.4 Trip curves for function G
k
t=
I2
t=k

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12.3 Other functions
12.3.1 Indication of the cause of the trip and trip test button
Using the "i Test" button, you can retrieve the information stored in the past 48 hours. You can also perform a trip test by pressing and holding
the button for 7 seconds with Vaux and/or a current to the phases, and an Autotest by pressing and holding the button for 3 seconds, again with
the PR030/B battery unit connected.
12.4 Putting into service

12.4.1 Connections
For the connections provided by the user, it is recommended that you comply strictly with the recommendations contained in
this document.
This will enable us to satisfy all the international reference standards and guarantee the perfect operation of the relay even under
severe environmental and electromagnetic conditions. Take particular care with the earthing connections.
12.4.2 CS and TC connection check

If the PR121/P has been installed by the user, it is advisable (with the CB open and Vaux or the PR030/B) to check the proper
connection of the TC and/or CS cables before putting the circuit breaker into service; if this has not been done, make the right
connections. If any of the red LEDs come on, this means an error in the connection of the CS and/or TC. See par. 12.7.1.
12.4.3 Current sensor connection for external neutral

If you want to connect the current sensor for the external neutral conductor to a three-pole circuit breaker, remember to set
InN accordingly (see par 12.5, ref. 14)
During this procedure, the circuit breaker must be open and preferably isolated.
12.5 User interface
Captions on the front of the PR121/P unit:
Ref. Description
1 Alarm indicator LED for protection function L
2 Alarm indicator LED for protection function S
3 Alarm indicator LED for protection function I
4 Alarm indicator LED for protection function G
5 DIP switch for fine-setting of current threshold l1
6 DIP switch for the main setting of the current threshold l1
7 DIP switch for setting current threshold I2
10 DIP switch for setting trip time t1
11 DIP switch for setting trip time t2 and type of curve

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Ref. Description
12 DIP switch for setting trip time t4 and type of curve
13 Position indicator for the DIP switches for the mains frequency
14 Position indicator for the DIP switches for setting the neutral protection
15 Rating plug
16 Position indicator for the DIP switches for setting the threshold I1
20 Position indicator for the DIP switches for setting the time t1
23 DIP switch for setting the mains frequency and adjusting the neutral protection
24 "i Test" test and info button
25 Test connector for connecting or testing the release using an external device (PR030/B battery unit, BT030 wireless
communication unit and SACE PR010/T unit)
26 Serial number of the PR121/P protection release
12.5.1 Trip Test

Before you start, it is advisable to run a test ("Trip Test") on the whole TC chain by pressing and holding the button "i Test" for at least 7 s. A positive outcome
is shown by the circuit-breaker opening (see Watchdog). To be able to do the test, you need to connect the PR030/B battery unit.
12.5.2 Initial settings

ABB SACE will see to applying the adhesive labels on the PR121/P for all the variables relating to the circuit breaker (e.g. Type of circuit breaker,
Rating Plug size, etc.)
It should be noted that ABB SACE provides a sensible definition for each possible setting (see par. 12.5.4).
Before putting the PR121/P into service, it is nonetheless absolutely essential for the user to carefully define each parameter
that can be changed.
12.5.3 Changing protection functions

This paragraph enables the user to set the protection functions implemented in the PR121/P unit. Only the setting methods and which values can
be selected are explained here. For all other information on the technical characteristics of the protection functions, see par.12.2.5.
No parameter settings can be made if the PR121/P unit is in alarm conditions.
12.5.3.1 Example of setting

In the diagrams on the front plate (see par. 12.5) relating to the settings, the position of the DIP switch is indicated by the white part.
An example of how to set the DIP switch for the protection function L is given below, where In = 2000A:
Frequency
Frequency
A faulty configuration of the dip-switches generates a configuration error which is signalled by means of a LED (see par.12.7.1).

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12.5.4 PR121/P default settings
The PR121/P is supplied by ABB SACE with the following preset parameters:
# Protection Thresholds Time

1 L 1 In 144 s
2 S Off 0.1 s
3 I 4 In --
4 G Off 0.1 s
15 Net Frequency 50 Hz
18 Neutral sel. 50 %
12.6 Operating instructions / Operation in service
12.6.1 Adjusting the neutral

The neutral protection is normally set to a current value 50% of the adjustment made on the phases.
In some installations, where particularly high harmonics occur, the current circulating on the neutral may be higher than that of the phases.
In the SACE PR121/P release, this protection can be set for the following values: InN =0 - 50% - 100% - 200% * In.
The table below shows the values that can be set adjusting the neutral in the various possible combinations between types of circuit-breaker and
adjustment of the threshold In.
With three-pole circuit breakers, whitout external neutral sensor, the adjustment of the neutral must be set to OFF.
12.6.2 Table of neutral adjustments
Adjustments of the threshold I1 (Protection L)

Circuit breaker size I1 ≤ 0.5 I1 > 0.5
E1 50-100-200% 50-100%
E2 50-100-200% 50-100%
E3 50-100-200% 50-100%
E4 50-100% 50%
E4/f 50-100-200% 50-100%
E6 50-100% 50%
E6/f 50-100-200% 50-100%
Note 1: The I1=1In setting is intended as the maximum adjustment of the protection against overload. The actual maximum allowable adjustment must take into account
any temperature derating, the terminals used and the altitude.
Failure to comply with the setting limits for “I1” and “InN" can damage the circuit breaker, with consequent risks to the operator
too.
The relay records any erroneous setting between I1 and the neutral setting and signals this by means of a LED (see par. 12.7.1).
12.6.3 Replacing an electronic release

To complete the procedure for installing PR121/P take the following steps:
1. With the circuit breaker open and possibly disconnected, install the protection unit on the circuit breaker.
2. Power the unit with the PR030/B ONLY.
3. If there are no errors other than the configuration error (flashing orange LED), press and hold the "i Test" button for a few seconds
until all the red LEDs start to flash to confirm that installation is complete.
4. Remove the PR030/B.
5. Power the relay from any supply (Vaux, PR030/B, PR010/T).
6. Make sure there are no configuration errors (all LEDs off).
7. Circuit breaker and release can now be put into service.

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12.7 Definition of the alarms and signals for the PR121/P unit
12.7.1 Optical signals

The following table shows how the LEDs are managed in accordance with the IEC standard 60073 (and clause 4.2.3.2 in particular).
The LED alerts you to the status of the function set on its zone; e.g. in the figure in par. 12.5 the LED referenced as 1 identifies the status of the
function L.
LED flashing with LED flashing with
Flashing
two 0.5 sec pulses one pulse every 3
slowly (0.5Hz) Flashing fast (2Hz) LED on permanently
every 2 sec sec
Type of information All LEDs All LEDs Single LED All LEDs Single LED All LEDs Single LED
ORANGE
ORANGE
RED
RED
RED
RED
RED
RED
RED
TC error
CS error
Rating Plug error
Protection timing alarm
Last trip (1)
Test button pressed and x
no failure detected (2)
L prealarm
Settings inconsistency
Normal relay
operation (3)
HW Trip(4)
(1) Information on the "Last trip" is displayed when the LED relating to the protection unit that has been tripped comes on. The LED remains on
for 2 sec, or permanently if an outside power supply (from the PR030/B) is being used.
(2) The information is displayed with all the LEDs on for as long as the test button is pressed and held, or for 2 sec.
(3) If other signals aren't present, the unit's operating mode is indicated 3 sec after the unit has been turned on.
(4) Configuration or connection error.
12.7.2 Troubleshooting
The following table lists a series of typical service conditions, to help you understand and solve hypothetical faults or malfunctions.
N.B.:
1. Before consulting the following table, check for a few seconds for any optical signals provided by the LEDs.
2. FN indicates the normal operation of the PR121/P.
3. If the following suggestions fail to solve the problem, please contact the ABB SACE customer support service.
N° Situation Possible causes Suggestions

1 The trip test cannot be run 1. The busbar current is > 0. 1. FN
2. The TC is not connected 2. Check TC connection (see par.12.4.2)
2 Trip times lower 1. Threshold too low 1. Correct threshold
than expected 2. Curve too low 2. Correct curve
3. Incorrect neutral selection 3. Correct neutral adjustment
3 Trip times higher 1. Threshold too high 1. Correct threshold
than expected 2. Curve too high 2. Correct curve
3. Curve type "t=k/I2" 3. Select curve type "t=k"
4. Incorrect neutral selection 4. Correct neutral adjustment
4 Rapid trip, with I3=Off Iinst tripped FN short-circuit with high I
5 Earth fault current beyond threshold, G function automatically inhibited FN
but no trip occurs
6 Expected trip does not happen Function OFF FN enable protection function
if necessary

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12.7.3 In the case of a fault
If the PR121/P is suspected of being faulty, there are signs of malfunctions or it has generated an unexpected trip, we advise
you to strictly follow the recommendations below:
1. Press the "i Test" button (within 48 hours of opening the CB) and make a note of which LED is on, also recording the type of CB, the number
of poles, any connected accessories, the In, and the serial number (see par. 12.5).
2. Prepare a brief description of the opening (when did it happen?, how many times?, was it always under the same conditions? what type of
load? what current? is the event reproducible?)
3. Send/communicate all the information collected, together with the circuit diagram for the circuit-breaker, to your nearest ABB Customer Support
service.
The more the information given to the ABB Customer Support service is complete and accurate, the easier the technical analysis on the problem
encountered will be, enabling us to take all action to help the user without delay.
12.8 Accessories
12.8.1 ABB SACE PR010/T test and configuration unit
Testing with the SACE PR010/T unit enables you to monitor the proper operation of thresholds and trip times of the protection functions "L", "S",
"I", and "G". The test unit is wired to the relay by a dedicated connector (see ref. 25 par.12.5).
12.8.2 BT030 communication unit

Using the BT030 wireless communication unit, the PR121/P can be connected by radio to a hand-held PC (PDA) or normal PC, thus extending
the amount of information available to the user. In fact, using the SD-Pocket communication software by ABB SACE, you can read the values of
the currents flowing through the circuit breaker, the value of the last 20 currents broken and the protection settings.
12.8.3 PR021/K and HMI030 units

The PR121/P can also be connected to the optional PR021/K external signalling unit (see par. 16), for the signalling by means of no-potential power
contacts of alarms and tripped protections, and to the HMI030 unit to view various kinds of information on the display.
12.8.4 PR030/B power supply unit

The PR030/B power supply unit is a separate unit for powering the relay, auto test and trip test.

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13. SACE PR122/P Release - Identification
The PR122/P units available, in accordance with the IEC standards, together with the various protections and the various standard and optional
modules, are illustrated in the following figure.
PR122/P PR122/P
Protections PR122/P PR122/P
For all versions

PR120/V - MEASURING
PR120/D-M - COM
PR120/K - SIGNALLING
PR120/D-BT - WL-COM
13.1 Standard
The PR122/P has been designed to work in accordance with the international standard:
13.2 Specifications
13.2.1 General
The PR122/P is a high-performance self-supplied protection unit with Protection, Measurement, Data storage, Communication (optional),
Self-test, Load control and Zone selectivity functions for the ABB SACE 'Emax' range of 3- and 4-pole low-voltage air circuit breakers. The unit's
user interface also enables parameter setup and complete the prealarm and alarm management for the protection and watchdog functions.
The protections available are:

S short-circuit with adjustable delay
U phase unbalance
OT temperature out of range
It should be noted that the reference current for the PR122/P is the In (the rated current defined by the front Rating Plug) and not the Iu (the
uninterrupted rated current of the CB itself). Example: the CB E1B800 with a 400A Rating Plug has an Iu of 800A and an In of 400A.
The protection unit is self-supplied by current sensors and primary voltages if the PR120/V module is installed.
The unit is made using digital microprocessor technology and interfaces with the user by means of a graphic display and keyboard.
With the optional PR120/V module, the PR122/P also assures the following protections:
UV undervoltage
OV overvoltage
RV residual voltage
RP reverse active power
UF underfrequency
OF overfrequency

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Peak factor 6.3 max @ 2 In
The self-supply enables the protection unit to be powered with the busbar current using current transformers.
Using this supply mode, the unit's protection functions are assured, however, not the accessory functions regarding the modules.
The characteristics are given in the table below:
General characteristics E1 - E2 - E3 E4 - E6
Minimum single-phase busbar current for enabling relay 70 A 140 A

The external auxiliary power supply is provided using a galvanically-separated power pack.
common mode or leakage current (as defined in IEC 478/1 and CEI 22/3) no greater than 3.5mA.
The presence of the auxiliary power supply enables the relay unit to be used even with the circuit breaker open, as well as powering all the modules,
with the exception of the PR120/V module, which is powered by means of a connection to the busbars.
The characteristics of the power pack are given in the table below:

Auxiliary voltage
Maximum ripple 5%
13.2.2.3 Powered by the PR120/V module

For a full explanation of the features of the PR120/V, see par. 15.1.

Degree of protection (with PR122/P installed in the CB) IP 30
13.2.4 Description of inputs/outputs
13.2.4.1 Binary opto-insulated inputs

– K51/SZin: Zone selectivity: input for protection S
(only with Vaux)
– K51/Gzin: Zone selectivity: input for protection G
(only with Vaux)
13.2.4.2 Binary opto-insulated outputs
– K51/SZout: Zone selectivity: output for protection S

(only with Vaux)
– K51/GZout: Zone selectivity: output for protection G
(only with Vaux)

Local internal bus on rear connector; RS485 physical interface, ABB SACE protocol
External system bus, RS 485 physical interface, Modbus RTU protocol, baud rate 9600-19200 bps.

The PR122/P protection unit carries out 7 independent protection functions. In particular:
1. Protection against overload with inverse time “L”;
2. Protection against short-circuit with adjustable delay “S”;
3. Protection against instantaneous short-circuit “I”;
4. Protection against earth fault with adjustable delay “G”;
5. Protection against instantaneous short circuit at high currents "Iinst";
6. Protection against phase unbalance “U”;
7. Protection against overtemperature “OT”;

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The PR122/P unit allows current signal processing of the neutral pole with different relationships relative to the value of the phases.
A timing indication (message + "alarm" LED) is provided on the unit's display, which is activated during a protection alarm. It is disabled when
the alarm condition ceases or when the protection has been tripped. When the circuit breaker opens, the page with the "Trip" data is displayed
(when "i Test" is pressed, or automatically in the presence of Vaux).
With the optional PR120/V module, the PR122/P unit also has the following protection functions:
8. Protection against undervoltage “UV”;
9. Protection against overvoltage “OV”;
10. Protection against residual voltage “RV”;
11. Protection against reverse active power “RP”;
12. Underfrequency “UF”;
13. Overfrequency “OF”;
13.2.6.1 Calculating the RMS and peak

All the protection functions do their respective processing on the basis of the real rms value of the currents and voltages (the protection G is disabled
for current values greater than 8 In [where I4≥ 0.8In], greater than 6In [where 0.5In≤ I4<0.8In] and greater than 4In [where I4<0.5In]).
If the waveform has a deformation beyond the declared limit (6.3@2In), the tolerance for the calculation of the true rms value will increase. With
the optional PR120/V module, the UV, OV, RV voltage protections always work on the basis of the true rms value of the voltages.
13.2.6.2 Mains frequency

The PR122/P unit constantly measures the frequency of the mains voltages it is connected to.
If the frequency goes out of the permitted range by ±10% in relation to the rated frequency selected (50 or 60Hz), the "warning" LED comes on
and the warning message is displayed (see par. 13.6.3).
The signal can be combined with a relay of the PR120/K module or with those of the PR021/K unit.
13.2.6.3 Harmonic distortion

The PR122/P unit signals that a peak factor of 2.1 has been exceeded with a warning message and the "warning" LED lighting up (remember
that the IEC 60947-2 standard annex "F" establishes that the protection unit must function regularly with a peak factor ≤ 2.1, up to 2x In).
13.2.6.4 Circuit-breaker state

If an auxiliary supply is used, or it is powered from the optional PR120/V, the PR122/P unit records the state of the circuit breaker by means of
specific wiring on the circuit breaker. In the case where the presence of current is determined with the circuit-breaker in the "OPEN" state, a state
error is signaled by a warning message being displayed (see par. 13.6) and the "warning" LED lighting up.
13.2.7 Measurement functions

The current measuring (ammeter) function is available on all versions of the SACE PR122/P unit.
The display shows histograms with the currents of the three phases and of the neutral on the main page. In addition, the current of the phase
under the greatest load is given in numerical form. Where applicable, the earth fault current is displayed on a separate page.
The ammeter functions both in self-supply mode and with an auxiliary supply. In the latter case, the display is backlit and the ammeter is always
active. The tolerance for the ammeter measuring chain (current sensor plus relay) is described in paragraph 13.2.9.11.2.
- Currents: three phases (L1, L2, L3), neutral (N), earth fault;
- Instantaneous current values over a given time interval (data logger)
- Maintenance: number of operations, percentage of contact wear, opening data storage (latest 20 trips and 20 events).
When the optional PR120/V is connected, the following additional measurement functions are provided:
- Voltage: phase-phase, phase-neutral, residual voltage;
- Instantaneous voltage values over a given time interval (data logger);
- Power: active, reactive, apparent;
- Power factor;
- Frequency and peak factor;
- Energy: active, reactive, apparent, meter;
- Maintenance: number of operations, percentage of contact wear, opening data storage.
13.2.8 Watchdog
The PR122/P unit provides some watchdog functions able to guarantee the proper management of relay malfunctions. These functions are as
follows:
Watchdog for presence of Auxiliary power supply with "plug" icon displayed.
Rating PLUG validity.
Watchdog for proper connection of the current sensors (CS). Any anomalies are indicated by a special alarm message and the "alarm" LED
coming on, and the circuit breaker opens after 1s.
Watchdog for proper connection of the Trip Coil (TC). Any anomalies are indicated by a special alarm message and the "alarm" LED coming
on; if the PR120/D-M module is installed, this activates the coil opening command (YO), thus opening the CB.
Watchdog for protection of Hw Trip. In the event of the sensors being disconnected or a Rating Plug error, a CB opening command is given
by the TC being enabled.

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The "L" is the only protection that cannot be disabled because it is for self-protection against overloading of the relay itself. The types of trip curves
settable are divided into two groups according to the standard they refer to.
Standard trip curve according to IEC 60947-2
Only one type of curve is settable (t=k/I2) as defined by the IEC standard 60947-2.
The protection trip time - inverse time - is given by the expression:
where lf < 12ln and 1 s where lf > 12ln where If is the fault current and I1 the protection threshold.

There are 3 types of curves settable, defined by the IEC standard 60255-3 as A, B and C.
The protection trip time - inverse time - is given by the expression
k If
t= •b where I =
(I )
α
−1 I1
Where If is the fault current and I1 the protection threshold specified by the user.
a and k are two parameters, suggested by the standard, which vary the type of slope selected (e.g. for type B slope a = 1 and k = 13.5);
b is a parameter introduced by SACE to increase the number of curves with the same slope.
13.2.9.1.1 Thermal memory “L”
The thermal memory function can be enabled for cable protection. It is based on the “τL” parameter defined as the trip time of the curve (t1)
selected at 1.25xI1.
The release trip time is certainly 100% of the one selected, after an interval τL has passed since the last overload or since the last trip. Otherwise,
the trip time will be reduced, depending on the overload which has occurred and on the time that has elapsed.
The PR122/P is fitted with two instruments to make up this thermal memory. The first is only effective when the release is powered (it also records
overloads that have not lasted long enough to trip the release), while the second works even when the release is not powered, reducing any trip
times in the case of an immediate reclosing and is enabled as soon as the CB is tripped.
It is the PR122/P release that automatically decides which of the two to use, according to the various situations.
NB: The thermal memory function can only be set if the type of curve selected is the standard one (t=k/I2) (see par. 13.2.9.1).
This protection can be disabled; it can be of the fixed time (t=k) or inverse time (t=k/i2) type; in the latter case, the trip time is given by the expression:
100 t2
max , t2 where If > I2 where If is the fault current and I2 the protection threshold.
(If)2

13.2.9.2.1 Thermal memory “S”
The thermal memory function can be enabled for cable protection in the case where the curve with inverse time is selected. This is based on the
"tS" parameter defined as the trip time of the curve (t2) selected at 1.5xI2. The other characteristics are the same as those for thermal memory
"L" (see par. 13.2.9.1.1).
13.2.9.2.2 Start-up threshold “S”
The start-up function can be selected in the case where the curve with fixed time is selected.
The function can be disabled and it is a setting characteristic of the single protection units.
The start-up function enables the protection threshold (S, I and G) to be changed during a time interval lasting "ts", starting from "start-up". The
latter must be intended as follows:
– Turning on of the relay, under self-supply;
– Passage of the peak value of the maximum current over 0.1xIn. A new start-up is possible after the current has dropped below 0.1xIn.
It h
Start Up Threshold I2
Threshold I2
Start Up
Programmed time ts
• Start-up time
The start-up time is common to all the protections involved.
Range: 0.1 s … 1.5 s, with steps of 0.01 s.

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13.2.9.2.3 Zone selectivity “S”
The zone selectivity function, guaranteed only if an auxiliary voltage is provided, enables the area of the fault to be isolated, only isolating the part
of plant nearest to the fault, while keeping the rest of the plant operational.
This is done by connecting all the zone selectivity outputs of the releases belonging to the same zone to one another (ZSO=K51/SZout) and taking
this signal to the zone selectivity input (ZSI=K51/SZin) of the next release on the supply side. If the wiring has been done correctly, all the zone
selectivity inputs of the last circuit-breakers in the chain and all the outputs of the circuit-breakers at the head of each chain must be empty.
RELAY 0
ZSI0
ZSO1 ZSO2 ZSOn

RELAY 1 RELAY 2 ○ ○ ○ ○
RELAY n
ZSI1 ZSI2 ZSIn
ZSO 1a ZSO1b
RELAY 1a RELAY 1b Area 2 ○ ○ ○ ○
Area n
Area 1
As a practical example, the figure above shows a fault on the load side of the "Relay 1a" isolated by the latter without the "Relay 1" or the "Relay
0" being affected; a fault immediately downstream from the "Relay 1" will be isolated by the latter without the "Relay 0" being affected, thus ensuring
that the Areas 2...n remain operational.
The ZSO output can be connected to a maximum of 20 ZSI relays on the supply side in the selectivity chain.
The maximum length of cable for zone selectivity, between two units, is 300 meters.
Use corded shielded two-wire cable (see note A to par. 11.2.2).
The shield must only be earthed on the circuit-breaker of the supply-side relay (ZSI side).
Wiring and enabling zone selectivity "S" is an alternative to using protection "D" (if any) and operation is only guaranteed when there is an auxiliary
voltage.
The following logical table is implemented to manage the Zone Selectivity Input (ZSI) and Zone Selectivity Output (ZSO) signals:
Zone selectivity Imax > I2 ZSI signal ZSO signal Trip T

Excluded NO 0 0 No trip
Excluded YES 0 0 t2 programmed
Inserted NO 0 0 No trip
Inserted YES 0 1 tselectivity
Inserted YES 1 1 t2 programmed
The time t2 must be set at a value corresponding to at least tselectivity +50 ms.

The protection is enabled/disabled from the menu.
In the case where zone selectivity "S" is active, during the trip of the relay for "I", the ZSO (or DFW and BFW) output signal is activated in any case
to guarantee correct operation of the relay on the supply side (and on the load side).
13.2.9.3.1 Start Up Threshold “I”

The start-up function can be selected.
The function can be enabled from the menu on the protection "I" page.
The function behaves in exactly the same way as the protection "S" (see par. 13.2.9.9.2).
This protection can be disabled; it can be of the fixed time (t=k) or inverse time (t=k/i2) type; in the latter case, the trip time is given by the expression
æ 2 ö
max ç , t4 ÷ where I=I /I , I is the fault current and I is the protection threshold.
ç I2 ÷ f 4 f 4
è ø
It is possible to disable the trip control of the protection ("EnableTrip: Off").

For the whole duration of the earth fault, circuit-breaker opening does not take place, but only the alarm condition is signaled
("Alarm" LED lit and alarm message).

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The PR122/P unit can provide two different types of earth fault protection:
Internal protection G
This is provided inside the relay by vectorially summing the phase and neutral currents. The fault current is defined by the following formula:
r r r r r
I G = I1 + I 2 + I 3 + I N
In the case when the circuit does not show any fault, the module of the sum of these currents is always nil; vice versa the value of the fault current
will take on an increasingly large value depending on the size of the fault. This operating mode is enabled by default.
N.B.: it can be used also with CS for an external neutral.
Protection G with external toroid "Source Ground Return"

Also called "Source Ground return", this can be carried out when there is the need to check operation of a machine (transformer, generator or
motor etc.) which has star-configured windings.
The protection is assured by physically positioning an external toroid on the cable connected from the star center of the machine to the earthing
connection point.
The induced current on the winding of the toroid is proportional to the fault current which, in this case, only transits in the above-mentioned toroid.
To work in this mode, "Ground protection" must be selected on the Circuit breaker Settings menu.
The external toroid must be connected to the PR122/P by means of a corded shielded two-wire cable (see note A in par. 11.2.2)
with a length not exceeding 15m.
The shield must be earthed both on the circuit-breaker side and on the toroid side.
It is indispensable for the star center to be connected openly to earth and for it not to be used as a neutral conductor too (as in the TNC system),
making a protection according to the TT system.
The protections G and Gext can be enabled simultaneously.
13.2.9.4.1 Start Up Threshold “G”
The function can be enabled and disabled on the protection "G" page.
13.2.9.4.2 Zone selectivity “G”
The zone selectivity function can be enabled providing the fixed time curve , the wiring and the zone selectivity "G" enabling alternative to the one for
"D" have been selected and the function is assured only if auxiliary voltage is provided.
Zone selectivity "G" can be active at the same time as zone selectivity "S".
The behavior and wiring of the function are identical to those indicated for zone selectivity "S" (see par. 13.2.9.2.3).
13.2.9.5 Protection against phase unbalance “U”

The protection with fixed time, which can be excluded, trips in the case when, for a time greater than or the same as the time t6 set, an unbalance
is determined between two or more phases higher than the set threshold I6.
I max − I min
The percentage of unbalance is therefore calculated %unb = ⋅ 100 where Imax is the maximum and Imin is the minimum phase current.
I max
It is possible to disable the trip control of the protection ("Enable Trip: Off").
In that case, for the whole duration of the unbalance the CB will not be opened, but only the condition will be signaled by means
of the "warning" LED lit up and a warning message.
When the value of the phase current is above 6xIn, the function "U" excludes itself because, in this case, the other protections
intervene because the fault is considered as a phase fault.
The protection is not enabled for maximum phase current values lower than 0.3xIn.
13.2.9.6 Protection against overtemperature inside the relay, “OT”

There is a sensor inside the PR122/P unit that monitors the temperature of the unit.
This enables the signalling of any abnormal temperature conditions, which could cause temporary or continuous malfunctions of the unit's electronic
components.
This protection has two states of operation:
State of "WARNING TEMPERATURE" with –25°C < temp. < -20°C or 70°C < temp. < 85°C : the display is turned off
and the "WARNING" LED flashes
State of "ALARM TEMPERATURE" with temp. < –25°C or temp. > 85°C : the display is turned off,
the "WARNING" led remains on and the Trip is activated (if enabled by means of the "Over Temper. Trip = On" parameter).
N.B.:
In the event of Warning and Alarm, the display is momentarily turned off, to preserve its functionality.
The monitored temperature is not visible on the display.
The protection is always active, both with auxiliary supply and in self-supply.
Disabling the Trip control of the protection means that the PR122/P unit could work, with the circuit-breaker closed, in a range
of temperatures where correct operation of the electronics is not guaranteed.

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13.2.9.7 Load control function
Single loads can be enabled/disabled on the load side before the overload protection L intervenes and trips the circuit breaker on the supply
side. This is done by contactors or switch-disconnectors (wired outside the release), controlled by the PR122/P by means of contacts on the PR120/
K module or on the PR021/K external unit.
The current thresholds are lower than those available with the protection L, so that the load control can be used to prevent tripping due to overloads.
The function is active when an auxiliary power supply is present, or supply from PR120/V (see par. 15.1.4)
The operating logic involves the activation of three contacts when the preset thresholds LC1, LC2 and Iw are exceeded.
Thresholds LC1 and LC2 are expressed as a percentage of I1 (current threshold specified for protection L) while the "warning current" Iw is expressed
as an absolute value. The allowable values are given in the following table:
Warning current Iw 0.30 ÷ 3.00 step 0.05xIn

Threshold LC1 50% ÷ 100% step 1% xI1
From the PR122/P you can associate each of the PR120/K or PR121/K contacts with a configuration (NO or NC), a delay and the eventual latch.
13.2.9.8 Voltage protections "UV", "OV", "RV" (PROTECTIONS AVAILABLE ONLY WITH THE ADDITIONAL PR120/V MODULE)
The PR122/P unit provides 3 voltage protections, which can be disabled, with fixed adjustable time (t = k), active both with self-supply and with
auxiliary supply:
– Undervoltage "UV"
– Overvoltage "OV"
– Residual voltage "RV"
The protections work on the voltages. The threshold voltages indicated refer to the line voltage.
Apart from the normal timing and "Trip" operation, the voltage protections can be in a state defined as "alarm" (with the "emergency" led on and
an alarm message displayed) providing there is an auxiliary or PR120/V module power supply. In fact, in the case where the circuit-breaker is
open and no current is detected, the timing leads to the "alarm" state and not to "TRIP". This is because the fault linked to the voltages can persist
even with the circuit-breaker open and the unit would therefore always be under "timing". When the circuit-breaker is closed or the passage of
a current is detected, you pass immediately from the state of "alarm" to "TRIP" without timing (see par. 13.3.2).
13.2.9.8.1 Protection “UV”
When the minimum phase voltage drops below the set threshold U8 the protection counts down the preset time interval t8 and then opens.
13.2.9.8.2 Protection “OV”
When the maximum phase voltage exceeds the set threshold U9 the protection counts down the preset time interval t9 and then opens.
13.2.9.8.3 Protection “RV”
When the residual voltage exceeds the set threshold U10 the protection counts down the preset time interval t10 and then opens.
The residual voltage U0 is calculated by vectorially summing the phase voltages. It is therefore defined by the following formula
U0 = U1 + U2 + U3
13.2.9.9 Reverse active power protection "RP"(AVAILABLE ONLY WITH THE ADDITIONAL PR120/V MODULE)
The PR122/P unit provides protection (which can be disabled) with an adjustable fixed time (t = k), against reverse active power, active both with
self-supply and auxiliary supply.
When the total reverse active power (sum of the power of the 3 phases) exceeds the set reverse active power threshold P11, the protection counts
down the preset time interval t11 and then opens.
The minus sign ('-') in front of the threshold and power indicates reverse power. The threshold is indicated as a percentage of "Pn", where "Pn"
is the rated power of the circuit-breaker (3 Vn*In).
13.2.9.10 Frequency protections "UF", "OF"(AVAILABLE ONLY WITH THE ADDITIONAL PR120/V MODULE)
The frequency protections record the mains frequency variations above an adjustable threshold (f12, t12) or below (f13, t13), generating an alarm
or the opening of the circuit breaker.

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13.2.9.11 Summary table of the protection function settings for the PR122/P
Start-up threshold
Thermal memory
Zone selectivity
Trip Time Threshold
of TRIP only
Protection Trip Threshold Trip time
tolerance (2)
Disabling
Disabling
tolerance (2)
L
(t=k/i2)curve 0.4xIn ≤ I1 ≤ 1xIn 3s ≤ t1 ≤ 144s(1), Release between ± 10%, If ≤ 6In
IEC 60255-3 step 0.01xIn step 3s at I=3xI1 1.05 and 1.2 x I1 ± 20%, If > 6In
S 0.6 xIn ≤ I2 ≤10xIn Min, 0.05s ≤ t2 ≤ 0.8s, step 0.01s ± 7%,If ≤ 6 In The best of the two data
(t=k) step 0.1xIn 0.10s ≤ t2 start-up ≤ 1.5s, step 0.01s ± 10%,If > 6 In ± 10% or 40 ms
0.6 xIn ≤ I2 start-up ≤10xIn 0.04s ≤ t2 sel ≤ 0.20s, step 0.01s
step 0.1xIn
S 0.6xIn ≤ I2 ≤10xIn 0.05s ≤ t2≤ 0.8s, ± 7%,If ≤ 6 In ± 15%, If ≤ 6In

(t=k/i2) step 0.1xIn step 0.01s at 10xIn ± 10%,If > 6 In ± 20%, If > 6In
I 1.5xIn ≤ I3 ≤ 15xIn ≤ 30 ms ± 10%

(t=k) step 0.1xIn
G(4) 0.20xIn ≤ I4 ≤1xIn 0.1s ≤ t4 ≤ 1s, step 0.05s The best of the two data
(t=k) step 0.02xIn 0.1s ≤ t4 start-up ≤ 1.5s, step 0.01s ± 7% ± 10% or 40 ms
0.04s ≤ t4 sel ≤ 0.2s, step 0.01s
G(4) 0.20xIn ≤ I4 ≤1xIn 0.1s ≤ t4 ≤ 1s, step 0.05s ± 7% ± 15%

(t=k/i2) step 0.02xIn
Gext 0.20xIn ≤ I4 ≤1xIn 0.1s ≤ t4 ≤ 1s, step 0.05s The best of the two data
(t=k) step 0.02xIn 0.1s ≤ t4 start-up ≤ 1.5s, step 0.01s ± 7% ± 10% or 40 ms
0.20xIn ≤ I4 ≤1xIn 0.04s ≤ t4 sel ≤ 0.2s, step 0.01s
step 0.02xIn
Gext 0.20xIn ≤ I4 ≤1xIn 0.1s ≤ t4 ≤ 1s, step 0.05s ± 7% ± 15%

(t=k/i2) step 0.02xIn
Gext Idn = 0.3-0.5-0.7-1.0 0.06-0.10-0.20-0.30-0.40-0.50

(Idn) 2.0-3.0-5.0-7.0-10-20 0.80-1.00-3.00-4.8s(3) ± 10%
30A
U 5% ≤ I6 ≤ 90% %unb 0.5s ≤ t6 ≤ 60s, step 0.5s ± 10% The best of the two data
(t=k) step 5% ± 10% or 40 ms
OT fixed, defined by Instantaneous ± 1°C ---

(temp=k) SACE
Iinst Automatic, defined Instantaneous ± 5% +1mS

by SACE
LC1/LC2 loads 50%÷100% step 0.05xI1

control
Warning Iw 0.30÷3.00% step 0.05xIn
(1)
The minimum value of this trip is 1s regardless of the type of curve set (self- For all cases not covered by the above hypotheses, the following tolerance values apply:
protection).
(2)
These tolerances are based on the following assumptions:
- self-supplied relay at full power (without start-up) Protections Trip threshold Trip time
- presence of auxiliary power supply L Release between 1.05 and 1.25 x I1 ± 20%
- two-phase or three-phase power supply S ± 10% ± 20%
- preset trip time ≥ 100ms
I ± 15% ≤ 60ms
(3)
no-trip time
G ± 10% ± 20%
(4)
the protection G is disabled for current values greater than 4In, where I4 < 0.5 In,
Others ± 20%
greater than 6 In, where 0.5 In ≤ I4 < 0.8 In and greater than 8 In where I4≥ 0.8 In.

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13.2.9.11.1 Summary of the additional protection functions for the PR122/P with the optional PR120/V module
Start-up threshold
Thermal memory
Tolerance
of TRIP only
Protection Threshold Time Time
selectivity
threshold (2)
Disabling
Disabling
Range Range Tolerance (2)
Zone
UV 0.5xUn ≤ U ≤ 0.95xUn 0.1s ≤ t8 ≤ 5s, step 0.1s ± 5% ± 20%
(t=k) step 0.01xUn
OV 1.05xUn ≤ I9 ≤ 1.2xUn 0.1s ≤ t9 ≤ 5s, step 0.1s ± 5% The best of the two data
(t=k) step 0.01xUn ± 10% or 40 ms
RV 0.1xUn ≤ I10 ≤ 0.4xUn 0.5s ≤ t10 ≤ 30s, step 0.5s ± 5% The best of the two data
(t=k) step 0.05 Un ± 10% or 40 ms
RP - 0.3xPn≤ P11 ≤-0.1xPn 0.5s ≤ t11 ≤ 25s, step 0.1s ± 10% The best of the two data
(t=k) step 0.02 Pn ± 10% or 40 ms
UF 0.9fn ≤ f ≤ 0.99fn 0.5s ≤ t12 ≤ 3s, step 0.1s ± 5% The best of the two data
step 0.01 fn ± 10% or 40 ms
OF 1.01fn ≤ f ≤ 1.1fn 0.5s ≤ t13 ≤ 3s, step 0.1s ± 5% The best of the two data
step 0.01 fn ± 10% or 40 ms
13.2.9.11.2 Table of measurements

Range %
Phase and neutral currents 0.3 ... 6 In 1.5
Internal ground fault current 0.3 ... 4 In 1.5
(internal source ground return)
External ground fault current 0.3 ... 4 In 1.5
(external source ground return)
Phase-to-phase and phase voltages 50 Vphase-to-phase ... 1.1x690 Vphase-to-phase 1
(measured at the module's input
and thus independent of the precision
relating to the use of any VT)
Residual voltage 50 Vphase-to-phase ... 1.1x690 Vphase-to-phase 1
(for systems with neutral only)
Peak factor 0.3 ... 6 In 1.5
Total power factor 0.5 ... 1 2.5
Mains frequency 35 ... 80 Hz ± 0.2

Instantaneous active power on the 0.3 ... 6 Pn 2.5
single phase and total system
Instantaneous reactive power on the 0.3 ... 6 Pn 2.5
Instantaneous apparent power on 0.3 ... 6 Pn 2.5
the single phase and total system
Active energy 0.3 ... 6 Pn 2.5
Reactive energy 0.3 ... 6 Pn 2.5
Apparent energy 0.3 ... 6 Pn 2.5

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13.2.10 Trip curves
The trip curves given are for guidance and only show a sub-group of the possible selections (see par. 13.2.9.11).
13.2.10.1 Trip curves for functions L-I
t [s] 10 4
0,4 … 1
L 0,4 1
10 3
3 … 144
10 2
1,5 … 15
1,5 15
10
10 -1
0,05 … 0,8
10 -2
10 -3
10 -1 1 10 100
x In
13.2.10.2 Trip curves for functions L-S(t=k/i2)-I
t [s] 10 4
0,4 … 1
L
0,4 1
10 3 0,6 … 10
0,6 10
S
3 … 144
10 2 k
t= 2
1,5 … 15 I
1,5 15
10 0,05 … 0,8
10 -1
10 -2
10 -3
10 -1 1 10 100
x In

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t [s] 10 4
0,4 … 1
L 0,4 1
10 3 0,6 … 10
0,6 10
3 … 144
10 2 S
1,5 … 15 t=k
1,5 15
10
10 -1
0,05 … 0,8
10 -2
10 -3
10 -1 1 10 100
x In
13.2.10.4 Trip curves for function L in accordance with IEC 60255-3 (type A)
t [s] 10 4
0,4 1
0,4 … 1
L
10 3
k=0,14
a=0,02
10 2
3 … 144
10
10 -1
10 -1 1 10 100
x In

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13.2.10.5 Trip curves for function L in accordance with IEC 60255-3 (type B)
t [s] 10 4
0,4 1
0,4 … 1
L
10 3
k=13,5
a=1
10 2
3 … 144
10
10 -1
10 -1 1 10 100
x In
13.4.2.10.6 Trip curves for function L in accordance with IEC 60255-3 (type C)
t [s] 10 4
0,4 1
0,4 … 1
L
10 3
k=80
a=2
10 2
3 … 144
10
10 -1
10 -1 1 10 100
x In

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t [s] 10 4
0,2 … 1
0,2 1
10 3
10 2
k
t= 2
10 I
G
1
0,1 10
…1
10 -1
G
t=k
10 -2
10 -3
10 -1 1 10 100
x In
13.2.10.8 Trip curves for function U
t [s] 10 4
0,05 … 0,9
0,05 0,9
10 3
U
10 2
60
10
1060
0,5 …
0,5
10 -1
10 -2 10 -1 1 10
x In

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13.2.10.9 Trip curves for function UV
t [s] 10 4
0,5 … 0,95
0,5 0,95
UV
10 3
10 2
10
5
1
105
0,1 …
10 -1 0,1
10 -2
0,3 0,5 0,7 0,9 1,1 1,3
x Un
13.2.10.10 Trip curves for function OV
t [s] 10 4
1,05 … 1,2
1,05 1,2
OV
10 3
10 2
10
5
1
105
0,1 …
10 -1 0,1
10 -2
1 1,05 1,1 1,15 1,2 1,25 1,3
x Un

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13.2.10.11 Trip curves for function RV
t [s] 10 4
0,1 … 0,4
0,1 0,4
RV
10 3
10 2
30
10
0,5 …10
30
0,5
10 -1
0 0,2 0,4 0,6 0,8 1 1,2
x Un
13.2.10.12 Trip curves for function RP

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13.3.1 Connections
For the connections provided by the user, it is recommended that you comply strictly with the recommendations contained
in this document.
This will enable us to satisfy all the international reference standards and guarantee perfect operation of the relay even under
severe environmental and electromagnetic conditions.
Pay particular attention to the types of cable, the connections to earth and the recommended maximum distances.
The maximum length of the VT - PR120/V wiring must not exceed 15 meters.
The shield must be connected to earth on both sides.
Use VTs with a shield, connected to earth (see standard VT par. 13.3.2).
The VTs should only be used for voltages > 690V; for lower voltages the presence of the PR120/V module connected to the lower
or higher busbars will be sufficient.
13.3.1.1 Current sensor connection for external neutral
If you want to connect the current sensor for the external neutral conductor to a three-pole circuit breaker, remember to
set InN accordingly. During this procedure, the circuit breaker must be open and preferably isolated.
13.3.2 VT connections
Dielectric strength tests are not allowed on the inputs and outputs of the releases or on the secondary lines of any
connected VTs
The following is a summary table of standard VT connections according to the type of plant.
TV Standard (A): Single standard transformers, see par. 15.1.7.

The VTs must have a performance coming between the values of 10 and 20 VA inclusive, 4 kV insulation between the primary
and secondary.
"VT Standard" type transformer "VT Standard" type transformer
(Star/Star) (Delta/Delta)
Installation system
Application diagram Application diagram
TN-C B A
TN-S B A
IT with neutral B A
IT n.c A
TT with neutral B A
TT without neutral n.c A
Note: - for TN-C systems the connection must be made to PEN

- for TN-S systems the connection must be made to N for configurations with neutral or PE for configurations without neutral; if the
PE is used, the current thereon could be around a dozen mA. If a customer considers this value too high or has a residual current
protection which risks being tripped, then application diagram A must be used
- for IT and TT systems with neutral, the connection must be made to N
Application diagram A Application diagram B
N
13.3.3 CS and TC connection test

If the PR122/P was installed by the user, it is important, before closing the CB, to check the last line on the display when the
relay is turned on for the first time via a PR030/B battery unit. No CS and/or TC disconnected messages must appear; if they
do, do not close the circuit-breaker and make the correct connections.
13.3.4 Test Test 1/6

Before putting into service, a test can be conducted by means of the specific "Auto test" function which CB status
can be activated on the PR122/P. A positive result is shown on the display. Auto Test
Then a test can be conducted on the whole TC chain, again using the specific function (Trip test). A positive Trip Test (disabled)
result is shown by the circuit-breaker opening.
Check the open or closed state of the circuit-breaker on the same "PR122/P Test" screen, by checking CB open
"CB status".

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If the PR122/P is supplied ready installed in the circuit-breaker, it is up to ABB SACE to set all the variables referring to the circuit-breaker or the
specific application correctly (e.g. type of circuit breaker, Rating Plug size, mains frequency ...).
Vice versa, if the PR122/P is supplied separately, it will be up to the user to set all the necessary parameters correctly.
Note that ABB SACE defines each possible setting according the content of the paragraph on the default parameters (see par. 13.4.4).
Apart from this, it is absolutely indispensable for the user to modify the password and carefully define each modifiable
parameter, before putting the PR122/P into service.
13.3.6 Password management

Specify a password? [0***]
To enter "EDIT" mode it is necessary to enter a four-figure numerical password. The values attributable to the password go from 0000 to 9999.
For the default password see par.13.4.4.
Select the value of the first figure ( between '0' and '9' ) by means of the ↑ and ↓ keys and press ↵ to confirm the figure and then move on to enter
the next one.
After entering the fourth figure, check the password you have entered. If the password is correct, you go from the "READ" state to the "EDIT" state.
If the password is wrong, the message

Wrong password
appears and remains until the ESC key is pressed (or until an interval of 5 seconds has elapsed).
It is also possible to interrupt the password entry procedure by pressing the ESC key.
The password is valid for a maximum of two minutes from the last time a key was pressed. It is immediately reset in the case of a high priority alarm
or when the unit is reset.
On entering a page with no modifiable parameters, the state of the protection is put on "READ". If the password is still valid, to enter "EDIT" mode
(on a page with modifiable parameters) simply press the ↵ key.
Disabling the Password.

By setting the value of the password to [0000] (on the "Unit configuration" menu) the password prompt is disabled. It is therefore always possible
to switch from "READ" to "EDIT".
To enter a new password, select the "New Password" item on the "Settings/System" menu.
13.3.7 Changing the electronic release
13.3.7.1 Installation
To complete the procedure for installing a PR122/P unit, follow the steps below:
1. With the circuit breaker open and preferably isolated, install the protection unit on the circuit breaker
2. Power the unit ONLY from the PR030/B
3. If there are no other errors, the display will show the message Configuration (configuration error) accompanied by the
yellow LED coming on permanently (warning)
4. Enter the unit's "Settings" menu
5. Select "Circuit breaker"
6. Select "Unit installation"
7. Input the password
8. Select "Install" and press "ENTER"
9. When the red led flashes on and off and the message Installation (installation error) is displayed, remove the
PR030/B
10. Power the relay from any other source
Check for the absence of configuration errors.
13.3.7.2 Uninstalling
To complete the procedure for uninstalling a PR122/P unit, follow the steps below:
1. With the circuit breaker open and/or isolated power the unit from the PR030/B
6. Select "Uninstall" and press "ENTER"
7. If there are no error messages, remove the PR030/B
8. Remove the PR122/P unit from the circuit breaker
9. The remove the TC connector, proceed as indicated in the figure alongside.
It is not strictly necessary to complete the uninstalling procedure, but this enables the parameters relating to the circuit breaker, such as contact
wear and others, to be saved in the "KEY PLUG", otherwise these data would be lost. The data in question are then transmitted to the new PR122/
P unit installed on the same circuit breaker.

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13.4 User interface
1 2 3 10 9
11
8 4 5 7 6
Ref. Description
1 Pre-alarm indicator LED

2 Alarm indicator LED
3 Graphic display (the word ABB in the bottom left-hand corner indicates normal operation)
4 Serial number of the PR122/P
5 Rating plug
6 Pushbutton for exiting the sub-menus or for canceling (ESC)
7 Button for the cursor (UP)
8 Button for the cursor (DOWN)
9 ENTER key for confirming the data or changing the page
10 TEST connector for connecting or testing the release by means of an external device (PR030/B battery unit, BT030 wireless
communication unit and PR010/T test unit)
The Graphic Display is of the LCD type with 128x64 pixels and it is backlit when there is an auxiliary voltage or a self-supply from a PR120/V module.
The display is always lit when there is a Vaux or, in self-supply mode with a minimum busbar current or powered from the PR120/V module as
defined in par 13.2.2.1.
You can adjust the contrast on the display by means of the specific function available on the user interface settings menu (par. 13.5.4.1).
13.4.1 Use of pushbuttons

The modifiable fields can be filled in using the ↑ or ↓ keys and confirming with the ↵ key. Once you have entered the page you need, you can
move from one value to another by using the ↑ or ↓ keys. To change a value, position the cursor over the value (the modifiable field will appear
in reverse, i.e. white on a black background), and use the ↵ key.
To confirm the programming of the previously configured parameters, press the ESC key once only. A check will be carried out on the parameters
entered and then the programming confirmation page will be displayed. To return to the main menu, press the ESC key twice.
The "i Test" key must be used to perform the Trip test to view the information page and to see the last trip within 48 hours of the CB opening in
self-supply mode.
13.4.2 Read and Edit modes

The menus map (see par. 13.5.1) shows all the pages which can be obtained and how to move between them from the keyboard, in the "READ"
mode (just to read the data) or in the "EDIT" mode (to set the parameters).
Starting from any page displayed, two different functions can be obtained according to the state of the unit:
1. "READ": the default page will be displayed automatically after about 120 seconds (see par. 13.5.1).
2. "EDIT": the default page will be displayed automatically after about 120 seconds.
The allowable functions depending on the state are:

“READ”:
Consultation of the measurements and of the historical data
Consultation of the unit configuration parameters
Consultation of the protection parameters

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“EDIT”:
Everything allowed in READ mode
Configuration of the unit
Programming of the parameters relative to the protections
TEST Functions of the unit
To access the "EDIT" mode, it is necessary to press the ↵ key on a page with fields which can be edited. A password will then be required to enable
you to switch to the editing mode.
The use of the keys is summarized in the following table:
Key Function
Move between pages
Move within menu
Change parameter values
End setting phase and confirm result
Choose menu item
Access to surfing menus from the default page

Return to previous level when surfing within the menus, until you return to the default pages
Exit the parameter changing phase, aborting the change
This key is used to re-enable the display after it has gone off within 48 hours of the opening of the circuit breaker
in self-supply mode. Può essere utilizzato in congiunzione con gli altri tasti per combinazioni speciali che permettono
di accedere a pagine riservate.
13.4.3 Changing parameters

Moving within the Main Menu you can reach all the pages relating to the configurations and parameter settings with the opportunity to change
the values specified for the parameters.
After any programming, you need to Confirm/Cancel/Change any changes you have made. This procedure is not applicable to all the programming
activities.
Two examples are provided below: one concerns the case in which no confirmation is needed for the changes you have made, while in the other
a confirmation window appears.
Procedure not requiring the confirmation of any programming

For instance, to set the System Date, the correct sequence is as follows:
10:22:53
From the default page press ESC 400 A
to access the Main Menu (I1)
Menu 1/5
From the Main Menu, select SETTINGS Protections

Measurements
Settings
press the ↵ key (enter) Protections settings
Settings 7/8
Select SYSTEM Measure Store Time

Harmonic dist.
System
press the ↵ key (enter) System settings
System 1/4
Select the menu item DATE to change Date
Time
Language
press the ↵ key (enter)
January 12, 2003

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Password
You will be prompted to input a Password

complete the password entry procedure (par.13.3.6) 0***
Enter password
Date
Change the date using the keys ↓ (arrow down)
January 12, 2004
↑ (arrow up) and confirm by pressing the ↵ key (enter).
Enter password
Press ESC twice to return to the Main Menu.
Procedure requiring the confirmation of any programming
For instance, to change the Curve of the Protection L, the correct sequence is as follows:
10:22:53
From the default page press ESC 400 A

to access the Main Menu (I1)
Menu 1/5
Protections
From the Main Menu select the item PROTECTIONS
Measurements
Settings
Protections 1/13
From the Protections Menu select the item PROTECTION L L Protection

S Protection
I Protection
press the ↵ key (enter) Overload
L Protection 1/4
Function
From the Protection L Menu select the item CURVE Threshold I1
Time T1
press the ↵ key (enter) t=k/i2
Password
You will be prompted to input a Password (par. 13.3.6)

0***
complete the password entry procedure
Enter password

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Select the value you want from the list
Function 1/4
and confirm pressing the ↵ key (enter).
t=k/i2
t=0.14b/(i0.02-1)
Press ESC twice T=13.5b/(i-1)
Before accessing the Main Menu, the following box will appear:
Programming 1/3
Accept the new configuration
Confirm
Reject the new configuration (the previous configuration is retained)
Abort
Change the previously input values.
Modify
Confirm
To select the required option use the ↓ (arrow down),

↑ (arrow up) keys, and press ↵ (enter) to confirm.
13.4.3.1 Modification of basic configuration

The configuration of the unit must be done in EDIT mode.
Following the instructions given in par. 13.4.3, view the following on the display:
System 2/4
Change system date Date

Change system time Time
Select system language Language
07:56:28
System 4/4 Password

Time
Language 0***
New Password
**** Enter password
To change the system password, select the relevant menu item and press ↵ (enter); then you will be prompted to enter the OLD password, and
afterwards you can input the new one twice.
Press ESC twice to return to the Main Menu
Programming 1/3
Confirm
Accept the new configuration
Reject the new configuration (the previous configuration is retained) Abort
Change the previously input values. Modify
Confirm

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13.4.4 Default settings
The PR122/P is supplied by ABB SACE with the following predefined parameters:
# Protection On/Off Thresholds Time Curve T.M. ZS Trip
1 L -- 1 In 144 s It
2
Off -- --
2 S Off 6 In 50 ms K -- Off: 0.04s --
3 I On 4 In -- -- -- -- --
4 G Off 0.2 In 0.4 s K -- Off: 0.04s On
5 U Off 50 % 5s Off
6 OT -- Off
7 K LC1 Off 50 % I1
8 K LC2 Off 75 % I1
9 UV Off 0.9 Un 5s Off
10 OV Off 1.05 Un 5s Off
11 RV Off 0.15 Un 15 s Off
12 RP Off - 0.1 Pn 10 s Off
13 UF Off 0.9 Fn 3s Off
14 OF Off 1.1 Fn 3s Off
15 Language -- Engl
16 Net Frequency -- 50 Hz
17 PR021/K Off
18 Neutral sel. -- 50 %
19 Toroid Selec. -- None
20 Ext. ground tor. Off 100 A
21 Vs Un -- 380 V
22 S startup Off 6 In 100 ms
23 I startup Off 4 In 100 ms
24 G startup Off 1 In 100 ms
25 Password -- 0001
26 Measuring inteval -- 60 min
27 Iw Off 3 In
28 Power direction -- top → bottom
29 Harmonic dist. warning Off

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13.5.1 Menu
As seen previously, the PR122/P uses the display to show messages, diagrams and menus. These are organized in a logical and intuitive way.
The following is a general layout showing how to access the main menu pages.
10:22:53
400 A
(I1)
Current N
I1 : --- Ne : ---
I2 : --- Ig : ---
I3 : ---
Voltage *
U1 : - - - U12 : ---
U2 : - - - U23 : --- Menu 1/5 Measurements 1/6
U3 : - - - U31 : --- Protections Historicals

U3 : --- Measurements Power factor
Settings Energy
Protections settings Trip, measures, log
Active Power
P1 : ---
P2 : --- Menu 2/5 Measurements 6/6
P3 : --- Protections Peak factor

Measurements Main Frequency
P: ---
Settings Contact Wear
Measures, graphics, harmonics 0.0 %
Reactive Power
Q1 : ---
Q2 : --- Menu 3/5 Settings 3/8
Q3 : --- Protections Circuit Breaker

Q: ---
Settings Modules
General settings Optional modules
Apparent Power
S1 : ---
Menu 4/5 Settings 8/8
S2 : ---
S3 : --- Measurements Harmonic dist.
Settings System
S: ---
Test Display Contrast
Device test 30%
Menu 5/5
Settings
Test 1/6
Test
CB status
About
Auto Test
Product information
Trip Test (disabled)
CB open
About 1/2
Protection Unit
Circuit Breaker
Test 6/6
COM module Protection Unit

SIGNALLING module
Zone selectivity
Device test
* Menu displayed with the optional PR120/V module installed in the relay.

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Each time the unit is turned on, or after more than 2 minutes of inactivity on the keyboard, the display indicates the following page (default):
Percentage of the actual currents and 10:22:53

voltages with respect to the rated values Current of the phase under the greatest
(100%) 400 A
(I1) load
N Indication for the phase under the greatest

load (L1, L2, L3, N)
13.5.2 Protections menu

From the interface you can press ENTER to access the menu of the various protections available on the display
Menu 1/5 Protections 1/13
Protections L Protection
Measurements Enter ↵ S Protection
Settings I Protection
Protections settings Overload
Using the "arrow UP" and "arrow DOWN " you can view the various protections.
On the whole, the data that you can display when the optional additional PR120/V module is installed concern the protections:
L, S, I, G, U, UV, OV, RV, RP, UF, OF, OT, LOAD PROTECTION.
Example of surfing the Protections menu

From the Protection main page you can press ENTER to go to the Protection L Menu.
You can use "arrow UP" and "arrow DOWN" to select the items on the menu and confirm by pressing ENTER. Pressing this key triggers a Password
prompt, then you can select the functions associated with the protection L (as in the example)
Protections 1/13 L Protection 1/4 Password

Function
L Protection Enter ↵ Enter ↵
S Protection Threshold I1 0***
I Protection Time T1
Overload t=k/i2 Enter password
PSW + Enter ↵
Example of how to select the curve t=k/i2
Function 1/4
t=k/i2
t=0.14b/(i0.02-1)
T=13.5b/(i-1)
Similarly, to access the menus for the other protections, see the Protections Menu table below.
13.5.2.1 Protections menu table
Protection Parameter / Function
L Curve
Threshold I1
Time t1
Thermal memory ON / OFF
S Enable ON / OFF
Curve
Threshold I2
Time t2
Zone selectivity ON / OFF
Selectivity time

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Enable StartUp ON / OFF

StartUp threshold
StartUp time
I Enable ON / OFF
Threshold I3
StartUp threshold
StartUp time
Gext Enable ON / OFF

Curve
Threshold I4
Time t4
Enable Trip ON / OFF
Selectivity time
StartUp threshold
StartUp time
U Enable ON / OFF
Threshold I6
Time t6
UV Enable ON / OFF
Threshold U8
Time t8
OV Enable ON / OFF
Threshold U9
Time t9
RV Enable ON / OFF
Threshold U10
Time t10
RP Enable ON / OFF
Threshold P11
Time t11
UF Enable ON / OFF

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Threshold f12
Time t12
OF Enable ON / OFF
Threshold f13
Time t13
OT Enable Trip ON / OFF
Load Threshold 1
Control Enable ON / OFF
Threshold
Threshold 2
Enable ON / OFF
Threshold
Threshold lw
Enable ON / OFF
Threshold
Note: for an explanation of the characteristics of the single protections and their settings and corresponding curves, see par. 13.2.9.

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13.5.3 Measurements Menu
For a complete description of the functions of the PR120/V module, see par. 15.1.
The following is a summary of the parameters accessible from the menu in the PR122/P unit.
13.5.3.1 Measurements Menu table
Setting Parameter / Function Values Notes
Historicals
Trips Last trip
Events Events log
Measurements
I Max Current
Reset measurements
Peak
factor
Contact wear Percentage of wear on CB contacts
13.5.4 Settings Menu
The configuration parameters in the Settings menu are password protected. Among the most
Menu 3/5 significant values you can select, note the neutral threshold (values 50%, 100%, 150%, 200%), the
Protections external toroid size (values 100 A, 250 A, 400 A, 800 A), the mains frequency at the installation (values
Measurements 50 Hz, 60 Hz). For a more detailed description of the settings for the modules, refer to the
Settings documentation on the modules (ch. 15).
General settings
Settings 1/8 Circuit Breaker 1/3 Neutral protection 21/2
Enable
Circuit Breaker
Enter ↵ Neutral Protection Enter ↵ + PWD
Main Frequency Ground protection Neutral threshold
Modules Unit installation
Circuit breaker settings Neutral settings On
13.5.4.1 Settings Menu table
Parameter / Function Values Notes
Circuit breaker Neutral protection

Enable ON/OFF
Neutral threshold 50%-100%-150%-200%
Ground protection Said protection is provided only
in the event of an external toroid being used
External toroidal transformer Absent,SGR,Rc
Toroid size SGR
Toroid size Rc Idn = 1A, 10A
Mains 50 Hz - 60Hz
frequency
Modules Module
PR120/V - Measuring if any see par. 13.5.4.4.1
PR120/D-M - COM if any see par. 13.5.4.4.2
PR120/K - Signalling if any see par. 13.5.4.4.3
Local Bus unit Absent - Present
Data logger Enable ON/OFF
Sampling frequency
Stop event
Stopping delay
Restart
Stop
Measurement from 5 to 120 min, step 5 min
interval
Harmonic ON/OFF The warning indicates that the distortion exceeds
distortion factor 2.1

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Parameter / Function Values
System Date
Time
Language English/Italiano/Francais/Deutsch/Español
New password
Display Contrast
The summary table relates to the surfing of the pages dedicated to the PR120/V module (see par. 15.3) and to the PR021/K unit (see par. 16.1).
13.5.4.2 Neutral adjustment

In the SACE PR122/P release, this protection can be set for the following values : InN= 50% - 100% - 150% - 200% * In.
The values that can be used to adjust the neutral are given in the table below for the various possible combinations between types of circuit-breaker
and adjustment of the threshold In.
13.5.4.2.1 Neutral adjustments table
Adjustment for the threshold I1 (L Protection)

Circuit breaker size I1 ≤ 0.5 0.5 < I1 ≤ 0.66 (1) I1 > 0.66
E1 50-100-150-200% 50-100-150% 50-100%

E2 50-100-150-200% 50-100-150% 50-100%
E3 50-100-150-200% 50-100-150% 50-100%
E4 50-100% 50% 50% .......
E4/f 50-100-150-200% 50-100-150% 50-100%
E6 50-100% 50% 50%.......
E6/f 50-100-150-200% 50-100-150% 50-100%
Nota 1: The adjustment I1=1 In is meant as the maximum adjustment of the overload protection. The actual maximum allowable adjustment must take into account any
temperature derating, the terminals used and the altitude.
Failure to comply with the setting limits for “I1” and “InN” can cause circuit breaker damage with consequent risks even for the
operator.
In any case, the relay records any setting error between I1 and the Neutral setting and it signals this by means of the warning (see par. 13.6.3).
13.5.4.3 Mains frequency settings

In the mains frequency menu, you can choose between the frequency values: 50, 60 Hz.
Settings 2/8 Password Mains Frequency 1/2

Circuit Breaker 50 Hz
Enter ↵ Enter ↵
Main Frequency 0*** 60 Hz
Modules
4P
50 Hz Enter password
13.5.4.4 Modules
When you access the Settings menu, there is a set of menus available relating to the modules.
13.5.4.4.1 PR120/V - MEASURING module
Modules 1/4 MEASURING module 1/5
MEASURING module Voltage Transf

COM module Rated voltage
SIGNALLING module Positive Power flow
Optinal
Module modules
configuration Absent
In the measuring module you must enter a password and can then opt for the absence or presence of the voltage transformer. Moreover, you
can select the values of the primary voltage (100, 115, 120, ... 1000V) and secondary voltage (100, 110,..,230V). The power flow can be LOW
-> HIGH or HIGH-> LOW. After entering a password you can choose whether the neutral connection is to be Absent or Present. The phase sequence
and cosϕ signal can be enabled and disabled (ON /OFF) and the corresponding threshold values can be selected (see par. 15.1).

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13.5.4.4.2 PR120/D-M - COM module
Modules 2/4 COM module 1/5

MEASURING module Local / Remote
COM module Serial Address
SIGNALLING module Baudrate
Communication parameters Local
The local or remote modes can be selected after entering a password. The serial address can be displayed after entering a password. The Baud
Rate can be set on the values 9600 and 19200 bit/s. The physical protocol provides for the options: (8,E,1), (8,0,1), (8,N,2), (8,N,1). The addressing
can be selected as standard Modbus or ABB. For further information on the PR120/D-M communication module, see paragraph 15.2 in this manual.
13.5.4.4.3 PR120/K - SIGNALLING module

For a thorough examination of the signalling module, refer to the corresponding section of the module, paragraph 15.3.
13.5.4.4.4 PR120/D BT WL-COM module
This module is for wireless communication based on the Bluetooth standard between the PR122/P protection release and a hand-held PC (PDA)
or a laptop with a Bluetooth port. For further information, see the description of the module in paragraph 15.4.
13.5.4.4.5 Settings for the Local Bus unit
If the PR021/K unit is connected, you need to enable the local bus by selecting present.
13.5.5 Test Menu

Access to the Test menu is password protected.
Menu 4/5 Password Test 1/6

Measures CB status
Settings Enter ↵ 0*** Enter ↵ Auto Test
Test Trip Test (disabled)
Device test Enter password CB open
The menu shows the state of the CB, in the dialog module (COM module) the state of the springs and the position of the CB, and in this submenu
you can make the CB open or close.
Using the "Trip Test" function lets you view the disabling/enabling of the Trip. If it is enabled, the circuit breaker is opened. The function is only
available with a busbar current of nil (use Vaux, PR030/B or PR010/T).
On the page, only with Vaux, you can also see the state of the circuit breaker "STATUS", and thus make sure that the input is correctly wired.
The surfing path is summarized in the following table:
13.5.5.1 Test Menu table
CB status Open / Closed

Indefinite
Auto Test
Trip Test Enabled / Disabled
PR120/D-M State of springs Loaded / Unloaded
Module Position of CB Isolated / Withdrawn
Open CB
Closed CB
PR120/K Input ON
Module Auto Test ---
Zone Protection S
selectivity (status) Input ON/OFF
Force Output
Release Output
Protection G
(status) Input ON/OFF
Force Output
Release Output

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13.5.6 Information Menu
The Information Menu enables you to view the data relating to the protection unit and the type of circuit breaker.
About 1/2 Protection Unit 1/3 Circuit Breaker 1/3
Protection Unit Nr. : 00000000000ABB SACE Nr. :

ESC +↓
Enter ↵ Device : PR122/P Device : E1B800
Circuit Breaker
Version : LSIG + Enter ↵ Rated Curr. : 630 A
Protection Unit Normative : IEC Installation : Jan 00, 2000
Software : P 1.02 Maintenance : Jan 00, 2000
13.5.6.1 Information on the trip and opening data

The PR122/P unit saves all the information relating to the type of protection tripped, the opening data, the date and time. Using the "i Test" key
makes the release show all these data directly on the display. There is no need for an auxiliary power supply for this function. With an auxiliary
power supply, the information is shown immediately on the display without the need to press the "i Test" key and remains displayed indefinitely
until you press the key .
The information remains available for 48 hours with the circuit breaker open or without any current flowing in the busbars. The data relating to
the last 20 trips are stored in the unit's memory. By connecting a PR030/B battery unit or a BT030 wireless communication unit, you can retrieve
the information relating to the last 20 trips recorded.
Access to view the opening data is via the Historicals submenu in the Measurements menu. The following is an example of the information provided:
Last Trip N.02

1/3 Number of openings due to the protections and to the TRIP tests
15 Feb 2004
L Protection
Indication for protection tripped
I1: 625A I3: 623A
I2: 617A N: > 10.0 kA Value of the currents interrupted on phases (L1, L2, L3), neutral (Ne) and Ground (if G has been tripped).
Again in the Measurements menu, you can view the percentage of contact wear, which is an indication of the electrical life of the electrical contacts
in the circuit breaker.
In any case, functionality of the relay is in no way modified by the presence of the wear messages.
The prealarm message (wear > 80%, "warning" LED lighting up) indicates that the wear has reached a high value. The alarm message (100%
wear, "alarm" LED lighting up) indicates that it is necessary to check the state of contact wear.
The percentage of wear depends on the number of openings carried out by the circuit-breaker and by the absolute current interrupted during
each of them.
13.6 Definition of alarms and signals in the PR122/P unit
Signaling Description
• The prealarm threshold has been exceeded; one or more phases with current values in the range 0.9xI1< I < 1.05xI1.
(on the Ne it depends on the selection made; for instance, at 50% the values are halved)
• Presence, between two or three phases, of unbalance above the value programmed for the "U"
Warning (yellow) led protection, with protection trip disabled
• Presence of distorted wave form with form factor > 2.1;
• Contact wear greater than 80% (and less than 100%; with Vaux only);
• WARNING Threshold Iw exceeded;
• Circuit-breaker state error;
• Frequency out of range.
• Presence of overload on one or more phases with current values I >1.3 I1 (timing protection “L”)
(on the NE it depends on the selection made; for instance, at 200% the values are doubled)*;
• Timing in progress for protection function S;
• Timing in progress for protection function G;
Alarm (red) led • Timing in progress for the voltage (UV, OV, RV), frequency (OF, UF) protection functions;
• Timing in progress for the reverse active power protection function (RP);
• Timing in the case of unbalance between the phases (protection U) above the value set in the configuration
with protection trip set to on;
• Contact wear = 100%;
• Rating Plug disconnected;
• Trip Coil (TC) disconnected.
• Key plug error
• Current sensors disconnected.
* The IEC 60947-2 Standard defines the timing threshold L for current: 1.05 < I < 1.3 I1
13.6.2 Electrical signals
K51/p1..p4 Programmable electrical signals, if the PR120/K module or the PR021/K unit are installed and there is an auxiliary power supply.
Pressing the "i Test" key enables you to reset the activated contacts.

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13.6.3 Table of error and warning messages
All the messages which can be shown on the display relating to incorrect configurations, generic alarms or deriving from the protection functions
and linked to useful information are described below.
The following symbols in the warning signals have the following meanings:
= warning signal / Protection in alarm mode, with no trip (trip=off)
= Protection in alarm mode, with trip at end of delay (trip=on)
Error message Description Notes

Harmonic dist. Harmonic distortion alarm Busbar currents with form factor > 2.1
Contact wear Alarm for contact wear Contact wear = 100%
G Alarm for protection G
Gext Alarm for protection Gext
T Alarm Alarm for protection T Temperature outside range
T Alarm for protection T
U Alarm Alarm for protection U
UV Alarm Alarm for protection UV
OV Alarm Alarm for protection OV
RV Alarm Alarm for protection RV
RP Alarm Alarm for protection RP
UF Alarm Alarm for protection UF
OF Alarm Alarm for protection OF
LC1 Load Alarm for load control LC1
L1 Sensor Alarm for L1 phase current sensor Phase L1 sensor disconnected or faulty
Ne Sensor Alarm for Ne phase current sensor Phase Ne sensor disconnected or faulty
Gext Sensor Alarm for Gext current sensor Gext sensor disconnected or faulty
Warning signal Protection in alarm, with no trip (trip=off)
TC disconnected Trip Coil disconnected or faulty
Rating Plug Rating Plug Error absent or faulty
Power factor Alarm for power factor The power factor module is lower than the specified threshold
Phase cycle Phase cycle inverted
Invalid date Clock information lost
CB status CB state error Probable error in Q26 and/or Q27
Startup Error during relay installation
CB not defined State of circuit breaker inconsistent (Open/Closed) Probable error in Q26 and/or Q27
Local Bus Local Bus error See par. 13.7
Contact wear Contact wear prealarm Contact wear ≥ 80%
L prealarm Protection L prealarm
T prealarm Protection T prealarm
Frequency range Error: frequency out of range
Warning Iw Iw threshold exceeded
Timing L Timing protection L
Timing S Timing protection S
Timing G Timing protection G
Timing Gext Timing protection local Gext
Timing U Timing protection U
Timing UV Timing protection UV
Timing OV Timing protection OV

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Timing RV Timing protection RV
Timing RP Timing protection RP
Timing UF Timing protection UF
Timing OF Timing protection OF
13.6.4 Error messages displayed in pop-up windows

All the messages that appear on the display in a pop-up window are described below.
Error message Description

Password error
Session impossible A programming session cannot be started due to a contingency (e.g. a timer-controlled delay still elapsing)
Value outside range Value beyond the established limits
I2(S)<=I1(L) Incongruence between thresholds of protections L and S
NEC NEC requirements not satisfied
Unavailable Function is not available
Invalid date Date has not been set
Parameters revised Programming session concluded correctly
Cancelled Programming session cancelled
Failed Programming session rejected

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13.7 Troubleshooting PR122/P unit
Note:
1. Before consulting the following table, check for any error messages appearing for some seconds on the display.
3. In the case where the suggestions proposed do not lead to a solution of the problem, please contact the ABB SACE assistance service.
1 The trip test cannot be run 1. The busbar current is > 0. 1. FN

2. The TC is not connected 2. Check the messages on the display
3. Thermal memory enabled 3. Exclude if not necessary
4. Incorrect Neutral Selection 4. Correct neutral selection
5. The SdZ is inserted 5. Exclude if not necessary
3. Curve I2t inserted 3. Exclude if not necessary
4. Incorrect Neutral Selection 4. Correct neutral selection
4 Rapid trip, with I3=Off Iinst tripped FN with short-circuit with high I
5 High earth I, but no trip happens 1. Incorrect selection of the sensor 1. Set int. or ext. sensor
2. Function G prevented with I>4In 2. FN
6 Display off 1. Vaux missing and the current 1. FN, see 13.2.2.1
and/or voltages are below the
minimum value.
2. Temperature out of range 2. FN, see 13.2.9.8
7 The display is not back-lit Current below the FN
limit for lighting the display
8 Reading of I incorrect Current below the minimum FN
threshold that can be displayed
9 Reading of V, W and 1) Connection error between 1) Check connections between VT
power factor incorrect VT and PR120/V and PR120/V
2) VT parameter settings error 2) Set the correct parameters
10 " Local Bus" message No communication between PR122/P 1. If not present, disable PR021/K,
on display and PR021/K see 13.5.4.4.5
2. Check bus connection
3. Check PR021/K
11 Message "" Function disabled or data FN
instead of expected data out of range
12 The expected trip does not occur Trip function disabled FN enable trip if necessary
13 No activation of the Unbalance Values of I out of range FN, see 13.2.9.5
U protection
14 No display Vaux missing, the buffer FN, see 13.5.6.1
of the opening data capacitor is discharged
15 The password is not requested The password has been disabled FN, re-enter the password with a value
other than 0000.
16 Impossible to change any PR122/P in alarm situation FN
parameter
17 " Sensor time" or Possible failure inside relay Contact ABB Sace
" Start-up" message
If you suspect that the PR122/P is faulty, has a malfunction or has generated an unwanted trip, it is advisable to follow the
recommendations below very carefully from the Measurements menu Historicals Trip:
1. Make a note of the type of protection that has tripped by accessing the LAST TRIP page if there is an external power supply (Vaux or battery)
or by pressing "i Test" if in self-supply mode.
2. Note down the type of circuit-breaker, number of poles, any accessories connected, In, Serial Number (see par. 13.4) and the SW version.
3. Prepare a brief description of the opening (when did it happen?, how many times ?, was it always under the same conditions? what type of
load? what voltage? what current? is the event reproducible?)
service.
The completeness and accuracy of the information given to the ABB Assistance service will facilitate technical analysis of the problem encountered,
and will allow us to carry out all actions useful for the user rapidly.

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13.8 Accessories
The test with the SACE PR010/T unit enables you to check the proper operation of the inputs, outputs, thresholds and tripping times of the protection
functions "L", "S", "I", "G", OV, UV, RV, U. The test unit is connected to the relay by means of the front Test connector (see par. 13.4).
13.8.2 ABB SACE PR030/B power supply unit
The PR030/B is a momentary power supply unit to be inserted in the front test connector of the PR122/P.
Using this standard accessory, you can run an autotest, the trip test, and power the PR122/P unit whatever the state of the circuit breaker (open/
closed, in the test position or enabled and without an auxiliary power supply).
The battery inside the PR030/B guarantees a power supply to the unit for about 3h continuously (depending on the operations conducted on
the PR122/P and on the PR120/D-BT module).
The life of the battery diminishes if the PR030/B accessory is also used to perform the trip test and the autotest. It is essential to use the PR030/
B to read the trip data if the trip has occurred more than 48 hours earlier and the release was no longer powered.
13.8.3 BT030 wireless communication unit
The BT030 is a device for connecting to the Test connection on the PR122/P.
It enables Bluetooth communication between the protection release and a hand-held or laptop PC with a Bluetooth port.
This device is dedicated for use with the SD-Pocket application.
The BTO30 has a rechargeable Li-ion battery that can provide the power needed for it to function and for the protection release.

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14 SACE PR123/P Release - Identification
The PR123/P units available, in accordance with the IEC standards, together with the various protections and the various standard and optional
modules, are illustrated in the following figure:
Protections
For all versions

PR120/D-M - COM
PR120/K - SIGNALLING
PR120/D-BT - WL-COM
14.1 Standard
The PR123/P has been designed to work in accordance with the international standard:
14.2 Specifications
14.2.1 General
The PR123/P is a high-performance self-supplied protection unit with Protection, Measurement, Data storage, Communication (optional), Self-
test, Load control and Zone selectivity functions for the ABB SACE 'Emax' range of 3- and 4-pole low-voltage air circuit breakers. The unit's user
interface also enables parameter setup and completes the prealarm and alarm management for the protection and watchdog functions.
The protections available are:

S, S2 short-circuit with adjustable delay
D directional short-circuit with adjustable delay
U phase unbalance
OT temperature out of range
UV undervoltage
OV overvoltage
RV residual voltage
RP reverse active power
UF underfrequency
OF overfrequency
It should be noted that the reference current for the PR123/P is the In (the rated current defined by the front Rating Plug) and not the Iu (the
uninterrupted rated current of the CB itself).
Example: the CB E1B800 with a 400A Rating Plug has an Iu of 800A and an In of 400A
The protection unit is self-supplied by current sensors and primary voltages via the PR120/V module.
The unit is made using digital microprocessor technology and interfaces with the user by means of a graphic display and keyboard.

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Peak factor 6.3max @ 2 In
The self-supply enables the protection unit to be powered with the busbar current using current transformers.
Using this supply mode, only the unit's protection functions are assured, however, not the accessory functions regarding the modules.
The characteristics are given in the table below:
General characteristics E1 - E2 - E3 E4 - E6
Minimum single-phase busbar current for enabling relay 70 A 140 A

The external auxiliary power supply is provided using a galvanically-separated power pack.
common mode or leakage current (as defined in IEC 478/1 and CEI 22/3) no greater than 3.5mA
The presence of the auxiliary power supply enables the relay unit to be used even with the circuit breaker open, as well as powering all the modules,
with the exception of the PR120/V - MEASURING module, which is powered by means of a connection to the busbars.
The characteristics of the power pack are given in the table below:

Auxiliary voltage
Maximum ripple 5%
14.2.2.3 Powered by the PR120/V module

For a full explanation of the features of the PR120/V, see par. 15.1.

Degree of protection (with PR123/P installed in the CB) IP 30
14.2.4 Description of inputs/outputs

14.2.4.1 Binary opto-insulated inputs
– K51/SZin (K51/DFin): Zone selectivity: input for protection S or "direct" input for protection D
(only with Vaux)
– K51/Gzin (K51/DBin): Zone selectivity: input for protection G or "reverse" direction input for protection D
(only with Vaux)
14.2.4.2 Binary opto-insulated outputs
– K51/SZout (K51/DFout): Zone selectivity: output for protection S or "direct" output for protection D
(only with Vaux)
– K51/GZout (K51/DBout): Zone selectivity: output for protection G or "reverse" output for protection D
(only with Vaux)

Local internal bus on rear connector; RS485 physical interface, ABB SACE protocol
External system bus, RS485 physical interface, Modbus RTU protocol, baud rate 9600-19200 bps.

The PR123/P protection unit carries out 14 independent protection functions. In particular:
1. Protection against overload with inverse time “L”;
2. Protection against short-circuit with adjustable delay “S” and "S2";
3. Protection against directional short-circuit with adjustable delay “D”;
4. Protection against instantaneous short-circuit “I”;
5. Protection against earth fault with adjustable delay “G”;
6. Protection against instantaneous short circuit at high currents "I inst";
7. Protection against phase unbalance "U";
8. Protection against overtemperature "OT";
9. Protection against undervoltage "UV";

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10. Protection against overvoltage "OV";
11. Protection against residual voltage "RV";
12. Protection against reverse active power "RP";
13. Underfrequency "UF";
14. Overfrequency "OF";
The PR123/P unit allows current signal processing of the neutral pole with different relationships relative to the value of the phases.
A timing indication (message + "alarm" LED) is provided on the unit's display, which is activated during a protection alarm. It is disabled when
the alarm condition ceases or when the protection has been tripped. When the circuit breaker opens, the page with the "Trip" data is displayed
(when "i Test" is pressed, or automatically in the presence of Vaux).
14.2.6.1 Rms and peak calculation

All the protection functions do their respective processing on the basis of the real rms value of the currents and voltages (the protection G is disabled
for current values greater than 8 In [where 0.5In≤ I4<0.8In], greater than 6In [where I4<0.5In] and greater than 4In [where I4<0.5In]).
If the waveform has a deformation beyond the declared limit (6.3@2 In), the tolerance for the calculation of the true rms value will increase. The
UV, OV, RV voltage protections always work on the basis of the true rms value of the voltages.
14.2.6.2 Mains frequency

The PR123/P unit constantly measures the frequency of the mains voltages it is connected to.
If the frequency goes out of the permitted range by ±10% in relation to the rated frequency selected (50 or 60Hz), the "warning" LED comes on
and the warning message is displayed (see par. 14.6.3).
The signal can be combined with a relay of the optional PR120/K module or with those of the PR021/K unit.
14.2.6.3 Harmonic distortion

The PR123/P unit signals that a peak factor of 2.1 has been exceeded with a warning message and the "warning" LED lighting up (remember
that the IEC 60947-2 standard annex "F" establishes that the protection unit must function regularly with a peak factor ≤ 2.1, up to 2xIn).
14.2.6.4 Circuit-breaker state

If an auxiliary supply is used, or it is powered from the optional PR120/V, the PR123/P unit records the state of the circuit breaker by means of
specific wiring on the circuit breaker. In the case where the presence of current is determined with the circuit-breaker in the "OPEN" state, a state
error is signaled by a warning message being displayed (see par. 14.6) and the "warning" LED lighting up.
14.2.7 Measurement functions

The current measuring (ammeter) function is available on all versions of the SACE PR123/P unit.
The display shows histograms with the currents of the three phases and of the neutral on the main page. In addition, the current of the phase
under the greatest load is given in numerical form. Where applicable, the earth fault current is displayed on a separate page.
The ammeter functions both in self-supply mode and with an auxiliary supply. In the latter case, the display is backlit and the ammeter is always
active. The tolerance for the ammeter measuring chain (current sensor plus ammeter) is described in paragraph 14.2.9.16.
The PR123/P release provides a complete set of measurements:

- Currents: three phases (L1, L2, L3), neutral (Ne), earth fault
- Voltage: phase-phase, phase-neutral, residual voltage
- Instantaneous voltage values over a given time interval (data logger);
- Power: active, reactive, apparent
- Power factor
- Frequency and peak factor
- Energy: active, reactive, apparent, meter
- Harmonics calculation: up to the fortieth harmonic (waveform and module of the harmonics displayed); up to the thirty-fifth for frequency f=60Hz
- Maintenance: number of operations, percentage of contact wear, opening data storage.
- Data Logger: see par.16.4
The PR123/P can provide the trend of the measurements of certain quantities over an interval P, established by the user; these include: mean active
power, maximum active power, maximum current, maximum voltage and minimum voltage. The last 24 P intervals (adjustable from 5 to 120 min)
are stored in a non-volatile memory and displayed in a bar graph.
To examine the Measurement functions, see the relevant paragraphs (par. 15.1 and par. 14.5.3) for the PR120/V - MEASURING module.
14.2.8 Watchdog
The PR123/P unit provides some watchdog functions able to guarantee the proper management of relay malfunctions. These functions are as
follows:
Watchdog for presence of Auxiliary power supply with "plug" icon displayed.
Rating PLUG validity.
Watchdog for proper connection of the current sensors (CS). Any anomalies are indicated by a special alarm message and the "alarm" LED
coming on, and the circuit breaker opens after 1s.

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q Watchdog for proper connection of the trip coil (TC). Any anomalies are indicated by a special alarm message and the "alarm" LED coming
on. If the PR120/D-M module is installed, this activates the coil opening command (YO), thus opening the CB.
q Watchdog for protection of Hw Trip. In the event of the sensors being disconnected or a Rating Plug error, a CB opening command is given
by the TC being enabled.

The "L" is the only protection that cannot be disabled because it is for self-protection against overloading of the relay itself. The types of trip curves
settable are divided into two groups according to the standard they refer to.
Only one type of curve is settable (t=k/I2) as defined by the IEC standard 60947-2
where lf < 12ln and 1 s where lf > 12ln where If is the fault current and I1 the protection threshold.

There are 3 types of curves settable, defined by the IEC standard 60255-3 as A, B and C.
k If
t= •b where I = If is the fault current and I1 the protection threshold specified by the user.
(I )
α
−1 I1
a and k are two parameters, suggested by the standard, which vary the type of slope selected (e.g. for type B slope a = 1 and k = 13.5);
b is a parameter introduced by SACE to increase the number of curves with the same slope.
4.2.9.1.1 Thermal memory “L”

The thermal memory function can be enabled for cable protection. It is based on the “tL” parameter defined as the trip time of the curve (t1) selected
at 1.25xI1. The release trip time is certainly 100% of the one selected, after an interval tL has passed since the last overload or since the last trip.
Otherwise, the trip time will be reduced, depending on the overload which has occurred and on the time that has elapsed.
The PR123/P is fitted with two instruments to make up this thermal memory. The first is only effective when the release is powered (it also records
overloads that have not lasted long enough to trip the release), while the second works even when the release is not powered, reducing any trip
times in the case of an immediate reclosing and is enabled as soon as the CB is tripped.
It is the PR123/P release that automatically decides which of the two to use, according to the various situations.
N.B.: The thermal memory function can only be set if the type of curve selected is the standard one (t=k/I2) (see par. 14.2.9.1).

This protection can be disabled; it can be of the fixed time (t=k) or inverse time (t=k/i2) type. In the latter case, the trip time is given by the expression
⎡100 ⋅ t2 ⎤
max ⎢ , t2 ⎥ for I f > I2 where If is the fault current and I2 the protection threshold.
⎣⎢ (I f )
2
⎥⎦
14.2.9.2.1 Thermal memory “S”
The thermal memory function can be enabled for cable protection in the case where the curve with inverse time is selected. This is based on the
"tS" parameter defined as the trip time of the curve (t2) selected at 1.5xI2. The other characteristics are the same as those for thermal memory
"L" (see par. 14.2.9.1.1).
14.2.9.2.2 Start-up threshold “S”

The function can be disabled and it is a setting characteristic of the single protection units.
The start-up function enables the protection threshold (S, D, I and G) to be changed during a time interval lasting "ts", starting from "start-up". The
latter must be intended as follows:
- Turning on of the relay, under self-supply;
- Passage of the peak value of the maximum current over 0.1xIn. A new start-up is possible after the current has dropped below 0.1xIn.
It h
Start Up Threshold
Threshold I2
Start Up
Programmed time ts
• Start-up time
The start-up time is common to all the protections involved.
Range: 0.1 s ... 1.5 s, with steps of 0.01 s.

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14.2.9.2.3 Zone selectivity “S”
The zone selectivity function, guaranteed only if an auxiliary voltage is provided, enables the area of the fault to be isolated, only isolating the part
of plant nearest to the fault, while keeping the rest of the plant operational.
This is done by connecting all the zone selectivity outputs of the releases belonging to the same zone to one another (ZSO=K51/SZout) and taking
this signal to the zone selectivity input (ZSI=K51/SZin) of the next release on the supply side. If the wiring has been done correctly, all the zone
selectivity inputs of the last circuit-breakers in the chain and all the outputs of the circuit-breakers at the head of each chain must be empty.
RELAY 0
ZSI0
ZSO1 ZSO2 ZSOn

RELAY 1 RELAY 2 ○ ○ ○ ○
RELAY n
ZSI1 ZSI2 ZSIn
ZSO 1a ZSO1b
RELAY 1a RELAY 1b Area 2 ○ ○ ○ ○
Area n
Area 1
As a practical example, the figure above shows a fault on the load side of the "Relay 1a" isolated by the latter without the "Relay 1" or the "Relay
0" being affected; a fault immediately downstream from the "Relay 1" will be isolated by the latter without the "Relay 0" being affected, thus ensuring
that the Areas 2...n remain operational.
The ZSO output can be connected to a maximum of 20 ZSI relays on the supply side in the selectivity chain.
The maximum length of cable for zone selectivity, between two units, is 300 meters.
The shield must only be earthed on the circuit-breaker of the supply-side relay (ZSI side).
Wiring and enabling zone selectivity "S" is an alternative to using protection "D" and operation is only guaranteed when there is an auxiliary voltage.
The following logical table is implemented to manage the Zone Selectivity Input (ZSI) and Zone Selectivity Output (ZSO) signals:
Zone selectivity Imax > I2 ZSI signal ZSO signal Trip T

Inserted YES 0 1 tselectivity
Inserted YES 1 1 t2 programmed
The time t2 must be set at a value corresponding to at least tselectivity +50 ms.
14.2.9.3 Double S
Thanks to the new PR123/P release that enables two independent and simultaneously active protection S thresholds to be specified, selectivity
can assured even in critical conditions.
This function enables a better selectivity level to be obtained than using a release without a "double S".
14.2.9.4 Directional Protection “D”

The PR123/P unit carries out excludable directional protection against short-circuit with adjustable fixed time (t = k) active both with self-supply
and with auxiliary supply.
The protection functionality is very similar to protection "S" with fixed time, with the capacity to recognize the current direction during the fault
period as well. However, it is a phase and not a neutral protection.
The direction of the current enables the determination of whether the fault is on the supply side or the load side of the circuit-breaker. Especially
in ring distribution systems, this enables the distribution stretch where the fault occurred to be identified and isolated without interfering with
the rest of the installation (using zone selectivity).
To determine the direction of the current, the value of the phase reactive powers has to be higher than 2% of the nominal phase power
( PQ ≥ 2% ⋅ Pnphase ).
Protection D always considers I neutral = 100%.
The PR123 enables you to define the power flow in the circuit breaker from the menu
from high to low (High −> Low),
from low to high (Low −> High),
selectable in the menu Modules Measuring Module (PR120/V).

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As a result, the currents in the circuit breaker will be defined as "forward" or "backward" if their are in phase or out of phase with the previously-
defined power flow (for the default setting, see par.14.4.4).
In short:
Ifault (If) Power flow setting Power flow setting

High -> Low Low -> High
Value Direction T trip T trip
If < I7 either No trip No trip
If > I7 High → Low t7FW t7BW
If > I7 Low → High t7BW t7FW
Example:
Once the power flow has been set as "High → Low", the direction of the figure alongside is:
positive reactive power in → "forward" direction;
CB negative reactive power in → "backward" direction;
If the preset trip times were t7FW = 200ms and t7BW = 400ms, in this this case the
I relay would have opened the circuit breaker after t7FW = 200ms.
V
Inductive/resistive load
In short:
If If > I7 and the direction of the current detected is in phase, at the power flow set by the user the relay counts down the delay and opens
the circuit breaker in a time corresponding to t7FW .
If If > I7 and the direction of the current detected is out of phase, at the power flow set by the user the relay counts down the delay and opens
the circuit breaker in a time corresponding to t7BW .
Note:
· With the directional protection D activated, if the direction of the power cannot be determined the relay takes effect considering shorter
of the programmed times between t7fw and t7bw.
· This protection works on the basis of the phase currents, not the neutral current.
14.2.9.4.1 Start-up threshold “D”

The function can be enabled from the menu (see description of the protection menu 14.5.2)
14.2.9.4.2 "D" (directional) zone selectivity
The Directional Zone Selectivity (SdZ D) function is particularly useful in ring and grid type systems where, in addition to the zone, it is essential
to define the direction of the power flow that powers the fault.
The SdZ D can be set as an alternative to Zone Selectivity S and G and requires an auxiliary power supply.
To define the zone and power flow, each relay has two inputs (DFin and DBin) and two outputs (Dfout and DBout), which must be suitably
connected to the other relays (see example below).
As in the SdZ S and G, the relays interact with each other, sending cutout signals via the outputs and reading them via the inputs.
The general behavior is summarized in the table below.

(Example with power flow setting "High → Low”).
Ifault (If) Outputs status Inputs status T trip

Value Direction DFout DBout DFin DBin
If < I7 either 0 0 either either No trip
If > I7 High -> Low 1 0 0 either ts
If > I7 High -> Low 1 0 1 either t7FW
If > I7 Low-> High 0 1 either 1 t7BW
If > I7 Low-> High 0 1 either 0 ts

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If the power flow is in phase with the direction set on the relay, the output DFout is enabled (1).
Vice versa, if the power flow is out of phase, the output DBout is enabled (1).
The typical configuration of the system of circuit breakers for which the SdZ D is likely to be used is the sort of ring illustrated in the following
figure
Generator
Generatore
Relè
Relay4 4 Relè 3 1
Relay
DFout4 DFin3
DBin4 DBout3
DFin4 DBout4 DBin3 DFout3
CaricoCC
Load CaricoBB
Load
DBout2 DFin2
DFout1 DBin1
DBout1 DBin2
DFout2
Relè 1 1
Relay Relè 2 2
Relay
Forward
Flusso di potenza Load AA
Carico Flusso di potenza
Backward
forwardflow
power backward
power flow
: Output
Uscita attivata
enabled= =
1 1 Guasto
Fault
If a fault is detected (I fault If beyond the threshold I7) one of the sections in the system (Load A), the final circuit breakers for the section in
question (Relay1 and Relay2) communicate the presence of the fault to the connected circuit breakers (Relay4 and Relay3) by setting the
output signals DFout or DBout depending on the direction of the current (DFout1=On, DB2out=On). To be more precise, the circuit breakers
that limit the section affected by the fault see the direction of the fault current in different ways (Relay1=forward and Relay2=backward).
The circuit breakers (Relay1 and Relay2) delimiting the section affected by the fault are tripped with the selectivity time ts, while the circuit
breakers further away from the fault count down the time t7FW (Relay4) and t7BW (Relay3) without opening; in this way, the system is isolated,
in the time ts, to exclude the part affected by the fault.
The load A, where the fault has occurred, will be disconnected, but loads B and C will continue to be powered normally.
It should be noted that activation of the DBout3 output by the relay3 will have no effect on the relay4, because the latter is recording not an
out-of-phase (backward) fault current, but an in-phase (forward) current with the power flow defined previously by the user (High -> Low).
Note:
· With zone selectivity enabled, if the direction of the power flow cannot be ascertained, the relay is tripped considering the lesser of the
programmed times between t7fw and t7bw, without enabling any outputs (DFout or DBout).
· If, for some reason, one of the circuit breakers required to open does not do so, a specific function will activate the opening of the first
circuit breaker immediately upstream from it, after a further 100 ms approx. In the above example, if the circuit breaker does not open
with the relay1, only the circuit breaker with relay4 will open after a time ts+100 ms.
· The SdZ D operates on the basis of the phase currents, not of the neutral.

The protection is enabled/disabled from the menu.
In the case where zone selectivity "S" (or "D") is active, during the trip of the relay for "I", the ZSO (or DFW and BFW) output signal is activated
in any case to guarantee correct operation of the relay on the supply side (and on the load side).
14.2.9.5.1 Start-up threshold “I”
The start-up function can be selected.
The function can be enabled from the menu on the protection "I" page.

This protection can be disabled; it can be of the fixed time (t=k) or inverse time (t=k/i2) type. In the latter case, the trip time is given by the expression
æ 2 ö
max ç , t4 ÷ where I=I /I , I is the fault current and I is the protection threshold.
ç I2 ÷ f 4 f 4
è ø

For the whole duration of the earth fault, circuit-breaker opening does not take place, but only the alarm condition is signaled
("Alarm" LED lit and alarm message).

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The PR123/P unit can provide two different types of earth fault protection:
Internal protection G
This is provided inside the release by vectorially summing the phase and neutral currents. The fault current is defined by the following formula:
In the case when the circuit does not show any fault, the module of the sum of these currents is always nil; vice versa the value of the fault current
will take on an increasingly large value depending on the size of the fault. This operating mode is enabled by default.
N.B.: it can be used also with CS for an external neutral.
Protection G with external toroid "Source Ground Return"

Also called "Source Ground return", this can be carried out when there is the need to check operation of a machine (transformer, generator or
motor etc.) which has star-configured windings.
The protection is assured by physically positioning an external toroid on the cable connected from the star center of the machine to the earthing
connection point.
The induced current on the winding of the toroid is proportional to the fault current which, in this case, only transits in the above-mentioned toroid.
To work in this mode, "Ground protection" must be selected on the Circuit breaker Settings menu.
The external toroid must be connected to the PR123/P by means of a corded shielded two-wire cable (see note A in par. 11.2.2)
with a length not exceeding 15m.
The shield must be earthed both on the circuit-breaker side and on the toroid side.
It is indispensable for the star center to be connected openly to earth and for it not to be used as a neutral conductor too (as in the TNC system),
making a protection according to the TT system.
The protections G and Gext can be enabled simultaneously.
14.2.9.6.1 Start-up threshold “G”
The function can be enabled and disabled on the protection "G" page.
14.2.9.6.2 Zone selectivity “G”
The zone selectivity function can be enabled providing the fixed time curve, the wiring and the zone selectivity "G" enabling alternative to the one for
"D" have been selected and the function is assured only if auxiliary voltage is provided.
Zone selectivity "G" can be active at the same time as zone selectivity "S".
The behavior and wiring of the function are identical to those indicated for zone selectivity "S" (see par. 14.2.9.2.3).
14.2.9.7 Protection against phase unbalance “U”

The protection with fixed time, which can be excluded, trips in the case when, for a time greater than or the same as the time t6 set, an unbalance
is determined between two or more phases higher than the set threshold I6.
I max − I min
The percentage of unbalance is therefore calculated %unb = ⋅ 100 where Imax is the maximum and Imin is the minimum phase current.
I max
In that case, for the whole duration of the unbalance the CB will not be opened, but only the condition will be signaled by means
of the "warning" LED lit up and a warning message.
When the value of the phase current is above a 6xIn, the function "U" excludes itself because, in this case, the other protections
intervene because the fault is considered as a phase fault.
The protection is not enabled for maximum phase current values lower than 0.3xIn.
14.2.9.8 Protection against overtemperature inside the relay, “OT”

There is a sensor inside the PR123/P unit that monitors the temperature of the unit.
This enables the signalling of any abnormal temperature conditions, which could cause temporary or continuous malfunctions of the unit's electronic
components.
This protection has two states of operation:

State of “WARNING TEMPERATURE” with –25°C < temp. < -20°C or 70°C < temp. < 85°C : the display is turned off and
the "WARNING" LED flashes
State of “ALARM TEMPERATURE” with temp. < –25°C or temp. > 85°C : the display is turned off,
the "WARNING" led remains on and the Trip is activated (if enabled by means of the "Over Temper. Trip = On" parameter).
N.B.:
In the event of Warning and Alarm, the display is momentarily turned off, to preserve its functionality.
The monitored temperature is not visible on the display.
The protection is always active, both with auxiliary supply and in self-supply.
Disabling the Trip control of the protection means that the PR123/P unit could work, with the circuit-breaker closed, in a range
of temperatures where correct operation of the electronics is not guaranteed.

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14.2.9.9 Load control function
Single loads can be enabled/disabled on the load side before the overload protection L intervenes and trips the circuit breaker on the supply
side. This is done by contactors or switch-disconnectors (wired outside the release), controlled by the PR123/P by means of contacts on the PR120/
K module or on the PR021/K external unit.
The current thresholds are lower than those available with the protection L, so that the load control can be used to prevent tripping due to overloads.
The function is active when an auxiliary power supply or power by PR120/V module is present (see par.15.1.4).
The operating logic involves the activation of three contacts when the preset thresholds LC1, LC2 and Iw are exceeded.
Thresholds LC1 and LC2 are expressed as a percentage of I1 (current threshold specified for protection L) while the "warning current" Iw is expressed
as an absolute value. The allowable values are given in the following table:
Warning current Iw 0.30 ÷ 3.00 step 0.05xIn

From the PR123/P you can associate each of the PR120/K or PR121/K contacts with a configuration (NO or NC), a delay and any latch.
14.2.9.10 Voltage protections "UV", "OV", "RV"

The PR123/P unit provides 3 voltage protections, which can be disabled, with fixed adjustable time (t = k), active both with self-supply and with
auxiliary supply:
– Undervoltage “UV”
– Overvoltage “OV”
– Residual voltage “RV”
The protections work on the voltages. The threshold voltages indicated refer to the line voltage.
Apart from the normal timing and "TRIP" operation, the voltage protections can be in a state defined as "alarm" (with the "emergency" led on and
an alarm message displayed) providing there is an auxiliary or PR120/V module power supply. In fact, in the case where the circuit-breaker is
open and no current is detected, the timing leads to the "alarm" state and not to "TRIP". This is because the fault linked to the voltages can persist
even with the circuit-breaker open and the unit would therefore always be under "timing". When the circuit-breaker is closed or the passage of
a current is detected, you pass immediately from the state of "alarm" to "TRIP" without timing (for warning see par. 14.3.2).
14.2.9.10.1 Protection “UV”
When the minimum phase voltage drops below the set threshold U8 the protection counts down the preset time interval t8 and then opens.
14.2.9.10.2 Protection “OV”
When the maximum phase voltage exceeds the set threshold U9 the protection counts down the preset time interval t9 and then opens.
14.2.9.10.3 Protection “RV”
When the residual voltage exceeds the set threshold U10 the protection counts down the preset time interval t10 and then opens.
The residual voltage U0 is calculated by vectorially summing the phase voltages. It is therefore defined by the following formula
U0 = U1 + U2 + U3
14.2.9.11 Protection against Reverse active power “RP”
The PR123/P unit provides protection (which can be disabled) with an adjustable fixed time (t = k), against reverse active power, active both with
self-supply and auxiliary supply.
When the total reverse active power (sum of the power of the 3 phases) exceeds the set reverse active power threshold P11, the protection counts
down the preset time interval t11 and then opens.
The minus sign ('-') in front of the threshold and power indicates reverse power. The threshold is indicated as a percentage of "Pn", where "Pn"
is the nominal power of the circuit-breaker ( 3 Vn*In).
14.2.9.12 Frequency protections "UF", "OF"

The frequency protections record the mains frequency variations above an adjustable threshold (f12, t12) or below (f13, t13), generating an alarm
or the opening of the circuit breaker.
14.2.9.13 Double protections setting

Using the double protections setting, the PR123/P can save a set of alternative parameters for all the protections. The second set of parameters
(set B) can replace the default set (set A) by means of an external command. The passage from set A to set B can be made when there is a change
in the mains configuration or when there is an emergency capable of changing the load capacity and the short circuit levels.
The second set of parameters (set B) can be enabled by:

- digital input provided with the PR120/K module. For instance, it can be connected to an auxiliary contact of a bus-tie;
- communication network, by means of the PR120/D-M (e.g. when the switch is scheduled);
- directly from the user interface on the PR123/P (see settings menu par. 14.5.4).
- with a time that can be specified by set A or set B after the circuit breaker has closed.
In operation, the state (set A and set B) is indicated on the display.

The double setting is disabled by default. To enable it, see par. 14.5.1.4.

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14.2.9.14 Summary table of the protection function settings for the PR123/P
Start-up threshold
Thermal memory
Protection Threshold Time Tolerance Time
Disabling of
selectivity
threshold (2)
TRIP only
Range
Disabling
Range Tolerance (2)
Zone
L
(t=k/I2) 0.4xIn ≤ I1 ≤ 1xIn 3s ≤ t1 ≤ 144s(1), Release between ± 10%, If ≤ 6 In
curve IEC60255-3 step 0.01xIn step 3s at I=3xI1 1.05 and 1.2xI1 ± 20%, If > 6 In
S1 0.6 xIn ≤ I2 ≤10xIn Min, 0.05s ≤ t2 ≤ 0.8s, step 0.01s ± 7%,If ≤ 6 In The best of the two data
(t=k) step 0.1xIn 0.10s ≤ t2start-up ≤ 1.5s, step 0.01s ± 10%,If > 6 In ± 10% or 40 ms
0.6 xIn ≤ I2 start-up ≤10xIn 0.04s ≤ t2sel ≤ 0.20s, step 0.01s
step 0.1xIn
S1 0.6xIn ≤ I2 ≤10xIn 0.05s ≤ t2≤ 0.8s, ± 7%,If ≤ 6 In ± 15%, If ≤ 6 In

(t=k/I2) step 0.1xIn step 0.01 at 10xIn ± 10%,If > 6 In ± 20%, If > 6 In
S2 0.6xIn ≤ I2 ≤10xIn Min, 0.05s ≤ t2 ≤ 0.8s, step 0.01s ± 7%,If ≤ 6 In The best of the two data
(t=k) step 0.1xIn 0.10s ≤ t2start-up ≤ 1.5s, step 0.01s ± 10%,If > 6 In ± 10% or 40 ms
0.04s ≤ t2sel ≤ 0.40s, step 0.005s
D 0.6xIn ≤ I7 ≤10xIn 0.20s ≤ t7 ≤ 0.8s, step 0.01s The best of the two data
(t=k) step 0.1xIn 0.10s ≤ t7start-up ≤ 1.5s, step 0.01s ± 10% ± 10% or 40 ms
0.13s ≤ t7sel ≤ 0.50s, step 0.01s
I 1.5xIn ≤ I3 ≤ 15xIn ≤ 30 ms ± 10%

(t=k) step 0.1xIn
G(4) 0.20xIn ≤ I4 ≤1xIn 0.1s ≤ t4 ≤ 1s, step 0.05s The best of the two data
(t=k) step 0.02xIn 0.2s ≤ t4start-up ≤ 1s, step 0.02s ± 7% ± 10% or 40 ms
0.04s ≤ t4sel ≤ 0.2s, step 0.01s
G(4) 0.2xIn ≤ I4 ≤1xIn 0.1s ≤ t4 ≤ 1s, step 0.05s ± 7% ± 15%

(t=k/I2) step 0.02xIn
Gext 0.2xIn ≤ I4 ≤1xIn 0.1s ≤ t4 ≤ 1s, step 0.05s The best of the two data
(t=k) step 0.02xIn 0.2s ≤ t4start-up ≤ 1s, step 0.02s ± 7% ± 10% or 40 ms
0.04s ≤ t4sel ≤ 0.2s, step 0.01s
Gext 0.2xIn ≤ I4 ≤1xIn 0.1s ≤ t4 ≤ 1s, step 0.05s ± 7% ± 15%

(t=k/I2) step 0.02xIn
Gext Idn = 0.3-0.5-0.7-1.0 0.06-0.10-0.20-0.30-0.40-0.50

(Idn) 2.0-3.0-5.0-7.0-10-20 0.80-1.00-3.00-4.8s(3) ± 10%
30A
U 5% ≤ I6 ≤ 90% 0.5s ≤ t6 ≤ 60s, step 0.5s ± 10% The best of the two data
(t=k) step 5% ± 10% or 40 ms
OT fixed, defined by Instantaneous ± 1°C _____

(temp=k) SACE
Iinst Automatic, defined Instantaneous ± 5% +1mS

by SACE
UV 0.5xUn ≤ U ≤ 0.95xUn 0.1s ≤ t8 ≤ 5s, step 0.1s ± 5% ± 20%

(t=k) step 0.01xUn
OV 1.05xUn ≤ I9 ≤ 1.2xUn 0.1s ≤ t9 ≤ 5s, step 0.1s ± 5% The best of the two data
(t=k) step 0.01xUn ± 10% or 40 ms
RV 0.1xUn ≤ I10 ≤ 0.4xUn 0.5s ≤ t10 ≤ 30s, step 0.5s ± 5% The best of the two data
(t=k) step 0.05 Un ± 10% or 40 ms
RP - 0.3xPn≤ P11 ≤-0.1xPn 0.5s ≤ t11 ≤ 25s, step 0.1s ± 10% The best of the two data
(t=k) step 0.02 Pn ± 10% or 40 ms
UF 0.9fn ≤ f ≤ 0.99fn 0.5s ≤ t12 ≤ 3s, step 0.1s ± 5% The best of the two data
step 0.01 fn ± 10% or 40 ms
OF 1.01fn ≤ f ≤ 1.1fn 0.5s ≤ t13 ≤ 3s, step 0.1s ± 5% The best of the two data
step 0.01 fn

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Start-up threshold
Thermal memory
Protection Threshold Time Tolerance Time
Disabling of
selectivity
threshold (2)
TRIP only
Range
Disabling
Range Tolerance (2)
Zone
LC1/LC2 loads 50%÷100% step 0.05xI1
control
Warning Iw 0.30÷3.00% step 0.05xIn ± 10% or 40 ms
(1)
The minimum value of this trip is 1s regardless of the type of curve For all cases not covered by the above hypotheses, the following tolerance values
set (self-protection). apply:
(2)
These tolerances are based on the following assumptions:
- self-supplied relay at full power (without start-up) Protections Trip threshold Trip time
- presence of auxiliary power supply
- two-phase or three-phase power supply L Release between 1.05 and 1.25 x I1 ± 20%
- preset trip time ≥ 100ms S ± 10% ± 20%
(3)
no-trip time I ± 15% ≤ 60ms
(4)
the protection G is disabled for current values greater than 4In, where I4 < 0.5 In, G ± 10% ± 20%
greater than 6 In, where 0.5 In ≤ I4 < 0.8 In and greater than 8 In where I4≥ 0.8 In. Others ± 20%
14.2.9.15 Table of measurements

Range %
Phase and neutral currents 0.3 ... 6 In 1.5
Internal ground fault current 0.3 ... 4 In 1.5
(internal source ground return)
External ground fault current 0.3 ... 4 In 1.5
(external source ground return)
Phase-to-phase and phase voltages 50 Vphase-to-phase ... 1.1x690 Vphase-to-phase 1
(measured at the module's input
and thus independent of the precision
relating to the use of any VT)
Residual voltage 50 Vphase-to-phase ... 1.1x690 Vphase-to-phase 1
(for systems with neutral only)
Peak factor 0.3 ... 6 In 1.5
Total power factor 0.5 ... 1 2.5
Mains frequency 35 ... 80 Hz ± 0.2

Instantaneous active power on the 0.3 ... 6 Pn 2.5
Instantaneous reactive power on the 0.3 ... 6 Pn 2.5
Instantaneous apparent power on 0.3 ... 6 Pn 2.5
the single phase and total system
Active energy 0.3 ... 6 Pn 2.5
Reactive energy 0.3 ... 6 Pn 2.5
Apparent energy 0.3 ... 6 Pn 2.5

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14.2.10 Trip curves
The trip curves given are for guidance and only show a sub-group of the possible selections (see par. 14.5.2).
14.2.10.1 Trip curves for functions L-S(t=k/I2)-I
t [s] 10 4
0,4 & 1
L
0,4 1
10 3 0,6 & 10
0,6 10
S
3 & 144
10 2 k
t= 2
1,5 & 15 I
1,5 15
10 0,05 & 0,8
10 -1
10 -2
10 -3
10 -1 1 10 100
x In
t [s] 10 4
0,4 … 1
L 0,4 1
10 3 0,6 … 10
0,6 10
3 … 144
10 2 S
1,5 … 15 t=k
1,5 15
10
10 -1
0,05 … 0,8
10 -2
10 -3
10 -1 1 10 100
x In

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14.2.10.4 Trip curves for function L in accordance with IEC 60255-3 (type A)
t [s] 10 4
0,4 1
0,4 … 1
L
10 3
.
k=0,14
a=0,02
.
10 2
3 … 144
10
10 -1
10 -1 1 10 100
x In

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14.2.10.5 Trip curves for function L in accordance with IEC 60255-3 (type B)
t [s] 10 4
0,4 1
0,4 … 1
L
10 3
.
k=13,5
a=1
10 2
3 … 144
10
10 -1
10 -1 1 10 100
x In
14.2.10.6 Trip curves for function L in accordance with IEC 60255-3 (type C)
t [s] 10 4
0,4 1
0,4 … 1
L
10 3
k=80
a=2
10 2
3 … 144
10
10 -1
10 -1 1 10 100
x In

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14.2.10.7 Trip curves for function D
t [s] 10 4
10 3
0,6 ! 10
0,6 10
10 2
D
10
0,2 ! 10
0,8
10-1
10 -2 10 -1 1 10 100
x In
14.2.10.8 Trip curves for function U
t [s] 10 4
0,05 … 0,9
0,05 0,9
10 3
U
10 2
60
10
1060
0,5 …
0,5
10 -1
10 -2 10 -1 1 10
% Sbil

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14.2.10.9 Trip curves for function UV
t [s] 10 4
0,5 … 0,95
0,5 0,95
UV
10 3
10 2
10
5
1
105
0,1 …
10 -1 0,1
10 -2
0,3 0,5 0,7 0,9 1,1 1,3
x Un
14.2.10.10 Trip curves for function OV
t [s] 10 4
1,05 … 1,2
1,05 1,2
OV
10 3
10 2
10
5
1
105
0,1 …
10 -1 0,1
10 -2
1 1,05 1,1 1,15 1,2 1,25 1,3
x Un

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14.2.10.11 Trip curves for function RV
t [s] 10 4
0,1 … 0,4
0,1 0,4
RV
10 3
10 2
30
10
0,5 …1030
0,5
10 -1
0 0,2 0,4 0,6 0,8 1 1,2
x Un
14.2.10.12 Trip curves for function RP

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14.3.1 Connections
For the connections provided by the user, it is recommended that you comply strictly with the recommendations contained
in this document.This will enable us to satisfy all the international reference standards and guarantee perfect operation of
the relay even under severe environmental and electromagnetic conditions.
Pay particular attention to the types of cable, the connections to earth and the recommended maximum distances.
The maximum length of the VT - PR120/V wiring must not exceed 15 meters.
The shield must be connected to earth on both sides.
Use VTs with a shield, connected to earth (see standard VT par. 14.3.2).
The VTs should only be used for voltages > 690V; for lower voltages the presence of the PR120/V module connected to the lower
or higher busbars will be sufficient.
13.3.1.1 Current sensor connection for external neutral

If you want to connect the current sensor for the external neutral conductor to a three-pole circuit breaker, remember to
set InN accordingly. During this procedure, the circuit breaker must be open and preferably isolated.
14.3.2 VT connections
Dielectric strength tests are not allowed on the inputs and outputs of the releases or on the secondary lines of any
connected VTs
The following is a summary table of standard VT connections according to the type of plant.
VT Standard: Single standard transformers, see par. 15.1.7.

The VTs must have a performance coming between the values of 10 and 20 VA inclusive, 4 kV insulation between the
primary and secondary.
"VT Standard" type transformer "VT Standard" type transformer

(Star/Star) (Delta/Delta)
Installation system
Application diagram Application diagram
TN-C B A
TN-S B A
IT with neutral B A
IT n.c A
TT with neutral B A
TT without neutral n.c A
Note: - for TN-C systems the connection must be made to PEN
- for TN-S systems the connection must be made to N for configurations with neutral or PE for configurations without neutral; if the
PE is used, the current thereon could be around a dozen mA. If a customer considers this value too high or has a residual current
protection which risks being tripped, then application diagram A must be used.
- for IT and TT systems with neutral, the connection must be made to N
Application diagram A Application diagram B

N
14.3.3 CS and TC connection test
If the PR123/P was installed by the user, it is important, before closing the CB, to check the last line on the display when the
relay is turned on for the first time via a PR030/B battery unit. No CS and/or TC disconnected messages must appear; if they
do, do not close the circuit-breaker immediately and make the correct connections.
14.3.4 Test Test 1/6

Before putting into service, a test can be conducted by means of the specific "Auto test" function which CB status
can be activated on the PR123/P. A positive result is shown on the display. Auto Test
Then a test can be conducted on the whole TC chain, again using the specific function (Trip test). A positive Trip Test (disabled)
result is shown by the circuit-breaker opening.
Check the open or closed state of the circuit-breaker on the same "PR123/P Test" screen, by checking CB open
"CB Status".

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If the PR123/P is supplied ready installed in the circuit-breaker, it is up to ABB SACE to set all the variables referring to the circuit-breaker or the
specific application correctly (e.g. type of circuit breaker, Rating Plug size, mains frequency ...).
Vice versa, if the PR123/P is supplied separately, it will be up to the user to set all the necessary parameters correctly.
Note that ABB SACE defines each possible setting according the content of the paragraph on the default parameters (see par. 14.4.4).
Apart from this, it is absolutely indispensable for the user to modify the password and carefully define each modifiable
parameter, before putting the PR123/P into service.
14.3.6 Password management

Specify a password? [0***]
To enter "EDIT" mode it is necessary to enter a four-figure numerical password. The values attributable to the password go from 0000 to 9999.
For the default password see par. 14.4.4.
Select the value of the first figure ( between '0' and '9' ) by means of the ↑ and ↓ keys and press ↵ to confirm the figure and then move on to
enter the next one.
After entering the fourth figure, check the password you have entered. If the password is correct, you go from the "READ" state to the "EDIT"
state.
If the password is wrong, the message

Wrong password
appears and remains until the ESC key is pressed (or until an interval of 5 seconds has elapsed).
It is also possible to interrupt the password entry procedure by pressing the ESC key.
The password is valid for a maximum of two minutes from the last time a key was pressed. It is immediately reset in the case of a high priority alarm
or when the unit is reset.
On entering a page with no modifiable parameters, the state of the protection is put on "READ". If the password is still valid, to enter "EDIT" mode
(on a page with modifiable parameters) simply press the ↵ key.
Disabling the Password.

By setting the value of the password to [0000] (on the "Unit configuration" menu) the password prompt is disabled. It is therefore always possible
to switch from "READ" to "EDIT".
To enter a new password, select the "New Password" item on the "Settings/System" menu.
14.3.7 Changing the electronic release
14.3.7.1 Installation
To complete the procedure for installing a PR123/P unit, follow the steps below:
1. With the circuit breaker open and preferably isolated, install the protection unit on the circuit breaker
2. Power the unit ONLY from the PR030/B
3. If there are no other errors, the display will show the message Configuration (configuration error) accompanied by the yellow
LED coming on permanently (warning)
8. Select "Install" and press "ENTER"
9. When the red led flashes on and off and the message Installation (installation error) is displayed, remove the PR030/B
10. Power the relay from any other source
Check for the absence of configuration errors.
14.3.7.2 Uninstalling
To complete the procedure for uninstalling a PR123/P unit, follow the steps below:
1. With the circuit breaker open and/or isolated power the unit from the PR030/B
6. Select "Uninstall" and press "ENTER"
7. If there are no error messages, remove the PR030/B
8. Remove the PR123/P unit from the circuit breaker
9. The remove the TC connector, proceed as indicated in the figure alongside.
It is not strictly necessary to complete the uninstalling procedure, but this enables the parameters relating to the circuit breaker, such as contact
wear and others, to be saved in the "KEY PLUG", otherwise these data would be lost. The data in question are then transmitted to the new PR123/
P unit installed on the same circuit breaker.

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14.4 User interface
1 2 3 4 5 6 7
13
8 9 10 11 12
Ref. Description
1 Voltage takeoff isolator

2 Busbar voltage LED
3 Pre-alarm indicator LED
4 Alarm indicator LED
5 Graphic display (the word ABB in the bottom left-hand corner indicates normal operation)
6 Serial number of the PR123/P
7 Rating plug
8 Pushbutton for exiting the sub-menus or for canceling (ESC)
9 Button for the cursor (UP)
10 Button for the cursor (DOWN)
11 ENTER key for confirming the data or changing the page
12 TEST connector for connecting or testing the release by means of an external device (PR030/B battery unit, BT030 wireless
communication unit and PR010/ T test unit)
The Graphic Display is of the LCD type with 128x64 pixels and it is backlit when there is an auxiliary voltage or a self-supply from a PR120/V module.
The display is always lit when there is a Vaux or, in self-supply mode with a minimum busbar current or powered from the PR120/V module as
defined in par. 14.2.2.1
You can adjust the contrast on the display by means of the specific function available on the user interface settings menu (par. 14.5.4.1).
14.4.1 Use of pushbuttons

The modifiable fields can be filled in using the ↑ or ↓ keys and confirming with the ↵ key. Once you have entered the page you need, you can
move from one value to another by using the ↑ or ↓ keys. To change a value, position the cursor over the value (the modifiable field will appear
in reverse, i.e. white on a black background), and use the ↵ key.
To confirm the programming of the previously configured parameters, press the ESC key once only. A check will be carried out on the parameters
entered and then the programming confirmation page will be displayed. To return to the main menu, press the ESC key twice.
The "i Test" key must be used to perform the Trip test to view the information page and to see the last trip within 48 hours of the CB opening in
self-supply mode.
14.4.2 Read and Edit modes

The menus map (see par. 14.5.1) shows all the pages which can be obtained and how to move between them from the keyboard, in the "READ"
mode (just to read the data) or in the "EDIT" mode (to set the parameters).
Starting from any page displayed, two different functions can be obtained according to the state of the unit:
1. "READ": the default page will be displayed automatically after about 120 seconds (see par. 14.5.1).
2. “EDIT": the default page will be displayed automatically after about 120 seconds.
The allowable functions depending on the state are:

“READ”:
Consultation of the measurements and of the historical data
Consultation of the unit configuration parameters
Consultation of the protection parameters
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“EDIT”:
Everything allowed in READ mode
Configuration of the unit
Programming of the parameters relative to the protections
TEST Functions of the unit
To access the "EDIT" mode, it is necessary to press the ↵ key on a page with fields which can be edited. A password will then be required to enable
you to switch to the editing mode.
The use of the keys is summarized in the following table:
Key Function
Move between pages
Move within menu
Change parameter values
End setting phase and confirm result
Choose menu item
Access to surfing menus from the default pages

Return to previous level when surfing within the menus, until you return to the default pages
Exit the parameter changing phase, aborting the change
This key is used to re-enable the display after it has gone off within 48 hours of the opening of the circuit breaker
in self-supply mode. Può essere utilizzato in congiunzione con gli altri tasti per combinazioni speciali che permettono
di accedere a pagine riservate.
14.4.3 Changing parameters

Moving within the Main Menu you can reach all the pages relating to the configurations and parameter settings with the opportunity to change
the values specified for the parameters.
After any programming, you need to Confirm/Cancel/Change any changes you have made. This procedure is not applicable to all the programming
activities.
Two examples are provided below: one concerns the case in which no confirmation is needed for the changes you have made, while in the other
a confirmation window appears.
Procedure not requiring the confirmation of any programming

For instance, to set the System Date, the correct sequence is as follows:
10:22:53
Press ESC to access the Main Menu. 400 A

(I1)
Menu 1/5
From the Main Menu, select SETTINGS Protections
Measurements
Settings
Protections settings
Settings 8/9
Measure Store Time

Select SYSTEM
Harmonic dist.
System
press the ↵ key (enter) System settings
System 1/4
Date
Time
Select the menu item DATE to change Language
January 12, 2004

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Password
You will be prompted to input a Password

complete the password entry procedure (par. 14.3.6) 0***
Enter password
Date
Change the date using the keys ↓ (arrow down)
↑ (arrow up) and confirm by pressing the ↵ key (enter). January 12, 2004
Enter password
Press ESC twice to return to the Main Menu.
Procedure requiring the confirmation of any programming
For instance, to change the Curve of the Protection L, the correct sequence is as follows:
10:22:53
Press ESC to access the Main Menu. 400 A

(I1)
Menu 1/5
Protections
From the Main Menu select the item PROTECTIONS Measures
Measurements
Settings
Protections 1/15
L Protection
From the Protections Menu select the item PROTECTION L
S Protection
S2 Protection
press the ↵ key (enter) Overload
L Protection 1/4
From the Protection L Menu select the item CURVE Function

Threshold I1
Time T1
t=k/i2
You will be prompted to input a Password Password
complete the password entry procedure (par. 14.3.6)

0***
press the ↵ key (enter) Enter password

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Function 1/4
Select the value you want from the list t=k/i2

and confirm pressing the ↵ key (enter). t=0.14b/(i0.02-1)
T=13.5b/(i-1)
Press ESC twice
Programming 1/3
Accept the new configuration Confirm

Reject the new configuration (the previous configuration is retained) Abort
Change the previously input values. Modify
Confirm
To select the required option use the ↓ (arrow down), ↑ (arrow up) keys, and press ↵ (enter) to confirm.
14.4.3.1 Modification of basic configuration

The configuration of the unit must be done in EDIT mode.
Following the instructions given in par. 14.4.3, view the following on the display:
System 2/4
Date
Change system date
Change system time Time
Select system language Language

07:56:28
System 4/4 Password

Time
Language 0***
New Password
**** Enter password
To change the system password, select the relevant menu item and press ↵ (enter); then you will be prompted to enter the OLD password, and
afterwards you can input the new one twice.
Press ESC twice to return to the Main Menu
Programming 1/3
Confirm
Abort
Modify
Accept the new configuration Confirm
Reject the new configuration (the previous configuration is retained)
Change the previously input values.

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14.4.4 Default settings
The PR123/P is supplied by ABB SACE with the following predefined parameters (Set A and Set B):
# Protection On/Off Thresholds Time Curve T.M. ZS Trip
1 L -- 1 In 144 s It
2
Off -- --
2 S Off 6 In 50 ms K -- Off: 0.04s --
3 D Off 6 In 0.2s-0.2s Off: 0.13s
4 I On 4 In -- -- -- -- --
5 G Off 0.2 In 0.4 s K -- Off: 0.04s On
6 U Off 50 % 5s Off
7 OT -- Off
8 K LC1 Off 50 % I1
9 K LC2 Off 75 % I1
10 UV Off 0.9 Un 5s Off
11 OV Off 1.05 Un 5s Off
12 RV Off 0.15 Un 15 s Off
13 RP Off - 0.1 Pn 10 s Off
14 UF Off 0.9 Fn 3s Off
15 OF Off 1.1 Fn 3s Off
16 Language -- Engl
17 Net Frequency -- 50 Hz
18 PR021/K Off
19 Neutral sel. -- 50 %
20 Toroid Selec. -- None
21 Ext. ground tor. Off 100 A
22 Vs Un -- 380V
23 S startup Off 6 In 100 ms
24 I startup Off 4 In 100 ms
25 G startup Off 1 In 100 ms
26 Password -- 0001
27 Measuring interval -- 60 min
28 Iw Off 3 In
29 Harmonic dist. warning Off
30 Power direction -- top → bottom

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14.5.1 Menu
As seen previously, the PR123/P uses the display to show messages, diagrams and menus. These are organized in a logical and intuitive way.
The following is a general layout showing how to access the main menu pages.
10:22:53
400 A
(I1)
Current N
I1 : --- Ne : ---
I2 : --- Ig : ---
I3 : ---
Voltage
U1 : - - - U12 : ---
U2 : - - - U23 : --- Menu 1/5 Measurements 1/7
U3 : - - - U31 : --- Protections Historicals

U3 : --- Measurements Power factor
Settings Energy
Protections settings Trip, measures, log
Active Power
P1 : ---
P2 : --- Menu 2/5 Measurements 6/7
P3 : --- Protections Peak factor

P: ---
Settings Contact Wear
Measures, graphics, harmonics 0.0 %
Reactive Power
Q1 : ---
Q2 : --- Menu 3/5 Settings 3/9
Q3 : --- Protections Circuit Breaker

Q: ---
Settings Modules
General settings Optional modules
Apparent Power
S1 : ---
Menu 4/5 Settings 8/9
S2 : ---
S3 : --- Measurements Harmonic dist.
Settings System
S: ---
Test Display Contrast
Device test 30%
Menu 5/5
Settings
Test 1/6
Test
CB status
About
Auto Test
Product information
Trip Test (disabled)
CB open
About 1/2
Protection Unit
Circuit Breaker
Test 6/6
COM module Protection Unit

SIGNALLING module
Zone selectivity
Device test

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Each time the unit is turned on, or after more than 2 minutes of inactivity on the keyboard, the display indicates the following page (default):
Percentage of the actual currents and 10:22:53

voltages with respect to the rated values Current of the phase under the greatest
(100%) 400 A
(I1) load
N Indication for the phase under the greatest

load (L1, L2, L3, N)
14.5.2 Protections menu

From the interface you can press ENTER to access the menu of the various protections available on the display
Menu 1/5 Protections 1/15
Protections Enter ↵ L Protection

Measures
Measurements S Protection
Settings S2 Protection
Protections settings Overload
Using the "arrow UP" and "arrow DOWN " you can view the various protections.
On the whole, the data that you can display concern the protections:
L, S, S2, D, I, G, U, UV, OV, RV, RP, UF, OF, OT, LOAD PROTECTION.
Example of surfing the Protections menu

From the Protection main page you can press ENTER to go to the Protection L Menu.
You can use "arrow UP" and "arrow DOWN" to select the items on the menu and confirm by pressing ENTER. Pressing this key triggers a Password
prompt, then you can select the functions associated with the protection L (as in the example)
Protections 1/15 L Protection 1/4 Password

Function
L Protection Enter ↵ Enter ↵
S Protection Threshold I1 0***
S2 Protection Time T1
Overload t=k/i2 Enter password
PSW + Enter ↵
Example of how to select the curve t=k/i2 Function 1/4
t=k/i2
t=0.14b/(i0.02-1)
T=13.5b/(i-1)
Similarly, to access the menus for the other protections, see the Protections Menu table below.
14.5.2.1 Protections menu table
L Curve
Threshold I1
Time t1
Thermal memory ON / OFF
S Enable ON / OFF
Curve
Threshold I2
Time t2
Selectivity time

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StartUp threshold
StartUp time
S2 Enable ON / OFF
Threshold I2
Time t2
Selectivity time
StartUp threshold
StartUp time
D Enable ON / OFF
Threshold I7
Time t7 Fw
Time t7 Bw
Selectivity time
StartUp threshold
StartUp time
I Enable ON / OFF
Threshold I3
StartUp threshold
StartUp time
G Enable ON / OFF
Curve
Threshold I4
Time t4
Selectivity time
StartUp threshold
StartUp time
Gext Enable ON / OFF

Curve
Threshold I4
Time t4
Selectivity time

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StartUp threshold
StartUp time
U Enable ON / OFF
Threshold I6
Time t6
UV Enable ON / OFF
Threshold U8
Time t8
OV Enable ON / OFF
Threshold U9
Time t9
RV Enable ON / OFF
Threshold U10
Time t10
RP Enable ON / OFF
Threshold P11
Time t11
UF Enable ON / OFF
Threshold f1
Time t12
OF Enable ON / OFF
Threshold f2
Time t13
OT Enable Trip ON / OFF
Load Threshold 1
Control Enable ON / OFF
Threshold
Threshold 2
Enable ON / OFF
Threshold
Threshold lw
Enable ON / OFF
Threshold
Note: for an explanation of the characteristics of the single protections and their settings and corresponding curves, see par.
14.2.9.

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14.5.3 Measurements Menu
For a complete description of the functions of the PR120/V module, see par. 15.1.
The following is a summary of the parameters accessible from the menu in the PR123/P unit.
14.5.3.1 Measurements Menu table
Setting Parameter / Function Values Notes
Historicals
Trips Last trip
Events Events log
Measurements
I Max Maximum active current
P Max Maximum active power
P Mean Mean active power
U Max Maximum voltage
U Min Minimum voltage
Reset measurements
Power Cos ϕ measured
factor
Energy Energy meters
Reset meters
Peak
factor
Mains 50 Hz Measured value
frequency 60Hz
Contact wear Percentage of wear on CB contacts
Waveforms I1, I2, I3 Graph, harmonics
N Graph, harmonics
Voltage 12, 23, 31 Graph, harmonics
14.5.4 Settings Menu
The configuration parameters in the Settings menu are password protected. Among the most
Menu 3/5
significant values you can select, note the neutral threshold (values 50%, 100%, 150%, 200%), the
Protections external toroid size (values 100 A, 250 A, 400 A, 800 A), the mains frequency at the installation (values
Measurements 50 Hz, 60 Hz). For a more detailed description of the settings for the modules, refer to the
Settings documentation on the modules (ch. 15).
General settings
Enter ↵
Settings 1/9 Circuit Breaker 1/3 Neutral protection 21/2
Enable
Circuit Breaker Enter ↵ Neutral Protection Enter ↵ + PWD
Main Frequency Ground protection Neutral threshold
Modules Unit installation
Circuit breaker settings Neutral settings On
14.5.4.1 Settings Menu table
Circuit Neutral protection

breaker Enable ON/OFF
Neutral threshold 50%-100%-150%-200%
Ground protection Said protection is provided only
in the event of an external toroid being used
External toroidal transformer Absent, SGR, Rc
Toroid size SGR
Toroid size Rc Idn = 1A, 10A
Mains frequency 50 Hz - 60Hz
Modules Module
PR120/V - Measuring if any see par. 14.5.4.4.1
PR120/D-M - COM if any see par. 14.5.4.4.2
PR120/K - Signalling if any see par. 14.5.4.4.3
Local Bus unit Absent - Present

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Data logger Enable ON/OFF See Annex par. 16.4

Sampling frequency
Stop event
Stopping delay
Restart
Stop
Dual setting Enable ON/OFF
Default setting SET A / SET B
Dual Set CB closure
Dual Set with Vaux
Measurement interval from 5 to 120 min, step 5 min
Harmonic distortion ON/OFF The warning indicates that the distortion exceeds
factor 2.1
System Date
Time
Language English/Italiano/Francais/Deutsch/Español
New password
Display Contrast
The summary table relates to the surfing of the pages dedicated to the PR120/V module (see par. 15.3) and to the PR021/K unit (see par. 16.1).
14.5.4.2 Neutral adjustment

In the SACE PR123/P release, this protection can be set for the following values: InN = 50% - 100% - 150% - 200% * In.
The values that can be used to adjust the neutral are given in the table below for the various possible combinations between types of circuit-breaker
and adjustment of the threshold In.
14.5.4.2.1 Neutral adjustments table
Adjustment for the threshold I1 (L Protection)

Circuit breaker size I1 ≤ 0.5 0.5 < I1 ≤ 0.66(1) I1 > 0.66
E1 50-100-150-200% 50-100-150% 50-100%

E2 50-100-150-200% 50-100-150% 50-100%
E3 50-100-150-200% 50-100-150% 50-100%
E4 50-100% 50% 50%
E4/f 50-100-150-200% 50-100-150% 50-100%
E6 50-100% 50% 50%.......
E6/f 50-100-150-200% 50-100-150% 50-100%
Note 1: The adjustment I1=1 In is meant as the maximum adjustment of the overload protection. The actual maximum allowable adjustment must take into account any
temperature derating, the terminals used and the altitude.
Failure to comply with the setting limits for “In” and “InN” can cause circuit breaker damage with consequent risks even for
the operator.
In any case, the relay records any setting error between I1 and the Neutral setting and it signals this by means of the warning (see par. 14.6.3).
14.5.4.3 Mains frequency settings

In the Mains frequency menu, you can choose between the frequency values: 50, 60 Hz.
Settings 2/9 Password Main Frequency 1/2
Circuit Breaker Enter ↵ Enter ↵ 50 Hz

Main Frequency 0*** 60 Hz
Modules
4P
50 Hz Enter password

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14.5.4.4 Modules
When you access the Settings menu, there is a set of menus available relating to the modules.
14.5.4.4.1 PR120/V - MEASURING module
Modules 1/4 MEASURING module 1/5
MEASURING module Voltage Transf

COM module Rated voltage
SIGNALLING module Positive Power flow
Optinal
Module modules
configuration Absent
In the measuring module you must enter a password and can then opt for the absence or presence of the voltage transformer. Moreover, you
can select the values of the primary voltage (100, 115, 120, ... 1000V) and secondary voltage (100, 110,..,230V). The power flow can be LOW
-> HIGH or HIGH-> LOW. After entering a password you can choose whether the neutral connection is to be Absent or Present. The phase sequence
and cosϕ signal can be enabled and disabled (ON /OFF) and the corresponding threshold values can be selected (see par. 15.1).
14.5.4.4.2 PR120/D-M - COM module
Modules 2/4 COM module 1/5
MEASURING module Local / Remote

COM module Serial Address
SIGNALLING module Baudrate
Communication parameters Local
The local or remote modes can be selected after entering a password. The serial address can be displayed after entering a password. The Baud
Rate can be set on the values 9600 and 19200 bit/s. The physical protocol provides for the options: (8,E,1), (8,0,1), (8,N,2), (8,N,1). The addressing
can be selected as standard Modbus or ABB. For further information on the PR120/D-M communication MODULE, see paragraph 15.2 in this
manual .
14.5.4.4.3 PR120/K - SIGNALLING module
For a thorough examination of the signalling module, refer to the corresponding section of the module, paragraph 15.3.
14.5.4.4.4 PR120/D WL-COM module
This module is for wireless communication based on the Bluetooth standard between the PR123/P protection release and a hand-held PC (PDA)
or a laptop with a Bluetooth port. For further information, see the description of the module in paragraph 15.4.
14.5.4.4.5 Settings for the Local Bus unit

If the PR021/K unit is connected, you need to enable the local bus by selecting present.
14.5.5 Test Menu

Access to the Test menu is password protected.
Menu 4/5 Password Test 1/6
Measures Enter ↵ Enter ↵ CB status

Settings 0*** Auto Test
Test Trip Test (disabled)
Device test Enter password CB open
The menu shows the state of the CB, in the dialog module (COM module) the state of the springs and the position of the CB, and in this submenu
you can make the CB open or close.
Using the "Trip Test" function lets you view the disabling/enabling of the Trip. If it is enabled, the circuit breaker is opened. The function is only
available with a busbar current of nil (use Vaux, PR030/B or PR010/T).
On the page only with Vaux, you can also see the state of the circuit breaker "STATUS", and thus make sure that the input is correctly wired.

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The surfing path is summarized in the following table:
14.5.5.1 Test Menu table
CB status Open/Closed INPUT PWD

Indefinite
Auto Test Display test
Trip Test Enabled / Disabled
PR120/D-M State of springs Loaded / Unloaded
Module Position of CB Isolated / Withdrawn
Open CB
Close CB
PR120/K Input ON
Module Auto Test ---
Zone Protection S
selectivity (status) Input ON/OFF
Force Output
Release Output
Protection G
(status) Input ON/OFF
Force Output
Release Output
14.5.6 Information Menu

The Information Menu enables you to view the data relating to the protection unit and the type of circuit breaker.
About 1/2 Protection Unit 1/3 Circuit Breaker 1/3
Protection Unit Nr. : 00000000000ABB SACE Nr. :

ESC +↓
Enter ↵ Device : PR123/P Device : E1B800
Circuit Breaker
Version : LSIG + Enter ↵ Rated Curr. : 630 A
Protection Unit Normative : IEC Installation : Jan 00, 2000
Software : P 1.02 Maintenance : Jan 00, 2000
14.5.6.1 Information on the trip and opening data

The PR123/P unit saves all the information relating to the type of protection tripped, the opening data, the date and time. Using the "i Test" key
makes the release show all these data directly on the display. There is no need for an auxiliary power supply for this function. With an auxiliary
power supply, the information is shown immediately on the display without the need to press the "i Test" key and remains displayed indefinitely
until you press the key .
The information remains available for 48 hours with the circuit breaker open or without any current flowing in the busbars. The data relating to
the last 20 trips are stored in the unit's memory. By connecting a PR030/B battery unit or a BT030 wireless communication unit, you can retrieve
the information relating to the last 20 trips recorded.
Access to view the opening data is via the Historicals submenu in the Measurements menu. The following is an example of the information provided:
Last Trip N.02

1/3 Number of openings due to the protections and to the TRIP tests
15 Feb 2004
L Protection Indication for protection tripped
I1: 625A I3: 623A
I2: 617A N: > 10.0 kA Value of the currents interrupted on phases (L1, L2, L3), neutral (Ne) and Ground (if G has been tripped).
Again in the Measurements menu, you can view the percentage of contact wear, which is an indication of the electrical life of the electrical contacts
in the circuit breaker.
In any case, functionality of the relay is in no way modified by the presence of the wear messages.
The prealarm message (wear > 80%, "warning" LED lighting up) indicates that the wear has reached a high value. The alarm message (100%
wear, "alarm" LED lighting up) indicates that it is necessary to check the state of contact wear.
The percentage of wear depends on the number of openings carried out by the circuit-breaker and by the absolute current interrupted during
each of them.

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14.6 Definition of alarms and signals in the PR123/P unit
Signalling Description
• The prealarm threshold has been exceeded; one or more phases with current values in the range
0.9xI1< I < 1.05xI1. (on the Ne it depends on the selection made; for instance, at 50% the values are halved);
• Presence, between two or three phases, of unbalance above the value programmed for the "U" protection,
Warning (yellow) led with protection trip disabled;
• Presence of distorted wave form with factor> 2.1;
• Contact wear greater than 80% (and less than 100% with Vaux only);
• WARNING Threshold Iw exceeded;
• Circuit-breaker state error;
• Frequency out of range.
• Presence of overload on one or more phases with current values I >1.3 I1 (timing protection “L”)
(on the Ne it depends on the selection made; for instance, at 200% the values are doubled)*;
• Timing in progress for protection function S;
• Timing in progress for protection function I;
Alarm (red) led • Timing in progress for protection function G;
• Timing in progress for protection function D;
• Timing in progress for the voltage (UV, OV, RV), frequency (OF, UF) protection functions;
• Timing in progress for the reverse active power protection function (RP);
• Timing in the case of unbalance between the phases (protection U) above the value set in the configuration
with protection trip set to on;
• Contact wear = 100%;
• Rating Plug disconnected;
• Trip Coil (TC) disconnected;
• Key plug error;
• Current sensors disconnected.
* The IEC 60947-2 Standard defines the timing threshold L for current: 1.05 < I < 1.3 I1
14.6.2 Electrical signals
K51/p1..p4 Programmable electrical signals, if the PR120/K module or the PR021/K unit are installed and there is an auxiliary power supply.
Pressing the "i Test" key enables you to reset the activated contacts.
14.6.3 Table of error and warning messages

All the messages which can be shown on the display relating to incorrect configurations, generic alarms or deriving from the protection functions
and linked to useful information are described below.
The following symbols in the warning signals have the following meanings:
= warning signal / Protection in alarm mode, with no trip (trip=off)
= Protection in alarm mode, with trip at end of delay (trip=on)

Harmonic dist. Harmonic distortion alarm Busbar currents with form factor > 2.1
Contact wear Alarm for contact wear Contact wear = 100%
G Alarm for protection G
Gext Alarm for protection Gext
T Alarm Alarm for protection T Temperature outside range
T Alarm for protection T
U Alarm Alarm for protection U Protection U delay counting down
UV Alarm Alarm for protection UV
OV Alarm Alarm for protection OV
RV Alarm Alarm for protection RV
RP Alarm Alarm for protection RP
UF Alarm Alarm for protection UF
OF Alarm Alarm for protection OF

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Ne Sensor Alarm for Ne phase current sensor Phase Ne sensor disconnected or faulty
Gext Sensor Alarm for Gext current sensor Gext sensor disconnected or faulty
TC disconnected Trip Coil disconnected or faulty
Rating Plug Rating Plug Error absent or faulty
Power factor Power factor error The power factor module is lower than the specified threshold
Phase cycle Phase cycle inverted
Invalid date Clock information lost
CB status CB status error Probable error in Q26 and/or Q27
Startup Error during relay installation
CB not defined State of circuit breaker inconsistent (Open/Closed) Probable error in Q26 and/or Q27
Local Bus Local Bus error See par. 14.7
Contact wear Contact wear prealarm Contact wear ≥ 80%
L prealarm Protection L prealarm
T prealarm Protection T prealarm
Frequency range Error: frequency out of range
Warning Iw Iw threshold exceeded
Timing L Timing protection L
Timing S Timing protection S
Timing S2 Timing protection S2
Timing G Timing protection G
Timing Gext Timing protection Gext
Timing D Timing protection D
Timing U Timing protection U
Timing UV Timing protection UV
Timing OV Timing protection OV
Timing RV Timing protection RV
Timing RP Timing protection RP
Timing UF Timing protection UF
Timing OF Timing protection OF
14.6.4 Error messages displayed in pop-up windows

All the messages that appear on the display in a pop-up window are described below.
Error message Description

Password error
Session impossible A programming session cannot be started due to a contingency (e.g. a timer-controlled delay still elapsing)
Value outside range Value beyond the established limits
I2(S) ≤ I1(L) Incongruence between thresholds of protections L and S or S2
I3(I) ≤ I2(S) Incongruence between thresholds of protections I and S or S2
I3(I) ≤ I7(D) Incongruence between thresholds of protections I and D
I7(D) ≤ I1(L) Incongruence between thresholds of protections L and D
Sel. D/S Zone selectivity enabled in both protection D and S or S2
Sel. D/G Zone selectivity enabled in both protection D and G or Gext
NEC NEC requirements not satisfied
Unavailable Function is not available
Invalid date Date has not been set
Parameters revised Programming session concluded correctly
Cancelled Programming session cancelled
Failed Programming session rejected

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14.7 Troubleshooting PR123/P unit
Note:
1. Before consulting the following table, check for any error messages appearing for some seconds on the display.
3. In the case where the suggestions proposed do not lead to a solution of the problem, please contact the ABB SACE assistance service.
1 The trip test cannot be run 1. The busbar current is > 0 1. FN

2. The TC is not connected 2. Check the messages on the display
3. Thermal memory enabled 3. Exclude if not necessary
4. Incorrect Neutral Selection 4. Correct Neutral Selection
5. The SdZ is inserted 5. Exclude if not necessary
3. Curve I2t inserted 3. Exclude if not necessary
4. Incorrect Neutral Selection 4. Correct Neutral Selection
4 Rapid trip, with I3=Off Iinst tripped FN with short-circuit with high I
5 High earth I, but no trip happens 1. Incorrect selection of the sensor 1. Set int. or ext. sensor
2. Function G prevented with I>4 In 2. FN
6 Display off 1. Vaux missing and the current 1. FN, see 14.2.2.1
and/or voltage are below the
minimum value
2. Temperature out of range 2. FN, see 14.2.9.8
7 The display is not back-lit Current and/or voltages below the FN
limit for lighting the display
8 Reading of I incorrect Current below the minimum FN
threshold that can be displayed
9 Reading of V, W and power 1) Connection error between VT 1) Check connections between VT and PR120
factor incorrect and PR120/V 2) Set the correct parameters
2) VT parameter settings error
10 " Local Bus" message No communication between PR123/P 1. If not present, disable PR021/K,
on display and PR021/K see 14.5.4.4.5
2. Check bus connection
3. Check PR021/K
11 Message "" Function disabled or data out FN
instead of expected data of range
12 The expected trip does not occur Trip function disabled FN enable trip if necessary
13 No activation of the Unbalance Values of I out of range FN, see 14.2.9.7
U protection
14 No display Vaux missing, FN, see 14.5.6.1
of the opening data the buffer capacitor is discharged
15 The password is not requested The password has been disabled FN, re-enter the password with a value
other than 0000
16 Impossible to change any PR123/P in alarm situation FN
parameter
17 " Sensor time" or Possible failure inside relay Contact ABB Sace
" Start-up" message
If you suspect that the PR123/P is faulty, has a malfunction or has generated an unwanted trip, it is advisable to follow the
recommendations below very carefully from the Measurements menu, Historicals Trip:
1. Make a note of the type of protection that has tripped by accessing the LAST TRIP page if there is an external power supply (Vaux or battery)
or by pressing "i Test" if in self-supply mode.
2. Note down the type of circuit-breaker, number of poles, any accessories connected, In, Serial Number (see par. 14.4) and the SW version.
3. Prepare a brief description of the opening (when did it happen?, how many times?, was it always under the same conditions? what type of
load? what voltage? what current? is the event reproducible?)
service.
The completeness and accuracy of the information given to the ABB Assistance service will facilitate technical analysis of the problem encountered,
and will allow us to carry out all actions useful for the user rapidly.

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14.8 Accessories

The test with the SACE PR010/T unit enables you to check the proper operation of the inputs, outputs, thresholds and tripping times of the protection
functions "L", "S", "I", "G", OV, UV, RV, U. The test unit is connected to the relay by means of the front Test connector (see par. 14.4).
14.8.2 ABB SACE PR030/B power supply unit

The PR030/B is a momentary power supply unit to be inserted in the front test connector of the PR123/P.
Using this standard accessory, you can run an autotest, the trip test, and power the PR123/P unit whatever the state of the circuit breaker (open/
closed, in the test position or enabled and without an auxiliary power supply).
The battery inside the PR030/B guarantees a power supply to the unit for about 3h continuously (depending on the operations conducted on
the PR123/P and on the PR120/D-BT module).
The life of the battery diminishes if the PR030/B accessory is also used to perform the trip test and the autotest. It is essential to use the PR030/
B to read the trip data if the trip has occurred more than 48 hours earlier and the release was no longer powered.
14.8.3 BT030 wireless communication unit

The BT030 is a device for connecting to the Test connection on the PR123/P.
It enables Bluetooth communication between the protection release and a hand-held or laptop PC with a Bluetooth port.
This device is dedicated for use with the SD-Pocket application.
The BT030 has a rechargeable Li-ion battery that can provide the power needed for it to function and for the protection release.

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15 Modules
15.1 PR120/V - MEASURING Module
15.1.1 General characteristics

The MEASURING module records and processes the phase voltages. The measurements are sent by the module to the protection release, enabling
the implementation of a set of protection and measurement functions. The module comes with a "Power" LED and a sealable isolator for dielectric
stiffness tests. The module also enables the relay to be powered.
15.1.2 Front view

- "Power" LED
- Isolator
Isolator
Before performing the dielectric stiffness test it is essential to turn the isolator into the Test position mode by turning
the screw anticlockwise until you reach the end of stroke position.
After performing a dielectric stiffness test, restore the isolator to its original position by turning it clockwise until you reach
the opposite end of stroke, because all the voltage protections are disabled while the isolator is in the test position.
Dielectric stiffness tests on any voltage transformers connected to the secondary lines alone are prohibited.
At the end of the procedure, make sure that the Power ON LED is on.
15.1.3 Releases with the module

- standard for PR123/P
- optional for PR122/P.
15.1.4 Powering the PR122/P and PR123/P units via the PR120/V module
The PR122/P and PR123/P units are powered by the MEASURING module via the busbar voltage.
The powering stage is capable of operating starting from a voltage of 80Vrms two-phase phase to phase up to 897Vrms ( 1.3 * 690Vrms ) three-
phase phase to phase at its input (coming directly from the busbars or from a transformer secondary). In the case of three-phase systems with
a rated voltage greater than 690Vrms phase to phase, a step-down transformer (with a transformation ratio of less than 1) is used. See par.
15.1.7.
The minimum three-phase busbar voltage needed to power the PR122 or PR123 relay alone (without any additional modules) is 35 Vrms.
The following tables show the phase-to-phase voltage values at the MEASURING module's input for which the relays and modules are enabled:
PR123/P Relay + PR120/K Module
ENABLING THE UNIT AND ITS FUNCTIONS THREE-PHASE (phase-to-phase voltage)

PR123/P Relay 4 PR120/K active contacts Relay display backlighting Enabling threshold
60Vrms
70Vrms
90Vrms

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PR123/P Relay + PR120/ D-BT - WL-COM Module
ENABLING THE UNIT AND ITS FUNCTIONS THREE-PHASE(phase-to-phase voltage)

PR123/P Relay PR120/D-BT WL module Relay display backlighting Enabling threshold
60Vrms
70Vrms
PR123/P Relay + PR120/K Module + PR120/D-BT - WL-COM Module
ENABLING THE UNIT AND ITS FUNCTIONS THREE-PHASE(phase-to-phase voltage)

PR123/P Relay 4 PR120/K active contacts PR120/D-BT WL module Relay display backlighting Enabling threshold
70Vrms
90Vrms
110Vrms
N.B.: for proper connection of PR120/V module, see figs. 43, 44 and 48 of Electric diagram.
15.1.5 Operating instructions / Operation in service
15.1.5.1 Using the Measurement submenus with the PR120/V

The menu for accessing the functions of the module, which is always provided on the PR123/P, but optional for the PR122/P, is illustrated below.
Menu 2/5
Protections
Measurements
Settings
Measures, graphics, harmonics
Measurements 1/7 Historicals 1/3 Last Trip n. 02
Historicals Trip Jan 06, 2004 08:52:11:733

Power factor Events L Protection
Energy Measurements I1: 625 A I3: 623 A
I2: 617 A Ne: > 10.0 kA
Trip, measures, log Trip list
Events Log n. 01
Jan 10, 2004 08:52:11:733

Vaux On
Measurements 1
Power factor 1/6
I Max
--- P Max
P Max
Measured Cosj Current
I Max Jan 10, 2004 04:31
I1: . . . . 5 min
Energy 21/2 Energy counters

Energy counters
Reset counters 0 kWh P Max Jan 10, 2004 04:31
0 kVARh .... 5 min
Energy counters 0 kVAh
P Mean Jan 10, 2004 04:31
.... 5 min
Continues overleaf

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Continues from previous page
Measurements 7/7 Measurements 6/6
Main Frequency U Max

Contact Wear U Min
Waveforms Reset measures
Graphics Reset measures
Peak factor U Max Jan 10, 2003 04:31
U1 : 416 V 5 min
I1 : --- I3 : ---
I2 : --- Ne : ---
Main Frequency U Min Jan 10, 2003 04:31
U1 : 416 V 5 min
50.0 Hz
Measured value
Waveforms 1/7 I1 = - - -
I1
I2
I3
Current, Harmonics
Measurements 21/2 I1 Total distorsion : 0.0 %

Refresh Harmonic n. 1/40 : 100.0 %
Harmonics
New graphic
Waveforms 4/7 Ne = - - -
I2
I3
Ne
Current, Harmonics
Measurements 2/2 Ne Total distorsion : 150.0 %

Harmonics
Harmonics
Continues overleaf

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Continues from previous page
Voltage 12 = 416 V
Measurements 2/2 U 12 Total distorsion : 0.0 %

Harmonics
Harmonics
15.1.5.2 Table of submenus for the PR120/V module

This menu is accessible using the path "Settings/Modules/ PR120/V module"
Voltage Absent for voltages below 690V

transformer
Rated voltage 100V-115V-120V-190V

208V-220V-230V-240V
277V-347V-380V-400V
415V-440V-480V-500V
550V-600V-660V-690V
Voltage Present for voltages above 690V, see par. 15.1.7
transformer
Primary voltage 100V-115V-120V-190V

208V-220V-230V-240V
277V-347V-380V-400V
415V-440V-480V-500V
550V-600V-660V-690V
910V-950V-1000V-1150V
Secondary voltage 100V-110V-115V-120V

200V-230V
Power Low → High PR120/V connected to the bottom CB terminals
flow High → Low PR120/V connected to the top CB terminals
Signals Phase sequence
Enabling status ON/OFF
Threshold 123/321 can be selected if enabling status is ON
Cos ϕ
Enabling status ON/OFF
Threshold from 0.5 to 0.95 step 0.01
15.1.5.3 Measurements menu table

For the sake of simplicity, the table refers to the Measurements menu already provided in the PR123/P, which is also applicable for the PR122/
P fitted with a PR120/V module.
Historicals Trips List of trips

Events Events log
Measurements
Maximum current
Maximum active power
Mean active power
Maximum voltage
Minimum voltage
Reset measurements
Power measured Cos ϕ
factor available in self-supply mode
Energy Energy meters
Reset meters

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Peak Peak value/rms value
factor available in self-supply mode
Mains 50-60Hz Measured value
frequency available in self-supply mode
Contact wear Percentage of contact wear
Waveforms Current I1/I2/I3/Ne
Refresh
Harmonics
Voltage 12/23/31
Refresh
Harmonics
15.1.5.4 Measurements menu
15.1.5.4.1 Historicals
Measures 1/7 A whole range of measurements is accessible from the "Measurements/Historicals" menu.
Historicals
Power factor
Energy
Trip, measures, log
15.1.5.4.2 Trips
The following is an example of a page showing the latest trip. You can access said page by selecting Trips via the path Measurements / Historicals
/ Trips. The page shows the values for the type of protection that has been tripped (L in the example).
Last Trip n. 02 Meter: counts progressively (0 … 65,535) as of the date

Jan 06, 2004 08:52:11:733 of the latest trips reset. It shows the latest 20 trips which
L Protection
can still be selected.
I1: 625 A I3: 623 A
I2: 617 A Ne: > 10.0 kA Time (in hours and minutes) when CB opened
15.1.5.4.3 Events
The following table shows a typical page concerning the latest events Log. You can access said page by selecting Events via the path Measurements
/ Historicals / Events.
Events Log n. 01
Meter: indicates "Latest" and measures the previous
events in the sequence -1, -2 up to -80 (e.g., the last but
Jan 10, 2004 08:52:11:733 one is shown as -1)
Vaux On
1
15.1.5.4.4 Measurements
This menu is for showing the following measurements:
I Max - Maximum current

P Max - Maximum active power
P Mean - Mean active power
U Max - Max line voltage (phase-to-phase)
U Min - Min line voltage (phase-to-phase)
Reset - Reset measurements
15.1.5.4.5 Power factor
Power factor
The unit provides the measurement of the global power factor. For phase power under 2% (0.02xPnphase)
the value is not displayed, but is replaced by ‘…..’.
---
Measured Cos

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15.1.5.4.6 Energy
The unit also provides meter readings of the total active,reactive and apparent energy of the system. The minimum value that can be displayed
is 0.001MWh or 0.001MVARh or 0.001MVAh. The energy meters' end of scale is approximately 2.15 billion kWh / kVARh / kVAh.
The meter can also be reset by pressing the "Reset meters" key on the menu.
For the ranges and precisions see par.14.2.9.15.
Energy counters Energy 2/2

Energy 21/2
Energy counters
Energy counters
ESC +↓ Reset counters
Reset counters Enter ↵ 0 kWh
0 kVARh + Enter ↵
Energy counters 0 kVAh Reset counters
15.1.5.4.7 Peak factor
Peak factor
On this page you can also measure the peak factor - i.e. the relationship between Ipeak / Irms - for each of
I1 : --- I3 : --- the phases. This measurement is not displayed for phase currents below 0.3xIn and it is not available for
I2 : --- Ne : --- phase currents above 6xIn. For the ranges and precisions see par. 14.2.9.15.
15.1.5.4.8 Mains frequency
Mains Frequency
This page enables you to view the mains frequency. This is calculated on the voltages (if Umax > 0.1Un).
50.0 Hz For the ranges and precisions see par. 14.2.9.15.
The measurement is guaranteed a maximum of 5 s after the change in frequency.
Measured value
15.1.5.4.9 Contact wear

This submenu shows the percentage of wear on the CB contacts.
15.1.5.4.10 Waveforms
I1 = - - -
When you access this menu page, 120 samples of the wave form of the selected phase are acquired and
displayed.
When you press the ↵ key, a new wave form is acquired and displayed.
Using the ↑ or ↓ keys, you can display the waveforms of the following measurement channels (L2, L3, Ne,
V1, V2, V3, Gt).
Value of harmonic N° N° of currently-selected harmonic
You can analyze the harmonic of the samples acquired and displayed on the "Waveforms" page, i.e. the
Ne Total distorsion : 150.0 %
page on the left is displayed, containing the module of the harmonics from the 1st to the 40th (up to the 35th
Harmonic n. 1/40 : 100.0 % for a mains frequency set to 60Hz) given as a percentage of the fundamental (harmonic n° 1), which is
consequently always given as 100%.
Using the ↑ and ↓ keys you can go to the bar of interest (at the "No." of harmonic required, the bar begins
to flash) and read the corresponding percentage value.
The measurement precision is 5%.
15.1.6 Data logger

The data logger is active both with Vaux and with a power supply from the PR120/V.
For further information, see par. 16.4.

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15.1.7 Electrical characteristics of the transformers
If the phase-to-phase line voltage is greater than 690Vac, it is essential to use a step-down transformer between the bars and the
PR120/V module. Voltage transformers can be installed up to 15 m away from the PR120/V module to which they are connected. Proper
operation is only guaranteed for star/star or delta/delta configurations.
The allowable primary and secondary rated voltages that must be set on the unit are specified in the table 15.1.5.2.
Mechanical characteristics
Fixture DIN rail EN 50022

Material self-extinguishing thermoplastic
Degree of protection IP30
Electrostatic protection shielded towards EARTH
Electrical characteristics
Precision class cl. 0.5

Performance ≥ 10 VA
Overload 20% permanent
Insulation 4 kV between inputs and outputs
4 kV between shield and outputs
4 kV between shield and inputs
Operating frequency range from 50 Hz to 60 Hz, ± 10%

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15.2 PR120/D-M - COM communication module

Dedicated communication module for connecting the relay to a Modbus net, and for remote supervisory and control activities on the circuit breakers.
15.2.2 Front view

- "Power" LED
- LED RX/TX (data send/receive signal).
15.2.3 Releases complete with the module

- optional for PR122/P
15.2.4 Power supply

The PR120/D-M - COM communication module is only powered by the relay if there is a 24V auxiliary voltage available.
15.2.5 Connection
Refer to fig.45 in the wiring diagram provided in this manual.
15.2.6 Communication functions available

The communication function on the PR122/P, PR123/P releases with PR120/D-M - COM is listed in the table:
PR122/P or PR123/P + PR120/D-M - COM
Protocol Modbus RTU

Physical interface RS-485
Baud rate 9600 - 19200 bit/s
15.2.7 PR120/D-M - COM module menu
Local/remote Local/remote
Serial address 1 ... 247
Baud rate 9600 bit/s
19200 bit/s
Physical protocol 8,E1 - 8,0,1 - 8,N,2 - 8,N,1
Addressing Modbus standard
ABB

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15.3 PR120/K signalling module

The module enables the local signalling of alarms and circuit breaker trips.
There are two possible configurations for the SIGNALLING module:
- default configuration: 1 digital input, 3 contacts with pole in common, 1 independent contact;
- alternative configuration: 4 independent contacts. In this case, the digital input is wired, but not brought up to the terminal block.
The two configurations are alternative to each other. You can switch from one configuration to the other without changing the module, by using
a different wiring, as illustrated in the wiring diagrams in figs. 46 or 47.
15.3.2 Front view

- "Power" LED
- N° 4 LED: associated with the signalling contacts.

15.3.4 Characteristics of the digital input

The unit enables the digital input to be associated with the following functions:
- enabling of an alternative set of parameters, set B (PR123/P only);
- outside trip control;
- zeroing release trips;
- resetting PR120/K contacts;
- local/remote enabling;
- resetting energy meters.
With the digital input the enabling relays have a common connection.
For the load control function, the module can be used as an actuator.
15.3.5 Characteristics of the signalling contacts

The following data are defined for resistive loads (cos ϕ = 1)
Type of contact SPST

Maximum switching voltage 130 Vdc 380 Vac
Maximum switching current 5A 8A
Maximum switching power 175 W 2000 VA
Breaking capacity @ 35 Vdc 5A ----

Breaking capacity @ 120 Vdc 0.2 A ----
Breaking capacity @ 250 Vdc ---- 8A
Breaking capacity @ 380 Vdc ---- 5.2 A
Contact/coil insulation 4000 Vrms

Contact/contact insulation 1000 Vrms

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15.3.6 Power supply
The PR120/K signalling module is powered in auxiliary mode by the relay and/or by the PR120/V as specified for the PR120/V module.
15.3.7 PR120/K module menu
Relay n. 1
(K51/p1) Signal source Standard or custom - see par.16.5
Delay 0...100s step 0.01s - Deliberate delay before activating the contact
NO/NC NO/NC - Contact normally-open (NO) or normally-closed
(NC)
Latch ON/OFF - With the contact "ON", once it has been activated it
stays switched
A specific reset action is needed to reset it
Relay n. 2
(K51/p2) Signal source Standard or custom
Delay 0...100s step 0.01s
NO/NC NO/NC as above
Latch ON/OFF
Relay n. 3
Delay 0...100s step 0.01s as above
NO/NC NO/NC
Latch ON/OFF
Relay n. 4
Delay 0...100s step 0.01s as above
NO/NC NO/NC
Latch ON/OFF
Input
Polarity active low
active high
Function Generic - no associated action

Outside trip - releases the circuit breaker
Reset trip - resets the data after a trip
Set B - switches from set A to set B
Local - forces the local status of the protection (local/remote)
Signal reset - programmable contact reset
Energy reset - energy meter reset
Delay - performs action after preset time

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15.3.8 Programming contacts K51/p1, K51/p2, K51/p3 and K51/p4
The PR120/K is fitted with four relays whose contacts are named K51/p1, K51/p2, K51/p3 and K51/p4,
which can signal different situations selectable by the user from among those given in the standard list, whereas customizations can be programmed
by selecting "custom" on the menu and setting the signal required with a PDA, SD-Testbus or PR010/T.
See Appendix 16.5.
15.3.9 Configurable input

There is an input with a configurable function in the Signalling module. The figure shows two cases, A and B, in which the input's status is active;
in case A the input does not stay valid beyond the enabling delay so the associated action does not take place, whereas in case B the action takes
place after the preset delay.
Times shorter than the delay
Preset delay
Consequent action Action

Action
Input status
15.3.9.1 Input configuration settings

You can select the level at which to consider the input enabled:
1. low input enabling level
2. high input enabling level
15.3.9.2 Input function settings (ACTION)

You can select the action associated with the input, i.e. the action that takes place after the programmed delay, when the input is enabled (on
high or low level ).
You can select one of the following actions:
1. Generic: no specific action is associated with the input. The status of the input is shown on the available display and remotely via the bus
2. Trip test: when the input is enabled for the specified delay, a trip test is performed
3. Trip reset: when the input is enabled for the specified delay a trip reset is performed
4. Set B: when the input is enabled for the specified delay, the Set B is enabled
5. Dial Local: when the input is enabled for the specified delay, there is a forcing of the dialogue local mode
6. Signalling module reset: when the input is enabled for the specified delay, the status of the relays in the PR120/K module is reset
7. Energy reset: when the input is active for the specified delay, the energy meters are reset.
15.3.9.3 Setting the input enabling delay

By means of the "Delay" parameter, you can specify the time elapsing before the input is enabled in the range 0.00 [s] to 100.00 [s] with 0.01[s]
steps.

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15.3.10 PR120/K module menu layout
The menu layout relating to relay n. 1 (K51/p1) is shown below as an example; the same applies to the menus for the other relays.
Signalling module 1/5
Relay n.1
Relay n.2
Relay n.3
Relay settings
Signalling module 5/5 Relay n.1 1/4 Signal source 1/13
Relay n.3 Signal source None

Relay n.4 Delay L prealarm
Input NO / NC L timing
Input None None
Signal source 13/13
Load Lc1
Load Lc2
Latched 21/2 Custom
Off None
On
Absent
Delay
0.00 s
Enter password
Input 1/3 Password
Polarity
Function 0***
Delay NO / NC 21/2
Active high Enter password NO

NC
Absent
Polarity 21/2
Active low
Active high
Absent
Function 21/7 Function
Generic Local
External Trip Reset signalling
Trip reset Energy reset
Set B
Delay
0.00 s
Enter password

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15.4 PR120/D-BT - WL-COM wireless communication module

This module enables wireless communication between the protection releases and a handheld PC (PDA) or a laptop with a Bluetooth port. The
module is designed specifically for use with the SD-Pocket application.
15.4.2 Front view

- "Power" LED
- LED Rx/Tx (send/receive signal)
- LED BT (Bluetooth link enabled)

15.4.4 Power supply

The PR120/D-BT WL-COM module is powered in auxiliary mode, from the PR120/V module, as specified in the description of the module, or by
a PR030/B power supply unit.
15.4.5 Connection
For a proper connection, bear in mind that the module's range of action is 10 meters in air.

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16 Appendices
16.1 PR021/K outside signalling unit
16.1.1 General information

The signalling unit converts the digital signals provided by the protection units into electrical signals by means of normally-open electric contacts.
Information on the status of the protection functions transits on a dedicated serial line connected to the release.
The following signals/contacts are available:
- L overload prealarm (the alarm signal remains enabled throughout the overload, until the release has been tripped)
- protections timing and trip (the protections trip signal remains enabled during the timing-controlled phase and after the release has been tripped)
- I protection trip
- timing and overheating threshold overrun
- two contacts for load control
- release trip
- communication error on serial line (connections between protection and signalling units)
- phase unbalance.
By setting the DIP switches, you can configure the signals of 7 programmable contacts, This can be done by selecting them directly in the PR122/
P or PR123/P relay, choosing from a long list, including: directional protection trip D, minimum and maximum voltage trip UV and OV, reverse
power trip RP and others.
Two contacts available on the SACE PR021/K (load control) unit enable you to control a release for opening and closing the circuit breaker. These
contacts enable various applications, including load control, alarms, signals, electric cutouts.
A Reset button enables you to zero the status of all the front optical signals and return the relays' contacts to the resting position.
The unit also contains ten LEDs to display the following information:
- Power ON: auxiliary power supply on
- Tx(int Bus): flashing synchronized with dialogue with the Internal Bus
- Eight LEDs associated with the signaling contacts
16.1.2 Power supply
Auxiliary power supply 24 V DC +/-20%

Maximum ripple 5%
Rated power @ 24V 4.4 W
16.1.3 General characteristics of the signalling relays
The following data are defined for resistive loads (cos ϕ = 1)
Type of contact SPST

Maximum switching voltage 130 Vdc 380 Vac
Maximum switching current 5A 8A
Maximum switching power 175 W 2000 VA
Breaking capacity @ 35 Vdc 5A ----

Breaking capacity @ 120 Vdc 0.2 A ----
Breaking capacity @ 250 Vdc ---- 8A
Breaking capacity @ 380 Vdc ---- 5.2 A
Contact/coil insulation 4000 Vrms

Contact/contact insulation 1000 Vrms
16.1.4 Relay functions

The available contacts can be used to manage the respective relays indicating an event (a given situation in the state of the device) that prompts
the required relays to be independently enabled after the delay specified by the user. The function is entirely similar to the one described in the
PR120/K signalling module in par. 15.3 and 16.5 of this manual.
16.1.5 PR021/K signalling unit menu

The unit's functions are accessible from the operator panel (PR123/P and PR122/P where applicable)
Modules 4/4 Local Bus Unit 1/8 Relay n.1 1/4
COM Module Presence Signal source

Enter ↵ + PWD Enter ↵
SIGNALLING Module Relay n.1 Delay
Local Bus Unit Relay n.2 NO / NC
Unit configuration Present None

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16.1.5.1 PR021/K unit menu table
Protection Parameter / Function Values Notes
PR021K unit Present

Absent Leave as Absent if there is no PR021/K
Relay n. 1 / 2 / 3 / 4 / 6 / 7 / 8
Signal source function None
L Prealarm
L Timing
S Timing
L Trip
S Trip
G Trip
I Trip
Any trip
Custom
Delay 0...100s step 0.01s - Deliberate delay before activating the contact
NO/NC NO/NC - Contact normally-open (NO) or normally-closed
(NC)
Latch ON/OFF - With the contact "ON", once it has been activated it
stays switched
A specific reset action is needed to reset it
16.1.5.2 Important note
The unit must be connected to the PR122/P or PR123/P by means of an internal busbar with a shielded, corded two-wire cable
(see note A, par. 11.2.2) no more than 15m long.
The shield must be earthed both on the circuit breaker side and on the PR021/K side. For the installation and operation of the
PR021/K accessory, refer to the specific user manual.

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16.2 SD-Pocket
SD-Pocket is a software application designed to connect the new releases to a handheld (PDA) or laptop PC to use wireless communication for
communicating with the PR121/P, PR122/P and PR123/P specifically for:
- configuring the protection thresholds (PR122/P - PR123/P)
- viewing the measurements, including the data stored in the data logger of the PR122/PR123 releases
- checking the conditions of the circuit breaker (e.g., status, number of maneuvers, fault data, etc., depending on the release in question).
The scenarios for using SD-Pocket include:
- during commissioning, for a rapid and error-free transfer of the protection settings to the releases (also using the files for exchanging data directly
from Docwin)
- during the normal operation of the equipment, for collecting information on the circuit breakers and the related loads (fault data, currents
measured and other data).
SD-Pocket requires a PDA with MS Windows Mobile 2003 and a Bluetooth interface, or a PC with MS Windows 2000 OS. The releases must
be complete with a PR120/D-BT WL or BT030 Bluetooth interface. It is not necessary, however, to have a PR120/D-M communication module.
SD-Pocket is distributed free of charge (freeware) and can be downloaded from the BOL site (http://bol.it.abb.com).
16.3 SD-Testbus
SD-TestBus is the installation and diagnostic software for ABB SACE products with a Modbus RTU communication. It can be used during
commissioning, or to find faults in an already up and running communication network.
This enables the connection to a PR121/P, PR122/P and PR123/P.
SD-TestBus runs an automatic scan on the RS-485 bus, recording all the devices connected and checking their configurations, and also testing
all the possible combinations of addresses, parity and baud rate.
With a simple click on SCAN you can pinpoint the devices that fail to respond, the configuration errors, the wrong addresses and parity errors,
and so on.
After scanning, the software shows warning messages on potential problems or configuration errors, enabling a complete diagnosis of the
communication network. These functions are not limited to the ABB SACE devices: any apparatus using the Modbus RTU standard protocol is
recorded and tested.
For the ABB SACE circuit breakers with an electronic release, the software provides a vast range of additional functions, for checking the wiring,
setting opening, closing or reset commands, and reading diagnostic information.
This program is so easy to use that it guarantees a trouble-free installation and commissioning of a Modbus communication network.
SD-TestBus is distributed free of charge (freeware) and can be downloaded from the BOL site (http://bol.it.abb.com ).

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16.4 Data logger (recorder)
The data logger function is available on the PR122/P and PR123/P units and it can be used to save the instantaneous values of certain analog and
digital measurements automatically in a large-sized memory buffer. The data can easily be downloaded from the unit using either the SD-Pocket
application with a Bluetooth port, or the SD-TestBus application via a Modbus bus, and transferred to any personal computer for processing. The
function stops the recording every time a trip occurs in order to facilitate failure analysis.
16.4.1 General characteristics:

Number of analogue channels: 8
Number of digital events: 64
Maximum sampling frequency: 4800 Hz
Maximum sampling time: 27s ( - sampling frequency 600 Hz)
16.4.2 Description of the data logger menu

You can access the data logger menu from the Settings menu in the PR122/P and PR123/P units:
Settings 4/9
Main Frequency
Modules
Data logger
Data logger
16.4.2.1 Enabling the data logger

The data logger can be enabled by inputting a password:
Data logger 1/1 Password Enable 2/2
Enable Enter ↵ PWD + Enter ↵ Off

Toroid size 0*** On
Off Enter password Off
16.4.2.2 Setting the sampling frequency

On the menu, you can specify the frequency with which the measurements are saved, choosing from 4 fixed frequencies, i.e. 600Hz, 1200Hz,
2400Hz or 4800Hz.
Data logger 1/6 Sampling freq. 1/4
Enable 600 Hz
Sampling freq.
Enter ↵ 1200 Hz
Stop event 2400 Hz
On 600 Hz
The maximum data recording times (see also par. 16.4.3) depend on the selected frequency and are illustrated in the following table:
Frequency RECORDING TIME

600 Hz 27.3 s
1200 Hz 13.6 s
2400 Hz 6.8 s
4800 Hz 3.4 s
16.4.2.3 Setting the standard stop events (triggers)

You can select one of the following stop events (triggers), see also par.16.5.2:
1. None
2. Any alarm
3. L timing
4. Any trip
Data logger 3/4 Stop event 1/5
Enable None
Sampling freq.
Enter ↵ Any Alarm
Stop event L Prealarm
Any Trip None
None
Custom

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If you select "None" for the stop event, the data logger can be stopped only by a stop command from the operator panel, from the system or following
a trip generated by the relay.
16.4.2.4 Setting and viewing customized stop events (triggers)

From the system, you can set customized stop events (triggers) to coincide with the events shown in paragraph 16.5.
In the event of a customized trigger point, the following window is displayed:
Stop event 5/5
L Prealarm
Any Trip
Custom
None
16.4.2.5 Setting the stopping delay

The stopping delay can be set between 0.00 [s] and 10.00 [s], in 0.01 [s] steps.
Data logger 4/6 Stop delay

Sampling freq.
Stop event Enter ↵ 0.00 s
Stop delay
0.00 s Enter password
In the event of a trip, this data storage process is stopped after 10 ms, even if a longer stopping delay has been selected.
16.4.2.6 Restart/Stop data logger

Using the Restart/Stop options, you can restart or stop the recording by the data logger:
Data logger 5/6 Data logger 6/6
Stop event Stop delay

Stop delay Restart
Restart Stop
Restart Stop
16.4.3 Recording time windows

The data logger's measurements are recorded in a time window, the duration of which is defined and synchronized by an event (trigger/stop
event) of your choice.
The following figure displays the time window, the trigger and the samples available in gray:
Stopping
delay
Measurements available
Samples
Pretrigger
Trigger
1/Freq Recording time
The user can select the sampling frequency (see par.16.4.2.2), the type of stop event (trigger) (see par.16.4.2.3) and the stopping delay (see
par.16.4.2.4) so as to obtain the required pre-trigger with respect to the selected event.
Depending on the selection you make, the stopping delay may be nil, or it may be lower or higher than the recording time, as illustrated in the
following figure:
Stopping delay = 0 Stopping delay < recording time Stopping delay > recording time
Trigger Trigger Trigger

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The maximum recording time is determined exclusively by the sampling frequency, established as shown in the table in par. 16.4.2.2. If the sum
of the stopping delay plus the time elapsing between a restart trigger and a trigger is less than the maximum recording time, then the recording
time will be shorter than the maximum, as illustrated in the following figure:
Recording time
Stopping delay
Restart Trigger Trigger

Maximum recording time
If the parameters relating to the data logger are changed while it is operating, the recording underway is terminated and a new recording
begins (after a restart trigger command) on the basis of the new parameters.
16.4.4 Description of the information given by the data logger system

16.4.4.1 Combination of devices for reading/setting data from the data logger system
By connecting to the release's outside bus, you can set certain data logger parameters, triggers or commands, or read certain types and sequences
of data in its memory.
The combinations of devices and the consequent software combinations that enables these functions are as follows:
1) PR122/P + BT030+SD-Pocket
2) PR122/P + PR120/D-M + SD-Testbus or remote system
3) PR122/P + PR120/D-BT + SD-Pocket
4) PR123/P + BT030+SD-Pocket
7) PR122/P + PR010/T *
8) PR123/P + PR010/T *
* With these combinations it is impossible to download sequences of stored data
In this manual, the term "from the system" is used to define both the operations that are carried out using one of the combinations with SD-Pocket
or SD-Testbus, and the operations that involve connecting to a remote system.
16.4.4.2 Access to saved data from the system

When the event associated with the stop event occurs or a stop command is received, the following data are saved in the recording block:
• Data logger Trigger, which indicates the type of stop event (trigger) that has prompted the stoppage of the data logger;
• Time-stamp of the stop event (trigger) (day/hour + minutes/seconds/milliseconds)(4 words);
• Data logger max file, which indicates which is the max file with consistent data;
• Data logger max address, which indicates the max address number of a block with consistent data.
The following information is recorded in the block for each sampling period:
1. current sample L1
4. current sample Ne
5. External ground current sample
6. voltage sample U12
9. digital inputs / outputs (among 16 possible options, e.g. inputs/outputs for Zone Selectivity, PR120/K contact status, ...)
10. alarms1 (among 16 possible options, e.g. L timing, G alarm, Prealarm)
11. alarms2 (among 16 possible options, e.g. UF timing, OV timing, Frequency error, RP timing)
12. trip (among 16 possible options, e.g. tripping of L, S, I, G, UV, OF, ...)

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16.4.4.3 Information from the system on the configuration and status of the data logger
The following information is provided on the status of the data logger:
STATUS
Waiting trigger: this means that the data logger is enabled and waiting for the occurrence of the event selected as the
trigger
Data logger triggered: this indicates that the trigger event has occurred and the data logger is still recording
Data logger stopped: this means that the recording has been terminated either because it has been completed or because
a data logger stop command has been received, or because a trip has occurred
CONFIGURATION
Data logger config: indicates whether or not the data logger is active
Data logger trigger type: indicates the stop event (trigger) setting
Data logger stopping delay: indicates the delay for the stop
16.4.5 Data logger commands from the system

When a data logger stop command is given, the recording is stopped from the system. The subsequent recording is enabled by a Restart trigger
command. The same applies to the operator panel, as illustrated in par. 16.4.2.6.
Example of data logger operation

The following figure shows an example of how a trigger works, the data logger's function, the effect of the stopping delay and of the restart and
subsequent stop commands on the data saving procedure.
Samples Samples
available available
Samples
Trigger
Waiting Trigger
Data logger triggered

Stopping
Data logger stopped delay
Modbus commands
Restart Stop Restart

Data logger enabled

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16.5 Table showing list of events
16.5.1 "Standard" events for PR120/K and for PR021/K selectable from the relay:
Event n. Description
0. None (none enabled)
1. L prealarm (L protection prealarm)
2. L timing (L protection timing)
3. S timing (S protection timing)
4. L trip (L protection trip)
5. S trip (S protection trip)
6. I trip (I protection trip)
7. G trip (G protection trip)
8. Any trip (tripping of any protection)
16.5.2 Standard" events for the data logger function, selectable from the relay:
Event n. Description
0. None (free running)
1. Any alarm (any alarm)
2. L timing (L protection timing)
3. Any trip (tripping of any protection)
16.5.3 "Custom" events for the data logger function, for PR120/K and PR021/K:
N. (decimal) Event Notes PR122 PR123

1920 G timing x x
2894 L1 or L2 or L3 sensor error or Trip Coil error x x
2688 LC1 alarm x x
2049 G alarm x x
2306 UV timing x x
4124 UV or OV or RV tripped x x
33672 CB connected and springs loaded x x
1793 Harmonic distortion > 2.1 x x
You can combine the status bits with "and" / "or" logical functions within the same group of events (byte). For more detailed information, refer to
the Modbus Interface document.
16.5.4 Combining the devices needed to customize settings
The "custom" events can be selected using a remote control system, SD-Pocket, or SD-TestBus.
The devices you need to enable you to do so can be selected from among the following:
1) PR122/P + BT030 + SD-Pocket

4) PR122/P + PR010/T
5) PR123/P + BT030 + SD-Pocket
7) PR123/P + PR120/D-BT + SD- Pocket
8) PR123/P + PR010/T

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17. Overall dimensions
Basic version with horizontal rear terminals
4 POLES
3 POLES
1SDC200212F0001
3 POLES
4 POLES
E1/E2 E3
Legend View A View A
door
4 POLES 4 POLES
2 Segregation (where foreseen)
3 3 POLES
POLES
3 Circuit-breaker M10 fixing
drilling (use M10 screws)
4 N° 1 M12 screw (E1, E2, E3)

or n° 2 M12 screws (E4, E6)
for earthing (included in the
supply)
5 Insulating or metal-insulated
wall
1SDC200213F0001
3 POLES 3 POLES
4 POLES 4 POLES
A B C D E F G
E1 386 296 148 148 10 130 117,5
E2 386 296 148 148 26 114 117,5
E3 530 404 202 202 26 114 117,5
E4 656 566 238 328 26 166 91,5
E4/f 746 - - 328 26 166 91,5
E6 908 782 328 454 26 166 91,5
E6/f 1034 - - 454 26 166 91,5
Mod. L2234 Apparecchio Scala

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E4
View A
3 POLES (E4)
4 POLES (E4)
4 POLES (E4/f)
1SDC200214F0001
E6
View A
3 POLES (E6)
4 POLES (E6)
4 POLES (E6/f)
1SDC200215F0001
Fig. 36

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Basic version with vertical rear terminals
E1 E2/E4 E3/E6
E1 E2 E3
Captive M12
included in the
supply
E4 E4/f E6 E6/f
Captive M12
included in the
supply
Captive M12
1SDC200216F0001
included in the
supply
Fig. 36a

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Basic version with front terminals
E1
E2
E3
1SDC200217F0001
Fig. 37

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Basic version with front terminals
E4 E4 E4/f
E6 E6 E6/f
1SDC200218F0001
Fig. 38

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Compartment dimensions Compartment door drilling
Depth

protection
3 POLES
4 POLES
Holes for passing through flexible cables Tightening torque of the main terminals: Nm 70
for mechanical interlocks Tightening torque of the earthing screw: Nm 70
High resistance M12 screw
Quantity per terminal
PHASE NEUTRAL
A B
E1 400 490
E2 400 490
E3 500 630
E4 700 790
E4/f - 880
E6 1000 1130
E6/f - 1260
Fig. 39

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E1 E2/E3/E4/E6
4 POLES
3 POLES
1SDC200220F0001
3 POLES
4 POLES
Legend E1/E2 E3
View A View A
1 Inside edge of compartment room
3 POLES 3 POLES
2 Segregation (where foreseen)
3 Fixing fixed part Ø 10 drilling (use

M8 screws)
4 N° 1 M12 screw (E1, E2, E3) or n° 2

M12 screws (E4, E6) for earthing
(included in the supply)
4 POLES 4 POLES
5 Run from connected for a TEST to
isolated
6 Alternative drilling with 25 mm

pitch for fixing fixed part
7 Ventilation drilling on the

switchgear
1SDC200221F0001
A B C D E F
3 poles 4 poles
E1 414 324 162 162 10 – –
E2 414 324 162 162 8 – –
E3 558 432 216 216 8 370 490
E4 684 594 252 342 8 530 610
E4/f 774 - - 342 8 – 700
E6 936 810 342 468 8 750 870
E6/f 1062 - - 468 8 - 1000
Fig. 40

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E4
View A
3 POLES (E4)
4 POLES (E4)
4 POLES (E4/f)
1SDC200222F0001
E6
View A
3 POLES (E6)
4 POLES (E6)
4 POLES (E6/f)
1SDC200223F0001

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Basic version with vertical rear terminals
E1 E2/E4 E3/E6
E1 E2 E3
Captive M12
included in the
supply
E4 E4/f E6 E6/f
Captive M12
included in the
supply
1SDC200224F0001
Captive M12
included in the
supply
Fig. 42

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Version with front terminals
E1
E2
E3
1SDC200225F0001
Fig. 43

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Version with flat terminals
E4 E4 E4/f
E6 E6 E6/f
1SDC200226F0001
Fig. 44

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Version with flat terminals
E1 E2
E1 E2 E3
E4 E4/f E6 E6/f
1SDC200227F0001
Fig. 45

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Compartment dimensions Compartment door drilling
Depth
3 POLES
4 POLES
protection
Holes for passing through flexible cables Tightening torque of the fixing screws: 20 Nm
for mechanical interlocks Tightening torque of the main terminals: 70 Nm
Tightening torque of the earthing screw: 70 Nm
High resistance M12 screw
Quanty per terminal
PHASE NEUTRAL
A B
E1 400 490
E2 400 490
E3 500 630
E4 700 790
E4/f - 880
E6 1000 1130
E6/f - 1260
Fig. 46

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Compartment door mechanical lock
Door drilling Minimum distance between the circuit-breaker and the switchgear wall
1SDC200231F0001
A
3 POLES 4 POLES
E1 180 180
E2 180 180
E3 234 234
E4 270 360
E4/f - 360
E6 360 486
E6/f - 486
Fig. 47

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18. Circuit diagrams
Warning
Before installing the circuit-breaker, carefully read notes F and O on the circuit diagrams

- tripped releases
- motor operating mechanism with springs discharged
Versions
The diagram shows a circuit.breaker in withdrawable versio; it can be applied to a fixed version circuit breaker as well
Fixed version
The control circuits are fitted between terminals XV (connector X is not supplied)
The control circuits aree fitted between the poles of connector X (terminal box XV is not supplied).
Version without overcurrent release

With this version, the applications indicated in figures 13, 14, 41, 42, 43, 44, 45, 46, 47, 48, 62.
With this version, the applications indicated in figures 42, 43, 44, 45, 46, 47, 48.
With this version, the applications indicated in figure 41 cannot be provided
Caption
* = See note indicated by the letter
A1 = Circuit breaker accessories
A3 = Accessories applied to the fixed part of the circuit breaker (for withdrawable version only)
A4 = Example switchgear and connections for control and signalling, outside the circuit breaker
A13 = PR021/K signalling unit (outside the circuit breaker)
AY = SACE SOR TEST UNIT Test/monitoring Unit (see note R)
D = Electronic time-delay device of the undervoltage release, outside the circuit breaker
K51 = PR121/P, PR122/P, PR123/P electronic overcurrent release with the following protection functions:
- L overload protection with inverse long time-delay trip-setting I1
- S short-circuit protection with inverse or defintive short time-delay trip-setting l2
- I short-circuit protection with instantaneous time-delay trip-setting l3
- G earth fault protection with inverse short time-delay trip-setting l4
K51/1...8 = Contacts for the PR021/K signalling unit
K51/GZin = (DBin) Zone selectivity: for protection G (only with Vaux and PR122/P or PR123/P release) or "reverse" direction input for protection
D (only with Vaux and PR123/P release)
K51/GZout = (DBout) Zone selectivity: for protection G (only with Vaux and PR122/P or PR123/P release) or "reverse" direction output for protection
D (only with Vaux and PR123/P release)
K51/IN1 = Digital programmable input (available only with Vaux and release PR122/P or PR123/P with indicator module PR120/K)
K51/P1...P4= Programmable electrical signalling (available only with Vaux and release PR122/P or PR123/P with indicator module PR120/K)
K51/SZin = (Dfin) Zone selectivity: input for protection S or "direct" input for protection D (only with Vaux and PR122/P or PR123/P release)
K51/SZout = (DFout) Zone selectivity: output for protection S or "direct" output for protection D(only with Vaux and PR122/P or PR123/P release)
K51/YC = Closing control from PR122/P or PR123/P microprocessor-based release with communication module PR120/D-M
K51/YO = Opening control from PR122/P or PR123/P microprocessor-based release with communication module PR120/D-M
Q = Circuit breaker
Q/1...27 = Circuit breaker auxiliary contacts
S51 = Contact for electrical signalling of circuit breaker open due to tripping of the overcurrent release. The circuit breaker may be closed
only after pressing the reset pushbutton, or after energizing the coil for electrical reset (if available).
S75E/1.4 = Contacts for electrical signalling of circuit breaker in racked-out position (only with withdrawable circuit-brakers).
S75I/1..5 = Contacts for electrical signalling of circuit breaker in racked-in position (only with withdrawable circuit-brakers)
S75T/1..4 = Contacts for electrical signalling of circuit breaker in test isolated position (only with withdrawable circuit-brakers)
SC = Pushbutton or contact for closing the circuit breaker
SO = Pushbutton or contact for opening the circuit breaker
SO1 = Pushbutton or contact for opening the circuit breaker with delayed trip
SO2 = Pushbutton or contact for opening the circuit breaker with instantaneous trip
SR = Pushbutton or contact for electrical circuit breaker reset

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Vaux = Auxiliary power supply voltage (see note F)
UI/N = Current sensor (Rogowski coil) located on neutral
UI/0 = Current sensor (Rogowski coil) located on the conductor connecting to earth the star point of the MV/LV transformer (see note G)
W2 = Serial interface with the accessories of PR121/P, PR122/P and PR123/P releases (internal bus)
X1...X7 = Connectors for the accessories of the circuit breaker
XF = Delivery terminal box for the position contacts of the withdrawable circuit-breaker (located on the fixed part of the circuit breaker)
XK1 = Connector for power circuits of PR121/P, PR122/P, and PR123/P releases
XK2 - XK3 = Connectors for auxiliary circuits of PR121/P, PR122/P and PR123/P releases
XV = Delivery terminal box for the auxiliary circuits of the fixed circuit breaker
YO1 = Overcurrent shunt opening release (trip coil)
YR = Coil to electrically reset the circuit breaker
Fig.11 = Contact for electrical signalling of springs charged.
Fig.12 = Contact for electrical signalling of undervoltage release energized (see notes B and S).
Fig.13 = Contact for electrical signalling of circuit breaker open due to tripping of the overcurrent release. The circuit-breaker may be closed only
after pressing the reset pushbutton.
Fig.14 = Contact for electrical signalling of circuit breaker open due to tripping of the overcurrent release and electrical reset coil. The circuit-
breaker may be closed only after pressing the reset pushbutton or energizing the coil.
Fig.21 = First set of circuit-breaker auxiliary contacts.
Fig.22 = Second set of circuit-breaker auxiliary contacts (not available for PR122/P and PR123/P releases)(see note V)
Fig.23 = Third set of supplementary auxiliary contacts outside the circuit breaker.
Fig.31 = First set of contacts for electrical signalling of circuit breaker in racked-in, test isolated, racked-out position.
Fig.32 = Second set of contacts for electrical signalling of circuit breaker in racked-in, test isolated, racked-out position.
Fig.41 = Auxiliary circuits of PR121/P release (see note F).
Fig.42 = Auxiliary circuits of PR122/P and PR123/P releases (see notes F, M and V).
Fig.43 = Circuits of the measuring module PR120/V of the releases PR122/P and PR123/P internally connected to the three-pole and four-pole
circuit breaker (optional for the release PR122/P) (see note U).
Fig.44 = Circuits of the measuring module PR120/V of the PR122/P and PR123/P releases externally connected to the circuit-breaker (optional
for the release PR122/P) (see note U).
Fig.45 = Circuits of the communication module PR120/D-M of the PR122/P and PR123/P releases (optional) (see note E).
Fig.46 = Circuits of the indicator module PR120/K of the PR122/P and PR123/P releases - connection 1 (optional) (see note V).
Fig.47 = Circuits of the indicator module PR120/K of the PR122/P and PR123/P releases - connection 2 (optional) (see note V).
Fig.48 = Circuits of the measuring module PR120/V of the releases PR122/P and PR123/P connected inside the three-pole circuit breaker with
outside neutral conductor (optional for the release PR122/P)(see note U).
Fig.62 = Circuits of the signalling unit PR021/K (outside the circuit breaker).
Incompatibilities
The circuits indicated in the following figures cannot be supplied simultaneously on the same circuit breaker:
6-7-8
13 - 14
22 - 46 - 47
43 - 44 - 48
Notes
A) The circuit breaker is only fitted with the accessories specified in the ABB SACE order acknowledgement. Consult this catalogue for information
on how to make out an order.
B) The undervoltage release is supplied for operation using a power supply branched on the supply side of the circuit breaker or from an
independent source. The circuit breaker can only close when the release is energized (there is a mechanical lock on closing).
If the same power supply is used for the closing and undervoltage releases and the circuit breaker is required to close automatically when the
auxiliary power supply comes back on, a 30 ms delay must be introduced between the undervoltage release accept signal and the energizing
of the closing release. This may be achieved using an external circuit comprising a permanent make contact, the contact shown in fig. 12 and
a time-delay relay.
E) For the EIA RS485 serial interface connection see document RH0298 regarding MODBUS communication.
F) The auxiliary voltage Vaux allows actuation of all operations of the PR121/P, PR122/P and PR123/P releases.
Having requested a Vaux insulated from earth, one must use “galvanically separated converters” in compliance with IEC 60950 (UL 1950) or
equivalent standards that ensure a common mode current or leakage current (see IEC 478/1, CEI 22/3) not greater than 3.5 mA, IEC 60364-
41 and CEI 64-8.
G) Earth fault protection is available with the PR122/P and PR123/P releases by means of a current sensor located on the conductor connecting

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to earth the star center of the MV/LV transformer.
The connections between terminals 1 and 2 (or 3) of current transformer UI/O and poles T7 and T8 of the X (or XV) connector must be made
with a two-pole shielded and stranded cable (type BELDEN 3105A/3105B) no more than 15 m long. The shield must be earthed on the circuit
breaker side and current sensor side.
N) With releases PR122/P and PR123/P, the connections to the zone selectivity inputs and outputs must be made with a two-pole shielded and
stranded cable (type BELDEN 3105A/3105B), no more than 300 m long. The shield must be earthed on the selectivity input side.
O) Systems with a rated voltage greater than 690V require the use of an insulation voltage transformer to connect to the busbars (connect
according to the diagrams on the sheet provided with the kit 1SDH000460R0508).
P) With releases PR122/P and PR123/P with communication module PR120/D-M, the coils YO and YC are controlled directly from contacts K51/YO and
K51/YC with maximum voltages of 110-120 V DC and 240-250 V AC.
R) The SACE SOR TEST UNIT + opening release (YO) is guaranteed to operate starting at 75% of the Vaux of the opening release itself.
While the YO power supply contact is closing (short-circuit on terminals 4 and 5), the SACE SOR TEST UNIT is unable to detect the opening coil
status.
Consequently:
- For continuously powered opening coil, the TEST FAILED and ALARM signals will be activated
- If the coil opening command is of the pulsing type, the TEST FAILED signal may appear at the same time. In this case, the TEST FAILED
signal is actually an alarm signal only if it remains lit for more than 20s.
U) The measuring module PR120/V is always supplied with relay PR123/P.
V) If fig. 22 is present (second set of auxiliary contacts) simultaneously as realy PR122/P (or PR123/P), the contacts for the zone selectivity in fig.
42 (K51/Zin, K51/Zout, K51/Gzin and K51/Gzout) are not wired. In addition, the indicator module PR120/K in figures 46 and 47 cannot be
supplied.

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Circuit diagram symbols (IEC 60617 and CEI 3-14 ... 3-26 Standards)

Delay Plug and socket Circuit-breaker-disconnector

(male and female) with automatic release
Mechanical or electrical Motor Switch-disconnector

connection (general symbol) (on-load isolating switch)


relay

star characteritic
Equipotentiality Make contact Overcurrent relay with

inverse short time-lag
characteritic
Converter with Break contact Overcurrent relay

galvanic separator with inverse long time-lag
characteritic

Twisted conductors (i.e., 3 Position switch (limit Fuse

conductors shown) switch), make contact (general symbol)
Connection of conductors Position switch (limit Current sensing

switch), break contact element

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Circuit diagram - Operating status
Three-pole circuit-breaker with PR121/P, PR122/P or PR123/P electronic release
Terminal
not connected
Four-pole switch with PR121/P, PR122/P, PR123/P electronic release Three-or four-pole switch-disconnector
Terminal
not connected

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Motor operating mechanism, opening, closing and undervoltage releases
Signalling contacts

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Signalling contacts

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Auxiliary circuits of the PR121, PR122 and PR123 releases
PR120/V measuring module

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PR120/D-M communication module
PR120/K signalling module

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PR021/K signalling unit
PR121/P
PR122/P
PR123/P

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1SDH000460R0002 L2234
Due to possible developments of standards as well as of

materials, the characteristics and dimensions specified in
the present catalogue may only be considered binding after
confirmation by ABB SACE.
ABB SACE S.p.A.

L.V. Breakers
Via Baioni, 35 - 24123 Bergamo - Italy
Tel.: +39 035.395.111 - Telefax: +39 035.395.306-433
http://www.abb.com
NOV PART NO.:
3AFE64492209
RDCO-01/02/03 Module layout
DDCS Communication
Option Modules CH 0
GND
CH 1
Overview Fixing Fibre optic channels

The RDCO-0x DDCS Communication Options are add-on screws
CH 2
modules for the RMIO Motor Control and I/O Board, used in
ACS 800 family frequency converters. RDCO modules are
available factory-installed as well as retrofit kits.
CHGND CH 3
The RDCO module includes the connectors for fibre optic
DDCS channels CH0, CH1, CH2 and CH3. The usage of these
channels is determined by the application program; see the
Firmware Manual of the drive. However, the channels are
normally assigned as follows:
CH0 – overriding system (e.g. fieldbus adapter) Installation
CH1 – I/O extensions WARNING! All electrical installation and
CH2 – Master/Follower link maintenance work on the drive should be carried
CH3 – PC tools (such as DriveWare). out by qualified electricians only.
There are several types of the RDCO. The difference between The drive and adjoining equipment must be
the types is the optical components. In addition, each type is properly earthed.
available with a coated circuit board, this being indicated by a
“C” suffix, e.g. RDCO-03C. Do not work on a powered drive. Before installation, switch off
the mains and other dangerous voltages (e.g. from external
Optical Component Type control circuits) to the drive. After switching off the mains,
Module Type always allow the intermediate circuit capacitors 5 minutes to
CH0 CH1 CH2 CH3 discharge before starting work on the frequency converter. It is
a good practice to check (with a voltage indicating instrument)
RDCO-01(C) 10 MBd 5 MBd 10 MBd 10 MBd
that the drive is in fact discharged before beginning work.
RDCO-02(C) 5 MBd 5 MBd 10 MBd 10 MBd There may be dangerous voltages inside the drive from
external control circuits even when the drive mains power is
RDCO-03(C) 5 MBd 5 MBd 5 MBd 5 MBd
shut off. Exercise appropriate care when working on the unit.
Neglecting these instructions may cause physical injury or
The optical components at both ends of a fibre optic link must
death.
be of the same type for the light intensity and receiver
sensitivity levels to match. Plastic optical fibre (POF) cables WARNING! The component boards of the drive
can be used with both 5 MBd and 10 MBd optical components. contain integrated circuits that are extremely
10 MBd components also enable the use of Hard Clad Silica sensitive to electrostatic discharge (ESD). Wear
(HCS) cables, which allow longer connection distances thanks an earthing wrist band when handling component
to their lower attenuation. boards. Do not touch the boards unnecessarily.
Do not remove any board from its antistatic packaging until
required.
Note: The optical component type does not reflect the actual
WARNING! Handle the fibre optic cables with
communication speed.
care. The maximum long term tensile load is 1 N;
the minimum short term bend radius is 35 mm.
Do not touch the ends of the fibres with bare
Delivery check hands as the fibre is extremely sensitive to dirt.
Use rubber grommets at cable entries to protect the cables.
The option package contains:
• RDCO-0x module The RDCO-0x module is to be inserted into the position
• Two screws (M3×8) marked “DDCS” on the drive. On installation, the signal and
• This document. power connection to the drive (RMIO board) is automatically
made through a 20-pin connector.
Compatibility The module is held in place with plastic retaining clips and two
screws. The screws also provide the earthing of module, and
The RDCO-0x is compatible with the motor control and I/O interconnect the GND signals of the module and the RMIO
board (RMIO) of the ACS 800. board.
(continued overleaf)
Installation Procedure Connectors:
1. Access the optional module slots on the drive. Whenever • 20-pin pinheader
necessary, refer to the Hardware Manual of the drive for • 4 transmitter/receiver connector pairs for fibre optic cable.
instructions on removing any covers. Type: Agilent Technologies Versatile Link. Communication
2. Insert the module carefully into the slot marked “DDCS” speed: 1, 2 or 4 Mbit/s
on the RMIO board until the retaining clips lock the Operating voltage: +5 V DC ±10%, supplied by the RMIO
module into position. board of the drive
3. Fasten the screws included in the package. Note that Current consumption: 200 mA max.
correct installation of the screws is essential for fulfilling
the EMC requirements and for proper operation of the Electromagnetic immunity: IEC 1000-4-2 (limits: industrial,
module. second environment); IEC 1000-4-3; IEC 1000-4-4;
IEC 1000-4-6
4. Lead the fibre optic cables from the external device to the
appropriate channel(s) of the RDCO. Inside the drive, Electromagnetic emissions: EN 50081-2; CISPR 11
route the cables as shown in its Hardware Manual. Make Dimensions (mm):
sure the cables are not kinked or laid against sharp
edges. Observe colour coding so that transmitters are 30 34
connected to receivers and vice versa. In case multiple
devices are to be connected to one channel, they must
be connected in a ring.
Technical data
Module types: RDCO-01(C), RDCO-02(C), RDCO-03(C)
95
Degree of protection: IP 20
Ambient conditions: The applicable ambient conditions
specified for the drive in its Hardware Manual are in effect.
20
3AFE 64492209 REV A EN

EFFECTIVE: 1.3.2002
ABB Oy ABB Inc.

AC Drives Drives & Power Products
P.O. Box 184 16250 West Glendale Drive
FIN-00381 Helsinki New Berlin, WI 53151
FINLAND USA
RDCO-0x
Telephone: +358 10 22 11 Telephone: 262 785-8378

Fax: +358 10 222 2681 800 243-4384
Internet: www.abb.com Fax: 262 780-5135
NOV PART NO.:
3AFE64504215
Technical Manual
ABB - User Manual
Profibus DP Adapter Module

118 This document contains proprietary and confidential National Oilwell Varco
information which belongs to National Oilwell Varco, it is Rig Solutions - Western Hemisphere
REMARKS loaned for limited purposes only and remains the property
of National Oilwell Varco. Reproduction, in whole or in 1530 W Sam Houston Parkway N
MAIN TAG NUMBER DISCIPLINE part, or use of this design or distribution of this information Houston Texas 77043
to others is not permitted without the express written Phone 713 935 8000
consent of National Oilwell. This document is to be
CLIENT PO NUMBER returned to National Oilwell Varco upon request and in Fax 713 827-8460
any event upon completion of the use for which it was
loaned.© Copyright National Oilwell Varco -
3AFE64504215 F
www.nov.com
Document number 3AFE64504215
Revision F
Page 2
REVISION HISTORY

www.nov.com
ABB Drives
User’s Manual
PROFIBUS DP Adapter Module
RPBA-01
PROFIBUS DP Adapter Module
RPBA-01
User’s Manual
3AFE 64504215 REV F EN
EFFECTIVE: 20.06.2005
© 2005 ABB Oy. All Rights Reserved.

5
Safety instructions
Overview
This chapter states the general safety instructions that must be
followed when installing and operating the RPBA-01 PROFIBUS
DP Adapter module.
The material in this chapter must be studied before attempting any
work on, or with, the unit.
In addition to the safety instructions given below, read the
complete safety instructions of the specific drive you are working
on.
General safety instructions

WARNING! All electrical installation and maintenance work on the
drive should be carried out by qualified electricians.
The drive and adjoining equipment must be properly earthed.
Do not attempt any work on a powered drive. After switching off
the mains, always allow the intermediate circuit capacitors 5
minutes to discharge before working on the frequency converter,
the motor or the motor cable. It is good practice to check (with a
voltage indicating instrument) that the drive is in fact discharged
before beginning work.
The motor cable terminals of the drive are at a dangerously high
voltage when mains power is applied, regardless of motor
operation.
There can be dangerous voltages inside the drive from external
control circuits even when the drive mains power is shut off.
Exercise appropriate care when working on the unit. Neglecting
these instructions can cause physical injury or death.
Safety instructions
6
Safety instructions
7
Table of contents
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Before you start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
What this manual contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Terms used in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Further information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PROFIBUS standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
The RPBA-01 PROFIBUS DP Adapter module . . . . . . . . . . . . . . . . . . . . . . 16
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Warranty and liability information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Quick start-up guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
PLC configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Mechanical and electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Drive configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Parameter setting examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table of contents
8
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
General cabling instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Bus termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Node selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
PROFIBUS connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Configuring the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
PROFIBUS connection configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Control locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DP-V0 communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
PROFIBUS DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Service Access Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Communication start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
PPO message types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
The Control Word and the Status Word . . . . . . . . . . . . . . . . . . . . . . . . . . 46
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Actual Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Parameter handling in cyclic communication (DP) . . . . . . . . . . . . . . . . . . . . 51
DP-V1 communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
PROFIBUS DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Service Access Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Communication start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
PPO message types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
The Control Word and the Status Word . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Table of contents
9
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Actual Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
DP-V1 read/write request sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Parameter data transfer examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
LED indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
PROFIdrive parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Definitions and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

PROFIBUS definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
PROFIBUS abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

RPBA-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
PROFIBUS link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Table of contents
10
Table of contents
11
Introduction
Intended audience
The manual is intended for the people who are responsible for
commissioning and using an RPBA-01 PROFIBUS DP Adapter
module. The reader is expected to have a basic knowledge of
electrical fundamentals, electrical wiring practices and how to
operate the drive.
Before you start

It is assumed that the drive is installed and ready to operate before
starting the installation of the extension module.
In addition to conventional installation tools, have the drive
manuals available during the installation as they contain important
information not included in this manual. The drive manuals are
referred to at various points of this document.
What this manual contains

This manual contains information on the wiring, configuration and
use of the RPBA-01 PROFIBUS DP Adapter module.
Safety instructions are featured in the first few pages of this
manual.
Overview contains a short description of the PROFIBUS protocol
and the RPBA-01 PROFIBUS DP Adapter module, a delivery
checklist, and information on the manufacturer’s warranty.
Quick start-up guide contains a short description of how to set
up the RPBA-01 PROFIBUS DP Adapter module.
Mechanical installation contains placing and mounting
instructions for the module.
Electrical installation contains wiring, bus termination and
earthing instructions.
Introduction
12
Programming explains how to program the master station and

the drive before the communication through the adapter module
can be started.
DP-V0 communication contains a description of how data is
transmitted through the RPBA-01 module using the
PROFIBUS-DP (DP-V0) protocol.
DP-V1 communication contains a description of how data is
transmitted through the RPBA-01 module using the DP-V1
extension of the PROFIBUS DP protocol.
Fault tracing explains how to trace faults with the status LEDs on
the RPBA-01 module.
PROFIBUS parameters presents the PROFIBUS Profile-specific
parameters.
Definitions and abbreviations explains definitions and
abbreviations concerning the PROFIBUS protocol family.
Technical data contains information on physical dimensions,
configurable settings and connectors of the module and the
specification of the PROFIBUS link.
Introduction
13
Terms used in this manual

Communication Module
Communication Module is a name for a device (e.g. a fieldbus
adapter) through which the drive is connected to an external
communication network (e.g. a fieldbus). The communication with
the module is activated with a drive parameter.
Data Sets and Data Words
Each data set consists of three 16-bit words, ie. data words. The
Control Word (sometimes called the Command Word) and the
Status Word, References and Actual Values (see the chapters DP-
V0 communication and DP-V1 communication) are types of data
words; the contents of some data words are user-definable.
RPBA-01 PROFIBUS DP Adapter module
The RPBA-01 PROFIBUS DP Adapter module is one of the
optional fieldbus adapter modules available for ABB drives. The
RPBA-01 is a device through which an ABB drive is connected to
a PROFIBUS network.
Parameter
A parameter is an operating instruction for the drive. Parameters
can be read and programmed with the drive control panel, or
through the RPBA-01 module.
Further information
Further information is available on the World Wide Web from
www.profibus.com.
Introduction
14
Introduction
15
Overview
Overview
This chapter contains a short description of the PROFIBUS
standard and the RPBA-01 PROFIBUS DP Adapter module, a
delivery checklist and warranty information.
PROFIBUS standard
PROFIBUS is an open serial communication standard that
enables data exchange between all kinds of automation
components. There are three main variations of PROFIBUS:
PROFIBUS-FMS (Fieldbus Message Specification),
PROFIBUS-DP (Decentralised Periphery) and PROFIBUS-PA
(Process Automation). The RPBA-01 PROFIBUS DP Adapter
module supports the PROFIBUS DP protocol, including its DP-V1
extension.
The physical transmission medium of the bus is a twisted pair
cable (according to the RS-485 standard). The maximum length of
the bus cable is 100 to 1200 metres, depending on the selected
transmission rate (see Technical data chapter). Up to 31 nodes
can be connected to the same PROFIBUS network segment
without the use of repeaters. With repeaters, it is possible to
connect 127 nodes (including repeaters and master station) to the
network.
In PROFIBUS communication, the master station – usually a
programmable logic controller (PLC) – polls the nodes which
respond and take the actions requested by the master. It is also
possible to send a command to several nodes at the same
broadcast; in this case the nodes do not send a response
message to the master.
The PROFIBUS protocol family is specified in the IEC 61158
standard. The communication with a drive is defined in the
PROFIdrive Profile – The PROFIBUS Profile for Adjustable Speed
Overview
16
Drives. For further information on PROFIBUS, refer to the above-

mentioned standards.
The RPBA-01 PROFIBUS DP Adapter module

The RPBA-01 PROFIBUS DP Adapter module is an optional
device for ABB drives which enables the connection of the drive to
a PROFIBUS network. The drive is considered as a slave on the
PROFIBUS network. Through the RPBA-01 PROFIBUS DP
Adapter module, it is possible to:
• give control commands to the drive
(Start, Stop, Run enable, etc.)
• feed a motor speed or torque reference to the drive
• give a process actual value or a process reference to the PID
controller of the drive
• read status information and actual values from the drive
• change drive parameter values
• reset a drive fault.
The PROFIBUS commands and services supported by the
RPBA-01 PROFIBUS DP Adapter module are discussed in the
chapters DP-V0 communication and DP-V1 communication.
Please refer to the user documentation of the drive as to which
commands are supported by the drive.
The adapter module is mounted into an option slot on the motor
control board of the drive. See the Hardware Manual of the drive
for module placement options.
Configuration of the master station requires a type definition
(GSD) file. For DP-V0 communication, the file is available from
www.profibus.com or an ABB representative (the filename is
ABB_0812.GSD). For DP-V1 communication, the type definition
(GSD) file is available from an ABB representative (the filename is
ABB10812.GSD).
Overview
17
PROFIBUS Slave Bus connector X1

master stations (see chapter
Electrical installation)
Fixing screw
(GND)
(frame)
DIP switch for
ABB Drive selecting bus
termination
Rotary node
ABB Drive
address
selection switches
Diagnostic LEDs
Top view (See chapter Side view
Fault tracing)
Figure 1. The construction of the PROFIBUS link and the

RPBA-01 Adapter module.
Compatibility
The RPBA-01 is compatible with all master stations that support
the PROFIBUS DP protocol.
Delivery check
The option package for the RPBA-01 PROFIBUS DP Adapter
module contains:
• PROFIBUS DP Adapter module, type RPBA-01
• two screws (M3x10)
• this manual.
Overview
18
Warranty and liability information

The manufacturer warrants the equipment supplied against
defects in design, materials and workmanship for a period of
twelve (12) months after installation or twenty-four (24) months
from date of manufacturing, whichever first occurs. The local ABB
office or distributor may grant a warranty period different to the
above and refer to local terms of liability as defined in the supply
contract.
The manufacturer is not responsible for
• any costs resulting from a failure if the installation,
commissioning, repair, alternation, or ambient conditions of the
drive do not fulfil the requirements specified in the
documentation delivered with the unit and other relevant
documentation
• units subjected to misuse, negligence or accident
• units comprised of materials provided or designs stipulated by
the purchaser.
In no event shall the manufacturer, its suppliers or subcontractors
be liable for special, indirect, incidental or consequential damages,
losses or penalties.
If you have any questions concerning your ABB drive, please
contact the local distributor or ABB office. The technical data,
information and specifications are valid at the time of printing. The
manufacturer reserves the right to modifications without prior
notice.
Overview
19
Quick start-up guide
Overview
This chapter presents the steps to take during the start-up of the
RPBA-01 PROFIBUS DP Adapter Module. For more detailed
information, see the chapters Mechanical installation, Electrical
installation, and Programming elsewhere in this manual.
WARNING! Follow the safety instructions given in this manual and

the Hardware Manual of the drive.
PLC configuration
• Install the RPBA-01 GSD file (e.g. ABB_0812.GSD).

20
• Select the operation mode (PROFIDRIVE, i.e. Generic, or

VENDOR SPECIFIC, i.e. ABB Drives).

21
• Set the PPO type, baud rate and node number.
Mechanical and electrical installation

• Set the node address using the rotary switches on the module.
(If the node address is set by software, set the switches to the
“0” position.)
• Set the bus termination switch to the desired position.
• Insert the RPBA-01 into its specified slot in the drive (SLOT2 for
ACS550, SLOT1 for ACS800).
• Fasten the two screws.
• Plug the fieldbus connector to the module.
Drive configuration
• Power up the drive.
• The detailed procedure of activating the drive for
communication with the module is dependent on the drive type.
Normally, a parameter must be adjusted to activate the
communication. Refer to the Firmware Manual of the drive for

22
information on the communication settings. With an ACS550

drive, set parameter 98.02 COMM. MODULE LINK to EXT FBA.
With an ACS800, set parameter 98.02 COMM. MODULE LINK
to FIELDBUS and parameter 98.07 COMM PROFILE to ABB
DRIVES or GENERIC (according to PLC hardware
configuration).
• If the configuration is correct, parameter group 51 should
appear in the parameter list of the drive and show the status of
the bus configuration parameters.
• If the node address is to be set by software, set the required
address at parameter 51.02 NODE ADDRESS.

23
Parameter setting examples

Generic drives profile (PROFIdrive) with PPO Type 1 (DP-V0)
Drive parameter Setting
ACS800 ACS550
10.01 EXT1 STRT/STP/DIR COMM.CW COMM

11.03 EXT REF1 SELECT COMM. REF COMM
16.01 RUN ENABLE COMM.CW COMM
16.04 FAULT RESET SEL COMM.CW COMM
98.02 COMM. MODULE LINK FIELDBUS –
98.02 COMM PROT SEL – EXT FBA
98.07 COMM PROFILE GENERIC –
51.01 MODULE TYPE PROFIBUS DP*

51.02 NODE ADDRESS 3
51.03 BAUDRATE 12000*
51.04 PPO-type PPO1*
51.21 DP MODE 0
51.27 FBA PAR REFRESH REFRESH
*Read-only or automatically detected
The RPBA-01 uses data-consistent communication, meaning that

the whole data frame is transmitted during a single program cycle.
Some PLCs handle this internally, but others must be
programmed to transmit data-consistent telegrams. For example,

24
Siemens Simatic S7 requires the use of special functions SFC15

and SFC14.
The start/stop commands and reference are according to the

PROFIdrive profile. (See the PROFIBUS state machine on page
77.) The reference value ±16384 (4000h) corresponds to the
nominal speed of the motor (parameter 99.08) in forward and
reverse directions.

25
ABB DRIVES profile (Vendor-specific) with PPO Type 2 (DP-V0)

Drive parameter Setting
ACS800 ACS550

11.02 EXT1/EXT2 SELECT COMM.CW COMM
11.03 EXT REF1 SELECT COMM. REF COMM
16.01 RUN ENABLE COMM.CW COMM
16.04 FAULT RESET SEL COMM.CW COMM
98.02 COMM. MODULE LINK FIELDBUS –
98.02 COMM PROT SEL – EXT FBA
98.07 COMM PROFILE ABB DRIVES –
51.01 MODULE TYPE PROFIBUS DP*

51.02 NODE ADDRESS 4
51.03 BAUDRATE 1500*
51.04 PPO-TYPE PPO2*
51.05 PZD3 OUT 1202 (CONST SPEED 1)**
51.06 PZD3 IN 104 (CURRENT)**
51.07 PZD4 OUT 2501 (CRIT SPEED SEL)**
51.08 PZD4 IN 105 (TORQUE)**
51.09 PZD5 OUT 2502 (CRIT SPEED 1 LO)**
51.10 PZD5 IN 106 (POWER)**
51.11 PZD6 OUT 2503 (CRIT SPEED 1 HI)**
51.12 PZD6 IN 107 (DC BUS VOLTAGE)**
••• •••
51.21 DP MODE 0
51.27 FBA PAR REFRESH REFRESH
*Read-only or automatically detected; **Example

26
From the PLC programming point, the ABB DRIVES profile is

similar to the Generic profile as shown in the first example.
The start/stop commands and reference are according to the ABB
DRIVES profile. (See the drive manuals for more information.)
If REF1 is used, the reference value ±20000 (decimal)
corresponds to the speed or frequency set by parameter 11.05
(EXT REF1 MAXIMUM) in the forward and reverse directions. If
REF2 is used, whether the limit 11.08 (EXT REF2 MAXIMUM)
corresponds to ±20000 or ±10000 is dependent on the drive type
and/or the application macro selected.
The minimum and maximum 16-bit integer values that can be
given through the fieldbus are -32768 and 32767 respectively.

27
Mechanical installation
WARNING! Follow the safety instructions given in this manual and

in the Hardware Manual.
Mounting
The RPBA-01 is to be inserted into its specific position in the drive.
The module is held in place with plastic retaining clips and two
screws. The screws also provide the earthing of the I/O cable
shield connected to the module, and interconnect the GND signals
of the module and the control board of the drive.
On installation of the module, the signal and power connection to
the drive is automatically made through a 34-pin connector.
Mounting procedure:
• Insert the module carefully into its position inside the drive until
the retaining clips lock the module into position.
• Fasten the two screws (included) to the stand-offs.
• Set the bus termination switch of the module to the required
position.
Note: Correct installation of the screws is essential for fulfilling the

EMC requirements and for proper operation of the module.
Note: Make sure the drive is properly grounded. For more

information, see the drive documentation.
28
29
Electrical installation
Overview
This chapter contains:
• general cabling instructions
• instructions for setting module node address number and bus
termination
• instructions for connecting the module to the PROFIBUS DP
network.
WARNING! Before installation, switch off the drive power supply.

Wait five minutes to ensure that the capacitor bank of the drive is
discharged. Switch off all dangerous voltages connected from
external control circuits to the inputs and outputs of the drive.
General cabling instructions

Arrange the bus cables as far away from the motor cables as
possible. Avoid parallel runs. Use bushings at cable entries.
Bus termination
The DIP switch on the front of the RPBA-01 module is used to
switch on bus termination. Bus termination prevents signal
reflections from the cable ends. Bus termination must be set to ON
if the module is the last or first module on the network. When using
PROFIBUS specific D-sub connectors with built-in termination, the
RPBA-01 termination must be switched off.
30
Note: The built-in termination circuitry of the RPBA-01 is of the

active type, so the module has to be powered for the termination
to work. If the module needs to be switched off during operation of
the network, the bus can be terminated by connecting a 220 ohm,
1/4 W resistor between the A and B lines.
Bus termination OFF Bus termination ON
ON ON
Figure 2. Bus termination switch
Node selection
Use the rotary node address selectors on the module to select the
node address number. The node address number is a decimal
number ranging from 01 to 99. The left selector represents the first
digit and the right selector the second digit. The node address can
be changed during operation, but the module must be re-initialised
for changes to take effect.
Note: When 00 is selected, the node number is defined by a

parameter in the fieldbus parameter group of the drive.
10x 1x
901 901
23
23
78
78
45 6 45 6
Figure 3. Node selectors
31
PROFIBUS connection
The bus cable is connected to connector X1 on the RPBA-01.
The connector pin allocation described below follows the
PROFIBUS standard.
5 1
X1
9 6
X1 Description
1 Not used
2 Not used
3 B Data positive (Conductor 1 in twisted pair).
4 RTS Request To Send
5 GND Isolated ground
BUS
6 +5V Isolated 5V DC voltage supply
7 Not used
8 A Data negative (Conductor 2 in twisted pair).
9 Not used
Housing SHLD PROFIBUS cable shield. Internally connected
to GND BUS via an RC filter and directly to
CHGND.
+5V and GND BUS are used for bus termination. Some devices,
like optical transceivers (RS485 to fibre optics) might require
external power supply from these pins.
RTS is used in some equipment to determine the direction of

transmission. In normal applications only the line A, line B and
shield are used.
32
PROFIBUS wiring example

The PROFIBUS cable shields are directly earthed at all nodes.
In the example below a recommended Siemens 6ES7 972-
0BA12-0XA0 connector (not included in the delivery) is connected
to the RPBA-01 module. The cable is a standard PROFIBUS
cable consisting of a twisted pair and screen.
Siemens 6ES7 972-0BA12-0XA0 connector
X1 SHLD X1 SHLD
A 1 A 1
RPBA-01 RPBA-01
B 2 B 2
A 3 A 3
PROFIBUS B 4 B 4
MASTER
A
B
GND
Figure 4. Connection diagram for the standard PROFIBUS cable
Note: Further information on PROFIBUS wiring is available from

the publication “PROFIBUS RS 485-IS User and Installation
Guideline” (www.profibus.com, order no. 2.262).
33
Programming
Overview
This chapter gives information on configuring the PROFIBUS
master station and the drive for communication through the
RPBA-01 PROFIBUS DP Adapter module.
Configuring the system

After the RPBA-01 PROFIBUS DP Adapter module has been
mechanically and electrically installed according to the instructions
in previous chapters, the master station and the drive must be
prepared for communication with the module.
Configuration of the master station requires a type definition
(GSD) file. For DP-V0 communication, the file is available from
www.profibus.com or an ABB representative (the filename is
ABB_0812.GSD). For DP-V1 communication, the type definition
(GSD) file is available from an ABB representative (the filename is
ABB10812.GSD).
Please refer to the master station documentation for more
information.
PROFIBUS connection configuration

The detailed procedure of activating the module for
communication with the drive is dependent on the drive type.
(Normally, a parameter must be adjusted to activate the
communication. See the drive documentation.)
As communication between the drive and the RPBA-01 is
established, several configuration parameters are copied to the
drive. These parameters – shown below in Table 5 – must be
checked first and adjusted if necessary. The alternative selections
for these parameters are discussed in more detail below the table.
Programming
34
Note: The new settings take effect only when the module is
powered up the next time or when the module receives a ‘Fieldbus
Adapter parameter refresh’ command from the drive.
Data transfer rates supported

The RPBA-01 supports the following PROFIBUS communication
speeds: 9.6 kbit/s, 19.2 kbit/s, 45.45 kbit/s, 93.75 kbit/s, 187.5
kbit/s, 500 kbit/s, 1.5 Mbit/s, 3 Mbit/s, 6 Mbit/s, 12 Mbit/s.
The RPBA-01 automatically detects the communication speed
and PPO-type used.
Table 5. The RPBA-01 configuration parameters.
Par. Parameter name Alternative settings Default
no. setting
1 MODULE TYPE (Read-only) PROFIBUS DP
2 NODE ADDRESS 0 to 126 3
3 BAUD RATE 1) (12000) 12 Mbit/s; (6000) 6 Mbit/s; 1500
(3000) 3 Mbit/s; (1500) 1.5 Mbit/s;
(500) 500 kbit/s; (187) 187.5 kbit/s;
(93) 93.75 kbit/s; (45) 45.45 kbit/s;
(19) 19.2 kbit/s; (9) 9.6 kbit/s;
(Read-only)
4 PPO-TYPE 1) (1) PPO 1; (2) PPO 2; (3) PPO 3; (1) PPO 1
(4) PPO 4; (5) PPO 5; (6) PPO 6;
(Read-only)
5 PZD3 OUT 0 to 32767 with format xxyy, where 0
xx = Parameter Group and
yy = Parameter Index.
See description below.
6 PZD3 IN See PZD3 OUT above 0
7 PZD4 OUT See PZD3 OUT above 0
... ...
Programming
35
19 PZD10 OUT See PZD3 OUT above 0

21 DP MODE (0) DPV0; (1) DPV1 0
27 FB PAR REFRESH REFRESH; DONE DONE
1)
The value is automatically updated (Read-only).
Note: Set also the extended Parameter Data (see page 67) to
ensure proper operation of the RPBA-01 with the drive.
1 MODULE TYPE
This parameter shows the module type as detected by the drive.
The value cannot be adjusted by the user.
If this parameter is undefined, the communication between the
drive and the module has not been established.
2 NODE ADDRESS
Each device on the PROFIBUS network must have a unique node
number. This parameter is used to define a node number for the
drive it is connected to, if the node address selection switches are
set to the zero position. When the node address selector switches
are used to define the node address (node address selectors not
in zero position) this parameter indicates the set node address.
3 BAUD RATE
Indicates the communication speed detected in kbit/s.
12000 = 12 Mbit/s
6000 = 6 Mbit/s
3000 = 3 Mbit/s
1500 = 1.5 Mbit/s
500 = 500 kbit/s
187 = 187.5 kbit/s
93 = 93.75 kbit/s
45 = 45.45 kbit/s
19 = 19.2 kbit/s
9 = 9.6 kbit/s
Programming
36
4 PPO-TYPE
This parameter indicates the detected PPO message type for the
PROFIBUS communication. See Figures 6 and 10 in the chapters
DP-V0 communication and DP-V1 communication respectively for
the supported PPO message types.
5 PZD3 OUT
This parameter represents process data word 3 of the PPO type
received by the drive over the PROFIBUS network. The content is
defined by a decimal number in the range of 0 to 32767 as follows:
0 not used
1 - 99 data set area of the drive
101 - 9999 parameter area of the drive
10000 - 32767 not supported by the drive
The data set area is allocated as follows:

1 data set 1 word 1
2 data set 1 word 2
3 data set 1 word 3
4 data set 2 word 1
5 data set 2 word 2
6 data set 2 word 3
7 data set 3 word 1
...
99 data set 33 word 3
The parameter area is allocated as follows:

Parameter number with format xxyy, where xx is the parameter
group number (1 to 99) and yy is the parameter number index
inside the group (01 to 99).
Programming
37
6 PZD3 IN
Process data word 3 of the PPO type sent from the drive to the
PROFIBUS network.
The content is defined by a decimal number in the range of 0 to
32767. See parameter PZD3 OUT for description of decimal
number allocation.
7 to 20 PZD4 OUT to PZD10 IN
See parameters PZD3 OUT and PZD3 IN.
21 DP MODE
Selects the PROFIBUS protocol version (DP-V0 or DP-V1).
Note: For DP-V0, GSD file version 1 or 2 (ABB_0812.GSD) must

be used. For DP-V1, GSD file version 3 or higher
(ABB10812.GSD) must be used.
27 FBA PAR REFRESH

Any parameter changes take effect only after the module is
restarted. Alternatively, this parameter can be set to REFRESH.
The parameter will automatically revert to DONE.
Control locations
ABB drives can receive control information from multiple sources
including digital inputs, analogue inputs, the drive control panel
and a communication module (e.g. RPBA-01). ABB drives allow
the user to separately determine the source for each type of
control information (Start, Stop, Direction, Reference, Fault Reset,
etc.). In order to give the fieldbus master station the most
complete control over the drive, the communication module must
be selected as source for this information. See the user
documentation of the drive for information on the selection
parameters.
Programming
38
Programming
39
DP-V0 communication
Overview
This chapter describes the PROFIBUS messaging used in the
communication with the drive when the RPBA-01 module is in DP-
V0 mode.
PROFIBUS DP
The RPBA-01 module supports the PROFIBUS-DP protocol
according to EN 50170 standard. PROFIBUS DP is a distributed
I/O system which enables the master to use a large number of
peripheral modules and field devices. The data transfer is mainly
cyclic: the master reads the input information from the slaves and
sends the output information back to the slaves.
The PROFIBUS DP protocol uses so-called PPOs
(Parameter/Process Data Objects) in cyclic communication. See
Figure 6 for the different PPO types and their composition.
Service Access Points

The services of the PROFIBUS Data Link Layer (Layer 2) are
used by PROFIBUS DP through Service Access Points (SAPs).
Precisely defined functions are assigned to individual SAPs.
For further information on Service Access Points, refer to the
manual of the PROFIBUS master, PROFIdrive – The PROFIBUS
Profile for Adjustable Speed Drives (version 2.0), or the EN 50170
standard.
DP-V0 communication
40
Communication start-up
The following Service Access Points (SAPs) are used to initiate
DP communication:
SAP no. Short Name Name
0 (Default) Data_Exch Transfer Input and Output Data
61 Set_Prm Send Parameter Data
62 Chk_Cfg Check Configuration Data
60 Slave_Diag Read Slave Diagnostic
SAP 61 (Set_Prm)
This SAP is used in the parameterisation of the drive.
Prm_Data (Parameter Data Standard)
Type: Octet String - Length: 8
Byte Value Description
0 B8h Station_Status
1 0 1 1 1 0 0 0
Reserved
WD_On
1 = Watchdog on
Freeze_Req
1 = Slave is requested to process in freeze mode
Sync_Req
1 = Slave is requested to process in SYNC mode
00 = Min TSDR and slave-related
Unlock_Req parameters may be overwritten
10 = Slave locked for other masters. All
Lock_Req parameters can be carried over
x1 = Slave released for other masters
1-2 Watchdog Factors 1 and 2 (set by the PROFIBUS master)

WdFactor1 × WdFactor2 × 10 ms = monitoring time of the
slave to verify that the master is still active.
3 0Bh Minimum Station Delay Respond Time
Time after which a slave station is allowed to send response
frames to the master. Calculated by multiplying the Hex
value with tBit (time required for transmitting one bit).
4-5 0812h Vendor Identification (for the RPBA-01: 0812h)
6 00h Group Identification
DP-V0 communication
41
7 - Reserved
Prm_Data (Parameter Data Extended)
8 10h Header byte
(default) 0 0 0 1 0 0 0 0
Fail-safe mode. Defines the action taken when the PLC
is switched from ‘RUN’ to ‘STOP’ mode.
00 = STOP (default)
01 = LAST SPEED
02 = USE FAIL-SAFE. The values of the PZDs are
defined by bytes 11-30 in the Prm_Data telegram.
Control zero mode. Defines the action taken if a

PROFIBUS telegram containing only zeros is received.
00 = USE FRAME (default). Note that, with this setting,
the drive might not be stopped (if it is running) since
also bit 10 (Remote Command) in the control word
is zero. However, the other PZD’s may still be
updated, but have the value zero.
01 = IGNORE
Operation mode. Determines which control/status word

and reference/actual values are used.
00 = PROFIDRIVE (i.e. Generic drive profile)
01 = VENDOR SPECIFIC (i.e. ABB Drives profile)
(default). With this setting,
• Fail-safe mode ‘STOP’ equals ‘LAST SPEED’
• the control word is forwarded unchanged to the
drive
• if the drive has a parameter for selection of
operation mode (i.e. communication profile),
make sure that the operation modes of the
RPBA-01 and the drive match.
Reserved
9 - 10 0-65536 Cut off time out in milliseconds.

11 - 12 0-65536 Fail-safe, PZD1 (CW)
13 - 14 0-65536 Fail-safe, PZD2 (REF)
15 - 16 0-65536 Fail-safe, PZD3
17 - 18 0-65536 Fail-safe, PZD4
19 - 20 0-65536 Fail-safe, PZD5
21 - 22 0-65536 Fail-safe, PZD6
23 - 24 0-65536 Fail-safe, PZD7
DP-V0 communication
42
25 - 26 0-65536 Fail-safe, PZD8

27 - 28 0-65536 Fail-safe, PZD9
29 - 30 0-65536 Fail-safe, PZD10
The extended Parameter Data bytes are configured via the
PROFIBUS network configuration tool. The functions are defined
in the GSD file.
SAP 62 (Chk_Cfg)
SAP 62 selects the PPO type to be used. The table below gives
the Hex values that must be sent to the drive to select the PPO
type.
Cfg_Data (Configuration Data)
Type: Octet String - Length: 4 to 28
PPO Type Hex Values Description Length in Bytes
1 F3 F1 4 PKW + 2 PZD words 12
3 F1 0 PKW + 2 PZD words 4
DP-V0 communication
43
SAP 60 (Slave_Diag)
This SAP gives diagnostic information on the slave station.
Diag_Data (Diagnostic Data)
Type: Octet String - Length: 6 (Standard) + 2 (Extended Diagnosis)
Byte Description
0 Station_Status_1
x x x x x x x x
Diag.Station_Non_Existent (Set by Master, reset by Slave)
Slave not found
Diag.Stagion_Not_Ready (Set by Slave)
Slave not ready for data exchange
Diag.Cfg_Fault (Set by Slave)
Received configuration data does not match original configuration data
Diag.Ext_Diag (Set by Slave)

Diagnostic entry present in slave-specific diagnostic area
Diag.Not_Supported (Set by Slave)
Service not supported by slave
Diag.Invalid_Slave_Response (Set by Master, reset by Slave)
Invalid response by slave
Diag.Prm_Fault (Set by Slave)
Invalid parameter or parameter value
Diag.Master_Lock (Set by Master, reset by Slave)
Slave is parameterised by another master
1 Station_Status_2
x 0 x x x 1 x x
Diag.Prm_Req (Set by Slave)
Slave requires re-configuration and re-parameterisation
Diag.Stat_Diag (Set by Slave)
Static diagnosis. Slave (temporarily) unable to provide valid
data
Always set to 1 by slave

Diag.WD_On (Set by Slave)
Watchdog on
Diag.Freeze_Mode (Set by Slave)
Freeze command received by slave
Diag.Sync_Mode (Set by Slave)
Sync command received by slave
Reserved
Diag.Deactivated (Set by Master, reset by Slave)
Slave is inacive
DP-V0 communication
44

Byte Description
2 Station_Status_3
x 0 0 0 0 0 0 0
Reserved
Diag.Ext_Diag_Overflow (Set by Slave)
3 Diag.Master_Add
The address of the master that parameterised this slave
4 - 5 Ident_Number (for RPBA-01: 0812h)
6 Ext_Diag_Data
The number of bytes reserved for Extended Diagnosis
(including this byte)
Fixed to 2
7 Ext_Diag_Data
Bit 0 = Communication temporarily lost
Bit 1 = Communication permanently lost
Bit 2 - 7 = Not used
SAP 0 (Data_Exchange)
Allows the master to send output data to a slave station and to
simultaneously request input data from the same station.
Outp_Data (Output Data)
Type: Octet String - Length: 4 to 28 (depending on the selected PPO Type)
Inp_Data (Input Data)
DP-V0 communication
45
PPO message types
Parameter Process data

Fixed area Freely mappable area
identification
DW1.1 DW1.2 DW1.3 DW3.1 DW3.2 DW3.3 DW5.1 DW5.2 DW5.3 DW7.1
OUT area IND VALUE CW REF PZD3 PZD4 PZD5 PZD6 PZD7 PZD8 PZD9 PZD10
IN area ID IND VALUE SW ACT PZD3 PZD4 PZD5 PZD6 PZD7 PZD8 PZD9 PZD10
PKW DW2.1 DW2.2 DW2.3 DW4.1 DW4.2 DW4.3 DW6.1 DW6.2 DW6.3 DW8.1
Type 1
Type 2
Type 3
Type 4
Type 5
OUT area – Data sent from Master to Slave (control data)

IN area – Data sent from Slave to Master (actual data)
Parameter Identification:
ID – Parameter Identification
IND – Index for Arrays
VALUE – Parameter Value (Max. 4 bytes)
PKW –Parameter ID/Value
Process Data:
CW – Control Word (see Table 7.)
SW – Status Word (see Table 8.)
REF – Reference
ACT – Actual Value
PZD – Process Data (application-specific)
DW – Data Word
Figure 6. PPO message types
DP-V0 communication
46
The Control Word and the Status Word

The Control Word (PROFIBUS Parameter 967) is the principal
means for controlling the drive from a fieldbus system. It is sent by
the fieldbus master station to the drive, the adapter module acting
as a gateway. The drive switches between its states according to
the bit-coded instructions on the Control Word, and returns status
information to the master in the Status Word (PROFIBUS
Parameter 968).
The contents of the Control Word and the Status Word are
detailed in Tables 7 and 8 respectively; see the drive
documentation for information on the drive-specific bits. The drive
states are presented in the PROFIBUS State Machine (Figure 9).
References
References are 16-bit words containing a sign bit and a 15-bit
integer. A negative reference (indicating reversed direction of
rotation) is formed by calculating the two’s complement from the
corresponding positive reference.
including analogue and digital inputs, the drive control panel and a
communication module (e.g. RPBA-01). In order to have the drive
controlled through PROFIBUS, the communication module must
be defined as the source for control information, e.g. Reference.
In the Vendor Specific mode, the scaling of the integer received
from the master as Reference is drive-specific. See its
programming manual for available control source selections and
Reference scaling factors.
In PROFIdrive mode, the speed reference (REF) in hexadecimal
(0…4000h) corresponds to 0…‘motor nominal speed’.
Actual Values
Actual Values are 16-bit words containing information on the
operation of the drive. The functions to be monitored are selected
by a drive parameter. The scaling of the integers sent to the
DP-V0 communication
47
master as Actual Values depends on the selected function, refer to

the drive documentation.
In PROFIdrive mode, the actual speed (ACT) in hexadecimal
Table 7. The Control Word (PROFIBUS Parameter 967). The

upper case boldface text refers to the states shown in Figure 9.
Bit Name Value Proceed to STATE/Description
0 ON 1 Proceed to READY TO OPERATE
OFF1 0 Emergency OFF, stop by the selected deceleration ramp.
Proceed to OFF1 ACTIVE; proceed further to READY
TO SWITCH ON unless other interlocks (OFF2, OFF3)
are active
1 OFF2 1 Continue operation (OFF2 inactive)
0 Emergency OFF, coast to stop.
Proceed to OFF2 ACTIVE; proceed further to SWITCH-
ON INHIBIT
0 Emergency stop, stop according to fastest possible
deceleration mode. Proceed to OFF3 ACTIVE; proceed
further to SWITCH-ON INHIBIT. Warning: Ensure motor
and driven machine can be stopped using this stop
mode.
3 OPERATION_ 1 Proceed to ENABLE OPERATION
ENABLE
0 Inhibit operation. Proceed to OPERATION INHIBIT
4 RAMP_OUT_ 1 Normal operation.
ZERO Proceed to RAMP FUNCTION GENERATOR: ENABLE
OUTPUT
0 Stop according to selected stop type
5 RAMP_HOLD 1 Normal operation.
Proceed to RAMP FUNCTION GENERATOR: ENABLE
ACCELERATOR
0 Halt ramping (Ramp Function Generator output held)
DP-V0 communication
48

6 RAMP_IN_ 1 Normal operation. Proceed to OPERATING
ZERO
0 Force Ramp Function Generator input to zero
Note: The function of this bit may depend on the ramp
parameter settings of the drive. See the drive documentation.
7 RESET 0 ⇒ 1 Fault reset if an active fault exists. Proceed to SWITCH-
ON INHIBIT.
0 (Continue normal operation)
8 INCHING_1 Inching 1. (See the drive documentation for information)
10 REMOTE_ 1 Fieldbus control enabled
CMD 0 Control Word <> 0 or Reference <> 0: Retain last Control
Word and Reference
Control Word = 0 and Reference = 0: Fieldbus control
enabled
11 Drive-specific. (See the drive documentation for
to information)
15
Table 8. The Status Word (PROFIBUS Parameter 968). The upper

case boldface text refers to the states shown in Figure 9.
Bit Name Value STATE/Description
0 RDY_ON 1 READY TO SWITCH ON
0 NOT READY TO SWITCH ON
1 RDY_RUN 1 READY TO OPERATE
0 OFF1 ACTIVE
2 RDY_REF 1 ENABLE OPERATION
0 DISABLE OPERATION
3 TRIPPED 1 FAULT
0 No fault
DP-V0 communication
49

4 OFF_2_STA 1 OFF2 inactive
0 OFF2 ACTIVE
0 OFF3 ACTIVE
6 SWC_ON_INHIB 1 SWITCH-ON INHIBIT ACTIVE
0 SWITCH-ON INHIBIT NOT ACTIVE
7 ALARM 1 Warning/Alarm
0 No Warning/Alarm
8 AT_SETPOINT 1 OPERATING. Actual value equals reference value
(i.e. is within tolerance limits)
0 Actual value differs from reference value
(= is outside tolerance limits)
9 REMOTE 1 Drive control location: REMOTE
0 Drive control location: LOCAL
10 ABOVE_LIMIT 1 Actual frequency or speed value equals or is greater
than supervision limit.
0 Actual frequency or speed value is within supervision
limit.
11 Drive-specific
to
15
DP-V0 communication
50
SWITCH-ON
MAINS OFF INHIBIT (SW Bit6=1)
Power ON OFF1 (CW Bit0=0)

PROFIdrive
State Machine
NOT READY
TO SWITCH ON (SW Bit0=0) CW = Control Word
A B C D
SW = Status Word
n = Speed
(CW=xxxx xxxx xxxx x110) I = Input Current
(CW Bit3=0) RFG = Ramp Function
Generator
READY TO
SWITCH ON f = Frequency
OPERATION (SW Bit0=1)
INHIBIT (SW Bit2=0)
from any state
operation ON (CW=xxxx xxxx xxxx x111)
inhibited
Fault
READY TO Main contactor ON FAULT

OPERATE (SW Bit1=1) (SW Bit3=1)
from any state

(CW Bit7=1)
OFF1 (CW Bit0=0)
OFF1 from any state from any state

ACTIVE (SW Bit1=0) Emergency Stop Emergency Stop
Enable operation OFF3 (CW Bit2=0) OFF2 (CW Bit1=0)
n(f)=0 / I=0 (CW Bit3=1) OFF3 OFF2
ACTIVE (SW Bit5=0) ACTIVE (SW Bit4=0)
B C D
n(f)=0 / I=0
Main contactor OFF
(CW Bit4=0)
C D ENABLE
A (CW Bit4=0 Bit5=0 Bit6=0)
(CW Bit5=0) (CW Bit4=1)
Inching 1 or 2 ON
(CW Bit8=1 or Bit9=1)
D RFG: ENABLE
OUTPUT INCHING 1
B or
(CW Bit6=0) (CW Bit5=1) INCHING 2
ACTIVE
RFG: ENABLE Inching 1 or 2 OFF
state ACCELERATION (CW Bit8=0 or Bit9=0)
C
(CW Bit6=1) Inching pause
condition
rising edge OPERATING ‘n=0 or f =0’ and ‘I=0’
of the bit (SW Bit8=1) and inching pause expired
D
Figure 9. The PROFIdrive state machine
DP-V0 communication
51
Parameter handling in cyclic communication (DP)

In cyclic PROFIBUS DP communication, parameter data is
transferred in PPO message types 1, 2 and 5 (see Figure 6.). The
Parameter Identification part consists of eight bytes (see below).
Parameter
Identification Process Data
CW REF
ID IND VALUE SW ACT (PD1, PD2...)
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Request Label
Response Label Parameter Number (PNU)
*Request Signal
*Not used (=0)
The Request Label is used by the master when transmitting data

to the slave, while the Response Label is used by the slave as a
positive or negative acknowledgement. The tables below show the
Request/Response functions.
Request labels (from Master to Slave)
Request Function Response labels
Ackn. (+) Ackn. (-)
0 No task 0 –
1 Request parameter value 1, 2 7
2 Change parameter value (word) 1 7, 8
3 Change parameter value (double word) 2 7, 8
4 Request description element (not supported) 3 7
5 Change description element (not supported) 3 7, 8
6 Request parameter value (array) 4, 5 7, 8
7 Change parameter value (array word) 4 7, 8
8 Change parameter value (array double word) 5 7,8
9 Request number of array elements 6 7
DP-V0 communication
52
Response label (Acknowledgement from Slave to Master)

Ackn. Function
0 No response
1 Transfer parameter value (word)
2 Transfer parameter value (double word)
3 Transfer description element
4 Transfer parameter value (array word)
5 Transfer parameter value (array double word)
6 Transfer number of array elements
7 Task cannot be executed, followed by error number
0 = Illegal parameter number
1 = Parameter value cannot be changed
2 = Lower or upper limit violated
3 = Erroneous subindex
4 = No array
5 = Incorrect data type
6 = Setting not allowed (can only be reset)
7 = Descriptive element cannot be changed
9 = Descriptive data not available
11 = No parameter change rights
15 = Text array not available
17 = Task cannot be executed due to operating status
(e.g. parameter is currently read-only)
18 = Other error
101 = Vendor specific error
102 = Request not supported
103 = Request cannot be completed due to communication error
110 = Failure during write to non-volatile memory
111 = Request aborted due to time-out
120 = Parameter cannot be mapped to PZD
(size mismatch or non-existent)
121 = Parameter cannot be mapped to PZD (end of memory)
122 = Parameter cannot be mapped to PZD (multiple PZD write)
130 = Cannot map Control Word bit (parameter 933 - 937,
e.g. double mapping of bits)
140 = Cannot change mode to TORQUE (frequency is used)
8 No parameter change rights for PKW interface
9 Parameter data signal (word)
10 Parameter data signal (double word)
DP-V0 communication
53
The allocation of data sets, drive parameters and PROFIdrive

parameters to the Parameter Identification part of the PPO type is
shown below. The Index column corresponds to the parameter
number (PNU) in the ID part of Parameter Identification. The Sub-
index column corresponds to the IND part of Parameter
Identification. The Example No. column refers to the examples on
the following pages.
Data set area
Range Example
Index Sub-index Request Label
(Decimal) No.
0h 1h 1
0h 2h 2
R/W 6/7 1, 2
•••
0h 63h 99
Drive parameters
Range Example
(Decimal) No.
0h 65h 101
0h 66h 102
R/W* 6/7 1, 2
•••
27h 0Fh 9999
*Write access depends on drive parameter type, or operation mode.
DP-V0 communication
54
PROFIdrive parameters
Range Example
(Decimal) No.
2h 2
3h 3
393h 915 R/W 6/7 6
••• •••
9h 9
2h 2
3h 3
394h 916 R/W 6/7 7
••• •••
9h 9
396h 0h 918 R/W 1/2 3, 4
•••
0h 1
9h 9
11h 17
3B3h 947 R 6 5
19h 25
21h 33
29h 41
•••
3CCh 0h 972 R/W 1/2 3,4
The complete PROFIdrive parameter list for the RPBA-01 can be

found as a separate chapter elsewhere in this manual.
Note: Continuous (cyclic) writing of PROFIdrive parameters

should be avoided as the values of these parameters are stored in
the flash memory of the RPBA-01. The estimated lifetime of the
flash memory is 1,000,000 program/erase cycles, and continuous
writing will cause the memory to fail prematurely.
DP-V0 communication
55
Example 1: Reading a drive parameter (or data set)

To determine the parameter number and subindex for drive
parameter reading, multiply the parameter number by one
hundred and then convert it to hexadecimal. The low byte is the
subindex (IND), and the high byte is the parameter number (PNU).
For example reading parameter 84.11 INPUT 1 from the drive:
84.11 × 100 = 8411 = 20DBh.
Parameter number is 20 and subindex is DB.
Request (Read parameter value [array])

Parameter Number (20h)
Subindex (DBh)*
CW REF PZD3 PZD4 PZD5 PZD6
Req 60 20 DB 00 00 00 00 00 04 7F 34 15 00 00 00 00 00 00 00 00
Resp 40 20 DB 00 00 00 00 64 03 37 34 15 00 00 00 00 00 00 00 00
SW ACT PZD3 PZD4 PZD5 PZD6

Parameter Value (100 Dec)
Subindex (DBh)*
Response (Change parameter value [array])
*2nd byte reserved
DP-V0 communication
56
Example 2: Writing a drive parameter (or data set)

parameter writing, multiply the parameter number by one hundred
and then convert it to hexadecimal. The low byte is the subindex
(IND), and the high byte is the parameter number (PNU). For
example write parameter 12.02 CONSTANT SPEED.1:
12.02 × 100 = 1202 = 04B2h.
Parameter is 04 and subindex is B2.
Request (Change parameter value [array])

Subindex (B2h)*
Req 70 04 B2 00 00 00 00 64 04 7F 34 15 00 00 00 00 00 00 00 00
Resp 40 04 B2 00 00 00 00 64 03 37 34 15 00 00 00 00 00 00 00 00

Subindex (B2h)*
Response (Transfer parameter value [array])
*2nd byte reserved
DP-V0 communication
57
Example 3: Reading a PROFIdrive parameter (word)

In this example, PROFIBUS Parameter No. 918 is used to read
the station number of the slave.
Request (Parameter value read)
Parameter Number (918 Dec)
IND Param. Value CW REF
Request 13 96 00 00 00 00 00 00 04 7F 34 15
Read:
Response 13 96 00 00 00 00 00 02 03 37 34 15
IND Param. Value SW ACT
Response (Parameter value updated)
The slave returns its station number (2).
DP-V0 communication
58
Example 4: Writing a PROFIdrive parameter (word)

In this example, current parameter settings are saved to the
FLASH memory of the drive. This is done by setting the value of
PROFIBUS Parameter No. 971 (3CBh) to 1.
Note that the drive always observes the Control Word (CW)
and Reference (REF) bytes. The values shown below are
examples.
Request (Parameter value write)
IND Param. Value CW REF
Request 23 CB 00 00 00 00 00 01 04 7F 34 15
Write:
Response 13 CB 00 00 00 00 00 00 03 37 34 15
IND Param. Value SW ACT
Response (Parameter value updated)
DP-V0 communication
59
Example 5: Reading a PROFIdrive parameter (array)

In this example, PROFIBUS Parameter No. 945 is used to read
the code of the latest acknowledged fault. As shown in Table 22
on page 103, parameter 945 is of the array type with subindexes
1, 9, 17 and 25.
Request (Request parameter value [array])
Subindex (Latest acknowledged fault)*

Param. Value CW REF
Request 63 B1 09 00 00 00 00 00 04 7F 34 15
Read:
Response 43 B1 09 00 00 00 23 00 03 37 34 15
Param. Value SW ACT

Subindex (Latest acknowledged fault)*
*2nd byte reserved
The slave returns the code of the latest acknowledged fault

(2300h). The fault codes are according to the DRIVECOM
standard. See also the User’s Manual of the drive for drive specific
fault codes.
The implementation of the PROFIdrive profile in the RPBA-01
supports the storage of the active and the five latest occurred
different faults in the fault buffer. The fault codes can be accessed
by PROFIdrive parameters 945 and 948 (see Table 22 on page
101). The value zero indicates no fault. The subindexes of these
parameters are related to each other, i.e. parameter 945 with
subindex 1 relates to subindex of parameter 948.
DP-V0 communication
60
Example 6: Configuring the process data written to the drive

PROFIBUS parameter 915 can be used to define which data is
written cyclically to a drive parameter as application-specific
process data.
In the example below, the value of drive parameter
12.02 CONSTANT SPEED 1 (4B2h) is selected to be taken from
PZD3. The parameter will continue to be updated with the
contents of PZD3 in each Request frame until a different selection
is made.
Subindex (IND) defines which process data word the required
data is taken from. Parameter Value selects the drive parameter to
which that word is mapped.

Subindex (03 = PZD3)*
Req 73 93 03 00 00 00 04 B2 04 7F 34 15 00 00 00 00 00 00 00 00
Resp 43 93 03 00 00 00 04 B2 03 37 34 15 00 00 00 00 00 00 00 00

*2nd byte reserved
Subsequently, the contents of PZD3 in each Request frame are

written to drive parameter 12.02 CONSTANT SPEED 1 until a
different selection is made.
DP-V0 communication
61
Example 7: Configuring the process data read from the drive

PROFIBUS Parameter No. 916 can be used to define which data
is read cyclically from the drive as application-specific process
data.
In the example below, drive parameter 1.04 CURRENT (68h) is
selected to be transmitted by the drive as PZD3. The selection is
in force until it is superseded by another selection.
data is transmitted in, and Parameter Value defines which drive
parameter is mapped to that word.

Req 73 94 03 00 00 00 00 68 04 7F 34 15 00 00 00 00 00 00 00 00
Resp 43 94 03 00 00 00 00 68 03 37 34 15 00 00 00 00 00 00 00 00

*2nd byte reserved
Subsequent response frames:

Resp xx xx xx xx xx xx xx xx xx xx xx xx 00 0B xx xx xx xx xx xx
PZD3 (Value of Drive Parameter 1.04)
DP-V0 communication
62
DP-V0 communication
63
DP-V1 communication
Overview
This chapter describes the PROFIBUS messaging used in the
communication with the drive when the RPBA-01 module is in DP-
V1 mode.
PROFIBUS DP
The RPBA-01 module supports the PROFIBUS-DP protocol
according to EN 50170 standard. PROFIBUS DP is a distributed
I/O system which enables the master to use a large number of
peripheral modules and field devices. The data transfer is mainly
cyclic: the master reads the input information from the slaves and
sends the output information back to the slaves.
The PROFIBUS DP protocol uses so-called PPOs
(Parameter/Process Data Objects) in cyclic communication. See
Figure 10 for the different PPO types and their composition.
Service Access Points

The services of the PROFIBUS Data Link Layer (Layer 2) are
used by PROFIBUS DP through Service Access Points (SAPs).
Precisely defined functions are assigned to individual SAPs.
For further information on Service Access Points, refer to the
manual of the PROFIBUS master, PROFIdrive – The PROFIBUS
Profile for Adjustable Speed Drives (version 3.1), or the EN 50170
standard.
DP-V1 communication
64
Communication start-up
The following Service Access Points (SAPs) are used to initiate
DP communication:
SAP no. Short Name Name
51 Server_SAP Acyclic Read/Write
61 Set_Prm Send Parameter Data
62 Chk_Cfg Check Configuration Data
60 Slave_Diag Read Slave Diagnostic Information
0 (Default SAP) Data_Exch Transfer Input and Output Data
SAP 61 (Set_Prm)
This SAP is used in the parameterisation of the drive.
Prm_Data (Parameter Data Standard)
Byte Value Description
0 B8h Station_Status
MSB 1 0 1 1 1 0 0 0 LSB
Reserved
WD_On
1 = Watchdog on
Freeze_Req
1 = Slave is requested to process in freeze mode
Sync_Req
1 = Slave is requested to process in SYNC mode
00 = Min TSDR and slave-related
Unlock_Req parameters may be overwritten
10 = Slave locked for other masters.
Lock_Req All parameters can be carried over
x1 = Slave released for other masters
1-2 Watchdog Factors 1 and 2 (set by the PROFIBUS master)

WdFactor1 × WdFactor2 × 10 ms = monitoring time of the
slave to verify that the master is still active.
3 0Bh Minimum Station Delay Respond Time
Time after which a slave station is allowed to send response
frames to the master. Calculated by multiplying the hex
value with tBit (time required for transmitting one bit).
4-5 0812h Vendor Identification (for the RPBA-01: 0812h)
6 00h Group Identification
DP-V1 communication
65
7 DPV1_Status_1
MSB x 0 x 0 0 x x x LSB
Dis_Start_Control (Disable Stop-Bit Control)

0 = Start bit monitoring in receiver enabled
1 = Start bit monitoring in receiver disabled
Dis_Stop_Control (Disable Stop-Bit Control)

0 = Stop bit monitoring in receiver enabled
1 = Stop bit monitoring in receiver disabled
WD_Base (Watchdog time base)

0 = 10 ms
1 = 1 ms
Reserved
Publisher_Enabled
0 = Slave not operated in DXB Publisher mode
1 = Slave operated in DXB Publisher mode
(Not supported)
Fail_Safe. Not supported.
DPV1_Enable
0 = Slave operated in DP mode
1 = Slave operated in DP-V1 mode
DP-V1 communication
66
8 DPV1_Status_2
MSB x x x x x x 0 x LSB
Chk_Cfg_Mode
0 = Chk_Cfg according to EN 50170 (default state)
1 = User-specific evaluation of Chk_Cfg
Reserved. To be parameterised with ‘0’.

Enable_Update_Alarm
0 = Enable_Update_Alarm disabled
1 = Enable_Update_Alarm enabled (Not supported)
Enable_Status_Alarm
0 = Enable_Status_Alarm disabled
1 = Enable_Status_Alarm enabled (Not supported)
Enable_Manufacturer_Specific_Alarm
0 = Enable_Manufacturer_Specific_Alarm disabled
1 = Enable_Manufacturer_Specific_Alarm enabled
(Not supported)
Enable_Diagnostic_Alarm
0 = Enable_Diagnostic_Alarm disabled
1 = Enable_Diagnostic_Alarm enabled (Not
supported)
Enable_Process_Alarm
0 = Enable_Process_Alarm disabled
1 = Enable_Process_Alarm enabled (Not supported)
Enable_Pull_Plug_Alarm
0 = Enable_Pull_Plug_Alarm disabled
1 = Enable_Pull_Plug_Alarm enabled (Not
supported)
9 DPV1_Status_3
MSB 0 0 0 x x x x x LSB
Alarm_Mode. Limits the number of active alarms.

0 = 1 alarm of each type 1 = 2 alarms in total
2 = 4 alarms in total 3 = 8 alarms in total
Prm_Structure
0 = Prm telegram according to EN 50170
1 = Prm telegram in structure form (DPV2 extension)
(Not supported)
IsoM_Req (Isochron Mode Request)

0 = Isochron Mode disabled
1 = Isochron Mode enabled (Not supported)
Reserved. To be parameterised with ‘0’.
DP-V1 communication
67
Prm_Data (Parameter Data Extended)

10 10h Header byte
(default) MSB 0 0 0 1 0 0 0 0 LSB
Fail-safe mode. Defines the action taken when the

PLC is switched from ‘RUN’ to ‘STOP’ mode.
00 = STOP (default)
01 = LAST SPEED
02 = USE FAIL-SAFE. The values of the PZDs are
defined by bytes 11-30 in the Prm_Data
telegram.
Control zero mode. Defines the action taken if a

PROFIBUS telegram containing only zeros is
received.
00 = USE FRAME (default). Note that, with this
setting, the drive might not be stopped (if it is
running) since also bit 10 (Remote Command)
in the control word is zero. However, the other
PZD’s may still be updated, but have the value
zero.
01 = IGNORE
Operation mode. Determines which control/status

word and reference/actual values are used.
00 = PROFIDRIVE (i.e. Generic drive profile)
01 = VENDOR SPECIFIC (i.e. ABB Drives profile)
(default). With this setting,
• Fail-safe mode ‘STOP’ equals ‘LAST SPEED’
• the control word is forwarded unchanged to
the drive
• if the drive has a parameter for selection of
operation mode (i.e. communication profile),
make sure that the operation modes of the
RPBA-01 and the drive match.
Reserved
11 - 12 0-65536 Cut off time out in milliseconds. 0 = Cut off disabled.

13 - 14 0-65536 Fail-safe, PZD1 (CW)
15 - 16 0-65536 Fail-safe, PZD2 (REF)
17 - 18 0-65536 Fail-safe, PZD3
19 - 20 0-65536 Fail-safe, PZD4
21 - 22 0-65536 Fail-safe, PZD5
23 - 24 0-65536 Fail-safe, PZD6
25 - 26 0-65536 Fail-safe, PZD7
DP-V1 communication
68
27 - 28 0-65536 Fail-safe, PZD8

29 - 30 0-65536 Fail-safe, PZD9
31 - 32 0-65536 Fail-safe, PZD10
The extended Parameter Data bytes are configured via the
PROFIBUS network configuration tool. The functions are defined
in the GSD file.
SAP 62 (Chk_Cfg)
SAP 62 selects the PPO type to be used. The table below gives
the Hex values that must be sent to the drive to select the PPO
type.
Cfg_Data (Configuration Data)
Type: Octet String - Length: 4 to 28
*PKW **PZD
PPO Hex
PROFIdrive parameter enabled size in size in
Type Values
bytes bytes
1 F3 F1 Acyclic Parameter Read 8 4
3 F1 Acyclic Parameter Read/Write 0 4
*PKW: “Parameter-Kennung-Wert” (Parameter ID Value)

**PZD: “Prozeßdaten” (Process data)
With PPO1, PPO2 and PPO5, reading/writing parameters is only
possible cyclically through the Parameter Identification (PKW)
channel. With PPO3, PPO4 or PPO6, acyclic parameter
reading/writing is available via the DP-V1 parameter read/write
service.
The PPO type can be changed during runtime. However, the
RPBA-01 will go offline while the configuration is being updated.
DP-V1 communication
69
SAP 60 (Slave_Diag)
This SAP gives diagnostic information on the slave station.
Byte Description
0 Station_Status_1
MSB x x x x x x x x LSB
Diag.Station_Non_Existent (Set by Master, reset by Slave)

Slave not found
Diag.Stagion_Not_Ready (Set by Slave)
Slave not ready for data exchange
Diag.Cfg_Fault (Set by Slave)
Received configuration data does not match original config. data
Diag.Ext_Diag (Set by Slave)
Diagnostic entry present in slave-specific diagnostic area
Diag.Not_Supported (Set by Slave)
Service not supported by slave
Diag.Invalid_Slave_Response (Set by Master, reset by
Slave)
Invalid response by slave
Diag.Prm_Fault (Set by Slave)
Invalid parameter or parameter value
Diag.Master_Lock (Set by Master, reset by Slave)
Slave is parameterised by another master
1 Station_Status_2
MSB x 0 x x x 1 x x LSB
Diag.Prm_Req (Set by Slave)

Slave requires re-configuration and re-parameterisation
Diag.Stat_Diag (Set by Slave)
Static diagnosis. Slave (temporarily) unable to provide
valid data
Always set to 1 by slave

Diag.WD_On (Set by Slave)
Watchdog on
Diag.Freeze_Mode (Set by Slave)
Freeze command received by slave
Diag.Sync_Mode (Set by Slave)
Sync command received by slave
Reserved
Diag.Deactivated (Set by Master, reset by Slave)
Slave is inactive
DP-V1 communication
70

Byte Description
2 Station_Status_3
MSB x 0 0 0 0 0 0 0 LSB
Reserved
Diag.Ext_Diag_Overflow (Set by Slave)
3 Diag.Master_Add
The address of the master that parameterised this slave
4 - 5 Ident_Number (for RPBA-01: 0812h)
6 Header Byte
7 Status Type = Status Message (0x81)
8 Slot Number (0x00)
9 Specifier (0x00)
10 Communication Diagnostic
MSB 0 0 0 0 0 0 x x LSB
Communication temporarily lost

Communication permanently lost
Reserved
SAP 0 (Data_Exchange)
Allows the master to send output data to a slave station and to
simultaneously request input data from the same station.
Outp_Data (Output Data)
Inp_Data (Input Data)
DP-V1 communication
71
PPO message types
Parameter Process data

Fixed area Freely mappable area
identification
Parameter
channel
DW1.1 DW1.2 DW1.3 DW3.1 DW3.2 DW3.3 DW5.1 DW5.2 DW5.3 DW7.1
OUT area IND VALUE CW REF PZD3 PZD4 PZD5 PZD6 PZD7 PZD8 PZD9 PZD10
IN area ID IND VALUE SW ACT PZD3 PZD4 PZD5 PZD6 PZD7 PZD8 PZD9 PZD10
PKW DW2.1 DW2.2 DW2.3 DW4.1 DW4.2 DW4.3 DW6.1 DW6.2 DW6.3 DW8.1
Type 1 DP-V0
Type 2 DP-V0
Type 3 DP-V1
Type 4 DP-V1
Type 5 DP-V0
Type 6 DP-V1
OUT area – Data sent from Master to Slave (control data)

IN area – Data sent from Slave to Master (actual data)
Parameter Identification:
ID – Parameter Identification
IND – Index for Arrays
VALUE – Parameter Value (Max. 4 bytes)
PKW – Parameter ID/Value
Process Data:
CW – Control Word (see Table 11.)
SW – Status Word (see Table 12.)
REF – Reference
ACT – Actual Value
PZD – Process Data (application-specific)
DW – Data Word
Figure 10. PPO message types
DP-V1 communication
72

The Control Word (PROFIBUS Parameter 967) is the principal
means for controlling the drive from a fieldbus system. It is sent by
the fieldbus master station to the drive, the adapter module acting
as a gateway. The drive switches between its states according to
the bit-coded instructions on the Control Word, and returns status
information to the master in the Status Word (PROFIBUS
Parameter 968).
The contents of the Control Word and the Status Word are
detailed in Tables 11 and 12 respectively; see the drive
documentation for information on the drive-specific bits. The drive
states are presented in the PROFIBUS State Machine (Figure 13).
References
References are 16-bit words containing a sign bit and a 15-bit
integer. A negative reference (indicating reversed direction of
rotation) is formed by calculating the two’s complement from the
corresponding positive reference.
including analogue and digital inputs, the drive control panel and a
communication module (e.g. RPBA-01). In order to have the drive
controlled through PROFIBUS, the communication module must
be defined as the source for control information, e.g. Reference.
In the Vendor Specific mode, the scaling of the integer received
from the master as Reference is drive-specific. See its
programming manual for available control source selections and
Reference scaling factors.
In PROFIdrive mode, the speed reference (REF) in hexadecimal
(0 … 4000h) corresponds to 0 … ‘motor nominal speed’.
Actual Values
Actual Values are 16-bit words containing information on the
operation of the drive. The functions to be monitored are selected
by a drive parameter. The scaling of the integers sent to the
DP-V1 communication
73
master as Actual Values depends on the selected function, refer to

the drive documentation.
In PROFIdrive mode, the actual speed (ACT) in hexadecimal
Table 11. The Control Word (PROFIBUS Parameter 967). The

0 ON 1 Proceed to READY TO OPERATE
OFF1 0 Emergency OFF, stop by the selected deceleration ramp.
Proceed to OFF1 ACTIVE; proceed further to READY
TO SWITCH ON unless other interlocks (OFF2, OFF3)
are active
Proceed to OFF2 ACTIVE; proceed further to SWITCH-
ON INHIBIT
0 Emergency stop, stop according to fastest possible
deceleration mode. Proceed to OFF3 ACTIVE; proceed
further to SWITCH-ON INHIBIT. Warning: Ensure motor
and driven machine can be stopped using this stop
mode.
3 OPERATION_ 1 Proceed to ENABLE OPERATION
ENABLE
0 Inhibit operation. Proceed to OPERATION INHIBIT
ZERO Proceed to RAMP FUNCTION GENERATOR: ENABLE
OUTPUT
0 Stop according to selected stop type
5 RAMP_HOLD 1 Normal operation.
Proceed to RAMP FUNCTION GENERATOR: ENABLE
ACCELERATOR
0 Halt ramping (Ramp Function Generator output held)
DP-V1 communication
74

6 RAMP_IN_ 1 Normal operation. Proceed to OPERATING
ZERO
0 Force Ramp Function Generator input to zero
Note: The function of this bit may depend on the ramp
parameter settings of the drive. See the drive documentation.
7 RESET 0 ⇒ 1 Fault reset if an active fault exists. Proceed to SWITCH-
ON INHIBIT.
0 (Continue normal operation)
10 REMOTE_ 1 Fieldbus control enabled
CMD 0 Control Word <> 0 or Reference <> 0: Retain last Control
Word and Reference
Control Word = 0 and Reference = 0: Fieldbus control
enabled
11 Vendor-specific bit as defined by PROFIdrive parameter
933.
934.
935.
936.
937.
DP-V1 communication
75
Table 12. The Status Word (PROFIBUS Parameter 968). The

0 RDY_ON 1 READY TO SWITCH ON
0 NOT READY TO SWITCH ON
1 RDY_RUN 1 READY TO OPERATE
0 OFF1 ACTIVE
2 RDY_REF 1 ENABLE OPERATION
0 DISABLE OPERATION
3 TRIPPED 1 FAULT
0 No fault
0 OFF2 ACTIVE
0 OFF3 ACTIVE
6 SWC_ON_INHIB 1 SWITCH-ON INHIBIT ACTIVE
0 SWITCH-ON INHIBIT NOT ACTIVE
7 ALARM 1 Warning/Alarm
0 No Warning/Alarm
8 AT_SETPOINT 1 OPERATING. Actual value equals reference value
(i.e. is within tolerance limits)
0 Actual value differs from reference value
(= is outside tolerance limits)
9 REMOTE 1 Drive control location: REMOTE
0 Drive control location: LOCAL
10 ABOVE_LIMIT 1 Actual frequency or speed value equals or is greater
than supervision limit.
0 Actual frequency or speed value is within supervision
limit.
DP-V1 communication
76

11 Vendor-specific bit as defined by PROFIdrive
parameter 939. (See the drive documentation.)
DP-V1 communication
77
SWITCH-ON
MAINS OFF INHIBIT (SW Bit6=1)
Power ON OFF1 (CW Bit0=0)

PROFIBUS
State Machine
NOT READY
TO SWITCH ON (SW Bit0=0) CW = Control Word
A B C D
SW = Status Word
n = Speed
(CW=xxxx xxxx xxxx x110) I = Input Current
(CW Bit3=0) RFG = Ramp Function
Generator
READY TO
SWITCH ON f = Frequency
INHIBIT (SW Bit2=0)
from any state
operation ON (CW=xxxx xxxx xxxx x111)
inhibited
Fault
READY TO Main contactor ON FAULT

from any state

(CW Bit7=1)
OFF1 (CW Bit0=0)

ACTIVE (SW Bit1=0) Emergency Stop Emergency Stop
Enable operation OFF3 (CW Bit2=0) OFF2 (CW Bit1=0)
n(f)=0 / I=0 (CW Bit3=1) OFF3 OFF2
ACTIVE (SW Bit5=0) ACTIVE (SW Bit4=0)
B C D
n(f)=0 / I=0
Main contactor OFF
(CW Bit4=0)
C D ENABLE
A (CW Bit4=0 Bit5=0 Bit6=0)
(CW Bit5=0) (CW Bit4=1)
Inching 1 or 2 ON
(CW Bit8=1 or Bit9=1)
D RFG: ENABLE
OUTPUT INCHING 1
B or
(CW Bit6=0) (CW Bit5=1) INCHING 2
ACTIVE
RFG: ENABLE Inching 1 or 2 OFF
state ACCELERATION (CW Bit8=0 or Bit9=0)
C
(CW Bit6=1) Inching pause
condition
rising edge OPERATING ‘n=0 or f =0’ and ‘I=0’
of the bit (SW Bit8=1) and inching pause expired
D
Figure 13. The PROFIBUS state machine
DP-V1 communication
78
DP-V1 read/write request sequence

A read/write service on a drive parameter is illustrated below.
Master DP-V1 Slave

PROFIdrive Write request DB47 Parameter request
Parameter request
Write response
without data
Read request DB47

without data
Parameter
Read response (–) processing
without data
Read request DB47

without data
PROFIdrive Read response

Parameter response with data Parameter response
The messaging employs DP-V1 data units. The PROFIdrive

parameter request is contained within the DP-V1 request as data.
Likewise, the DP-V1 response contains the PROFIdrive
parameter response as data.
A write request (Function number 5Fh – see Table 15 below) is
first sent containing the parameter request.
If the write request is valid, the RPBA-01 acknowledges it with DP-
V1 write response code 5Fh with no data. The master will then
send a read request. If the RPBA-01 is still busy performing the
internal parameter request, it will return a negative response with
the DP-V1 error code B5h (State conflict). In this case, the read
DP-V1 communication
79
request will be repeated by the master until the RPBA-01 has the
PROFIdrive response data ready.
If the write request is invalid, a negative response is returned with
a DP-V1 error code (see Table 17).
DP-V1 communication
80
PROFIBUS SD2 telegram for SAP 51

The Read/Write service uses a variable-length PROFIBUS SD2
telegram shown below.
DP header DP trailer
SD LE LEr SD DA SA FC DSA SSA DU FCS ED
68h x x 68h xx xx x xx xx x… xx 16h
SD = Start Delimiter
LE = Length
LEr = Length repeated
DA = Destination Address
SA = Source Address
FC = Function Code
DSAP = Destination Service Access Point
SSAP = Source Service Access Point
DU = Data Unit for DP services
FCS = Frame Checking Sequence
ED = End Delimiter
Data unit
DP-V1 Command/Response PROFIdrive V3 Parameter Channel
Request/Response header
DU0 DU1 DU2 DU3 Data
(see Table 18/19 below)
Byte Meaning Value

DU0 Function number See Table 15 below
DU1 Slot number 1 = Drive parameter access
DU2 Index 47 (0x2F)
DU3 Data length (Depends on type of message)
DU4…DUn PROFIdrive data
Figure 14. PROFIBUS SD2 telegram
DP-V1 communication
81
Table 15. DP-V1 function numbers

Value Meaning
0x48 Idle REQ, RES
0x51 Data transport REQ, RES
0x56 Resource manager REQ
0x57 Initiate REQ, RES
0x58 Abort REQ
0x5C Alarm REQ, RES
0x5E Read REQ, RES
0x5F Write REQ, RES
0xD1 Data transport negative response
0xD7 Initiate negative response
0xDC Alarm negative response
0xDE Read negative response
0xDF Write negative response
Table 16. DP-V1 error response

Byte Meaning and value
DU0 Function number = 0xDF (Error Write) = 0xDE (Error Read)
DU1 Error_Decode = 0x80 (DP-V1)
PROFIdrive: Always 128 (DP-V1 codes)
DU2 Error_Code_1: Error class/error code (see Table 17 below)
DU3 Error_Code_2: Always 0
DP-V1 communication
82
Table 17. DP-V1 error response: Error codes
MSB x x x x x x x x LSB
Error class Meaning Error code

0…9 (Reserved)
10 (0x0A) Application 0 = Read error
1 = Write error
2 = Module failure
3 … 7 = Reserved
8 = Version conflict
9 = Feature not supported
10 … 15 = User-specific
11 (0x0B) Access 0 = Invalid index
1 = Write length error
2 = Invalid slot
3 = Type conflict
4 = Invalid area
5 = State conflict
6 = Access denied
7 = Invalid range
8 = Invalid parameter
9 = Invalid type
12 (0x0C) Resource 0 = Read constraint conflict
1 = Write constraint conflict
2 = Resource busy
3 = Resource unavailable
4 … 7 = Reserved
13 … 15 User-specific
DP-V1 communication
83
Table 18. PROFIdrive Request header

Byte/
Field(s) Description Range
Word
Request Unique identification set by the master. 1 … 255 Byte
Reference Changed for each new request.
Request ID Request type for the issued block. Request Byte
Parameter (01h)
Change
Parameter (02h)
Axis To be set to 0 or 1. 0 … 255 Byte
No. of Number of parameters that are present 1 … 37 Byte
Parameters in the request.
Attribute Type of object being accessed. Value (10h) Byte
Note: “Text” is not supported. Description (20h)
Text (30h)
No. of Number of array elements accessed or 0, 1 … 234 Byte
Elements length of string accessed. Set to 0 if
non-array parameters are used.
Parameter Address of the parameter that is being 1 … 65535 Word
Index accessed. “0” is allowed by RPBA-01.
Subindex Addresses the first array element of the 0 … 65535 Word
parameter or the beginning of a string
access or the text array, or the
description element that is being
accessed.
Format* See Table 20. See Table 20 Byte
Number of Number of values following. 0 … 234 Byte
Values*
Values* The values of the request. In case of – See
odd number of bytes, a zero byte is Format
appended to ensure the word structure field
of the telegram.
*Only if Request ID is 02h (Change Parameter). The Format, Number of Values
and Values fields are repeated for other parameters.
DP-V1 communication
84
Table 19. PROFIdrive Response header

Field(s) Description Range
Response Mirrored from the request. 1 … 255
Reference
Response Response from the slave. In case any Request Param OK (01h)
ID requested services fail, a “not Request Param NAK (81h)
acknowledged” (NAK) response will be Change Param OK (02h)
indicated. Change Param NAK (82h)
Axis To be set to 1. 0 … 255
No. of Number of parameters that are present 1 … 37
Parameters in the response.
Format* See Table 20. See Table 20
Number of Number of values following. 0 … 234
Values*
Values* The values of the request. In case of –
odd number of bytes, a zero byte is
appended to ensure the word structure
of the telegram.
*Only if Response ID is 01h (Request Parameter OK). The Format, Number of
Values and Values fields are repeated for other parameters.
Table 20. Data types for Format field

Code Type
0x00 (Reserved)
0x01 … 0x36 Standard data types
0x37 … 0x3F (Reserved)
0x40 Zero
0x41 Byte
0x42 Word
0x43 Double word
0x44 Error
0x45 … 0xFF (Reserved)
DP-V1 communication
85
Table 21. PROFIdrive Parameter Request error codes

Error # Meaning Used at
00h Impermissible parameter Access to unavailable parameter
number
01h Parameter value cannot be Change access to a parameter value
changed that cannot be changed
02h Low or high limit exceeded Change access with value outside the
limits
03h Invalid subindex Access to unavailable subindex
04h No array Access with subindex to non-indexed
parameter
05h Incorrect data type Change access with value that does
not match the data type of the
parameter
06h Setting not permitted (can only Change access with value unequal to 0
be reset) when this is not permitted
07h Description element cannot be Change access to a description
changed element that cannot be changed
09h No description data available Access to unavailable description
(parameter value is available)
0Bh No operation priority Change access rights without rights to
change parameters
0Fh No text array available Access to text array that is not available
(parameter value is available)
11h Request cannot be executed Access is temporarily not possible for
because of operating mode reasons that are not specified in detail
14h Value impermissible Change access with a value that is
within limits but is not permissible for
other long-term reasons (parameter
with defined single values)
15h Response too long The length of the current response
exceeds the maximum transmittable
length
DP-V1 communication
86
16h Parameter address Illegal value or value that is not

impermissible supported for the attribute, number of
elements, parameter number or sub-
index, or a combination
17h Illegal format Write request: Illegal format or format of
parameter data that is not supported
18h Number of values inconsistent Write request: Number of values of
parameter data does not match number
of elements at the parameter address
65h … Manufacturer-specific –
FF
65h Vendor-specific error Vendor-specific error
66h Request not supported Request not supported
67h Communication error Request cannot be completed because
of communication error
6Dh
6Eh Non-volatile error Failure during write to non-volatile
memory
6Fh Time-out error Request aborted because of timeout
77h
78h PZD map failure Parameter cannot be mapped to PZD
(size mismatch or non-existent)
79h PZD memory failure Parameter cannot be mapped to PZD
(out of memory)
7Ah Multiple PZD map Parameter cannot be mapped to PZD
(multiple PZD write)
7Bh … Manufacturer-specific –
81h
82h Control word bit map Cannot map Control word bit
(parameter 933…937, e.g. double
mapping of bits)
DP-V1 communication
87
8Bh
8Ch Set torque mode error Cannot change mode to TORQUE
(frequency is used)
90h Illegal Request ID The request ID of the response is illegal
8Dh … Manufacturer-specific –
FFh
DP-V1 communication
88
Parameter data transfer examples

The following examples show how parameter data is transferred
using the DP-V1 mechanisms READ and WRITE.
Note: Only the “Data unit” part of the SD2 telegram is presented in
the examples. See Figure 14 on page 80.
Example 1a: Reading a drive parameter

subindex (IND), and the high byte is the parameter index (PNU).
For example, drive parameter number 12.04 corresponds to 12.04
× 100 = 1204 = 4B4h.
DP-V1 Write request (Read parameter value):
Function number
Slot number
Index
Data length
Request reference
Request ID (01h = Request Parameter)
Axis
Number of parameters
Attribute (10h = Value)
Number of elements
Parameter index
Subindex
DP 5F 01 2F 0A 05 01 01 01 10 01 00 04 00 B4 DP
header DP-V1 Command PROFIdrive V3 Parameter Channel trailer
DP-V1 communication
89
Positive Read response to DP-V1 Read request:

Function number
Slot number
Index
Data length
Response reference (mirrored)
Response ID
Axis
Format (42h = Word)
Number of values
Parameter value
DP 5E 01 2F 08 05 01 01 01 42 01 05 64 DP
header DP-V1 Response PROFIdrive V3 Parameter Channel trailer
Negative response to PROFIdrive Read request:

Function number
Slot number
Index
Data length
Response ID
Axis (mirrored)
Format (44h = Error)
Number of values
PROFIdrive error code
DP 5E 01 2F 08 05 81 01 01 44 01 00 14 DP
DP-V1 communication
90
Example 1b: Reading 3 drive parameters

In this example, three parameters (12.04, 12.05 and 12.06) are
read using one telegram.
DP-V1 Write request (Read parameter value):
Function number
Slot number
Index
Data length
Request reference
Request ID (01h = Request Parameter)
Axis
Number of elements
Parameter index
Subindex
DP 5F 01 2F 16 06 01 01 03 10 01 00 04 00 B4
•••
header DP-V1 Command PROFIdrive V3 Parameter Channel
10 01 00 04 00 B5
••• •••
(Par. Channel continued)
10 01 00 04 00 B6 DP
•••
(Par. Channel continued) trailer
DP-V1 communication
91
Positive Read response to DP-V1 Read request:

Function number
Slot number
Index
Data length
Response ID
Axis
Format (42h = Word)
Number of values
Parameter value
DP 5F 01 2F 10 06 01 01 03 42 01 01 90
•••
header DP-V1 Response PROFIdrive V3 Parameter Channel
42 01 03 84
••• •••
(Par. Channel cont’d)
42 01 01 F4 DP
•••
(Par. Channel cont’d) trailer
The values 190h (400), 384h (900) and 1F4h (500) are returned.
Example 2a: Writing a drive parameter

subindex (IND), and the high byte is the parameter index (PNU).
For example, drive parameter number 12.02 corresponds to 12.02
× 100 = 1202 = 4B2h.
DP-V1 communication
92
Function number
Slot number
Index
Data length
Request reference
Request ID (02h = Change)
Axis
Number of elements
Parameter index
Subindex
Format (42h = Word)
Number of values
Value
DP 5F 01 2F 0E 07 02 01 01 10 01 00 04 00 B2 42 01 02 58 DP
Slot number
Slot number
Index
Data length
Request reference (mirrored)
Response ID
Axis (mirrored)
5E 01 2F 04 07 02 01 01
DP DP
header PROFIdrive V3 trailer
DP-V1 Response
Parameter Channel
DP-V1 communication
93
Example 2b: Writing 2 drive parameters

In this example, the values 300 (12Ch) and 500 (1F4h) are written
to drive parameters 12.02 (4B2h) and 12.03 (4B3h) respectively
using one telegram.
Function number
Slot number
Index
Data length
Request reference
Request ID (02h = Change Parameter)
Axis
Number of elements
Parameter index
Subindex
DP 5F 01 2F 14 08 02 01 02 10 01 00 04 00 B2
•••
header DP-V1 Command PROFIdrive V3 Parameter Channel
10 01 00 04 00 B3
••• •••
(Par. Channel continued)
42 01 01 2C
••• •••
(Par. Channel cont’d)
42 01 01 F4 DP
•••
(Par. Channel cont’d) trailer
Value
Number of values
Format (42h = Word)
DP-V1 communication
94
Slot number
Slot number
Index
Data length
Response ID
Axis (mirrored)
5E 01 2F 04 08 02 01 02
DP DP
header PROFIdrive V3 trailer
DP-V1 Response
Parameter Channel
Example 3: Reading a PROFIdrive parameter

In this example, PROFIBUS parameter No. 918 (396h) is used to
read the station number of the slave.
DP-V1 Write request (Reading a PROFIdrive parameter):
Function number
Slot number
Index
Data length
Request reference
Request ID
Axis
Attribute
Number of elements
Parameter index
Subindex
DP 5F 01 2F 0A 09 01 01 01 10 00 03 96 00 00 DP
DP-V1 communication
95
DP-V1 Read response

Function number
Slot number
Index
Data length
Response ID
Axis (mirrored)
Format (42h = Word)
Number of values
Value or error values
DP 5E 01 2F 08 09 01 01 01 42 01 23 00 DP
The slave returns the code of the latest acknowledged fault

(2300h). The fault codes are according to the DRIVECOM
standard. See also the User’s Manual of the drive for drive specific
fault codes.
The implementation of the PROFIdrive profile in the RPBA-01
supports the storage of the active and the five latest occurred
different faults in the fault buffer. The fault codes can be accessed
by PROFIdrive parameters 945, 947 and 948 (see Table 22 on
page 101). The value zero indicates no fault. The subindexes of
these parameters are related to each other, i.e. parameter 945
with subindex 1 relates to subindex of parameter 947 and 948.
Example 4: Configuring the process data written to the drive

PROFIBUS parameter No. 915 (393h) can be used to define
which data is written cyclically to a drive parameter as application-
specific process data.
In the example below, the value of drive parameter 12.06 (4B6h) is
selected to be taken from PZD3. The parameter will continue to be
updated with the contents of PZD3 in each Request frame until a
different selection is made.
data is taken from. Parameter Value selects the drive parameter to
which that word is mapped.
DP-V1 communication
96
DP-V1 Write request

Function number
Slot number
Index
Data length
Request reference
Request ID (02h = Change)
Axis
Number of elements
Parameter index
Subindex
Format (42h = Word)
Number of values
Value
DP 5F 01 2F 0E 0A 02 01 01 10 01 03 93 00 03 42 01 04 B6 DP
DP-V1 Read response

Function number
Slot number
Index
Data length
Response ID
Axis (mirrored)
Format (42h = Word)
Number of values
DP 5E 01 2F 08 0A 01 01 01 42 01 00 68 DP
Subsequently, the contents of PZD3 in each Request frame are

written to drive parameter 12.06 until a different selection is made.
DP-V1 communication
97
Example 5: Determining the source of process data read from the

drive
PROFIBUS Parameter No. 916 (394h) can be used to define
which data is read cyclically from the drive as application-specific
process data. In the example below, the parameter is used to
determine which drive parameter the contents of PZD3 are taken
from. Subindex (IND) defines which process data word the
required data is transmitted in.
DP-V1 Write request
Function number
Slot number
Index
Data length
Request reference
Request ID (01h = Read)
Axis
Number of elements
Parameter index
Subindex
DP 5F 01 2F 0A 0B 01 01 01 10 01 03 94 00 03 DP
DP-V1 Read response

Function number
Slot number
Index
Data length
Response ID
Axis (mirrored)
Format (42h = Word)
Number of values
DP 5E 01 2F 08 0B 01 01 01 42 01 04 B5 DP
Value indicates the source of PZD3 as drive param. 12.05 (4B5h).
DP-V1 communication
98
DP-V1 communication
99
Fault tracing
LED indications
The RPBA-01 module is equipped with three diagnostic LEDs.
The description of the LEDs is below.
Host
ERROR
Indication
Off-line On-line
Name Colour Function

Flashing 1 Hz - Error in configuration:
Internal configuration mismatch.
Flashing 2 Hz - Error in User Parameter data:
The length/contents of the User Parameter data
set during initialisation of the module is not equal
ERROR
to the length/contents set during configuration of

Red
the network. Check that the selected DP mode
matches the GSD file used (see configuration
parameter 21 DP MODE on page 37).
Flashing 4 Hz - Error in initialisation of the
PROFIBUS communication ASIC.
Off - No diagnostics present
Lit - Module is On-Line and data exchange is
Off-Line On-Line
Green possible.
Off - Module is not On-Line
Lit - Module is Off-Line and no data exchange is
Red possible.
Off - Module is not Off-Line
Fault tracing
100
Host
ERROR
Indication
Off-line On-line
Name Colour Function

Host Indication
Green Lit - Link functional
Lit - Link lost permanently

Red
Flashing - Link lost temporarily
Fault tracing
101
Table 22. PROFIdrive profile-specific parameters.
Para- R/W* Data type Description

meter
915 R/W Array [10] Unsigned16 Assignment PZD1 to PZD10 in PPO-write
916 R/W Array [10] Unsigned16 Assignment PZD1 to PZD10 in PPO-read
918 R/W Unsigned16 Node address. Writing this parameter will
change the node address if the rotary
switches have the setting 0. Module re-
start required.
919 R Octet String4 Device system number.
927 R/W Unsigned16 Operator control rights (parameter
identification, PKW).
Value Mode
0 Parameters cannot be
written, only read (927 can
be written)
1 Parameters can be written
and read (default).
928 R/W Unsigned16 Control rights (process data, PZD).
Value Mode
0 PZD part is disabled, i.e.
Receipt of new PZD data is
ignored
1 PZD part is enabled
(default).
929 R Unsigned16 Selected PPO-type
Value PPO-type Configuration
1 PPO1 F3h, F1h
2 PPO2 F3h, F5h
3 PPO3 F1h
4 PPO4 F5h
5 PPO5 F3h, F9h
102

meter
930 R/W Unsigned16 Selection switch for operation mode.
Value Mode
1 Speed control mode: Control
word and status word for
frequency/speed used.
8001h Speed control mode: Control
word and status word for
torque used.
933 R/W Unsigned16 Selection switch for Control word, bit 11.
Value Module Control word bit
0 None
1 to 5 Vendor specific 1 to 5*
* The meaning of vendor specific bits is
defined by drive application program.
(See parameter 933 for coding)
939 R/W Unsigned16 Selection switch for Status word, bit 11.
Value Module Status word bit
0 None
1 to 3 Vendor specific 1 to 3*
* The meaning of vendor specific bits is
defined by drive application program.
103

meter
945 R Array[64] Unsigned16 Fault code (coded according to
DRIVECOM profile).
Subindex Contents
1 Active fault
9 **Last ackn. fault
17 **Second last ackn. fault
25 **Third last ackn. fault
33 **Fourth last ackn. fault
41 **Fifth last ackn. fault
947 R Array [64] Unsigned16 Fault number.
Subindex Contents
See parameter 945.
948 R Array [64] Unsigned16 Time difference. Seconds since the last
fault occured.
Subindex Contents
See parameter 945.
952 R/W Unsigned16 Number of faults occured. Writing a zero
clears the value.
953 R Unsigned16 **Last alarm
954 R Unsigned16 **Second last alarm
955 R Unsigned16 **Third last alarm
956 R Unsigned16 **Fourth last alarm
957 R Unsigned16 **Fifth last alarm
958 R Unsigned16 Sixth last alarm (not supported)
959 R Unsigned16 Seventh last alarm (not supported)
960 R Unsigned16 Eighth last alarm (not supported)
961 R Octet String4 Hardware configuration (manufacturer
specific ID of the drive)
104

meter
963 R Unsigned16 Detected baud rate:
0 = 12 Mbit/s
1 = 6 Mbit/s
2 = 3 Mbit/s
3 = 1.5 Mbit/s
4 = 500 kbit/s
5 = 187.5 kbit/s
6 = 93.75 kbit/s
7 = 45.45 kbit/s
8 = 19.2 kbit/s
9 = 9.6 kbit/s
255 = Invalid baud rate
964 R Unsigned16 Identification number of this device
(0812h)
965 R Octet String2 Profile number of this device (0302h)
Profile 3, Version 2
967 R Unsigned16 Control word (CW)
968 R Unsigned16 Status word (SW)
970 R/W Unsigned16 Load parameter record
Value Description
0 No action
1 Restore factory settings
The parameter must do a zero-to-one
transition and the motor must be stopped.
971 R/W Unsigned16 Save parameter record
Value Description
0 No action
1 Save the drive parameters
to non-volatile memory
105

meter
972 R/W Unsigned16 Software reset
Value Description
0 No action
1 Re-boot PROFIBUS module
* Read and/or Write
** Support depends on drive type
106
107
Definitions and abbreviations
PROFIBUS definitions
Acyclic Communication in which messages are sent only once
Communication on request
Array Parameter consisting of data fields of equal data type
Broadcast Non-acknowledged message from master to all bus
participants (compare Multicast)
Command Word See Control Word
Communication Any object of a real device that can be communicated
Object with (variable, program, data range, etc.). Stored locally
in the Object Dictionary.
Control Word 16-bit word from master to slave with bit-coded control
signals (sometimes called the Command Word).
Cyclic Communication in which Parameter-/Process Data-
Communication Objects are sent cyclically at pre-defined intervals
Device Class Classification according to the number of profile
functions included in the device
Drivecast Broad- and Multicast, a special message frame for
drives
Fault Event that leads to tripping of the device
GSD File ASCII-format device description file in a specified form.
Each device (active & passive stations) on PROFIBUS
has to have its own GSD File.
Index Access reference for Objects in PROFIBUS
Information Report Non-acknowledged message from master to one or all
groups of bus participants

108
Master Control system with bus initiative. In PROFIBUS

terminology, master stations are also called active
stations.
Multicast Non-acknowledged message from master to one group
of bus participants (compare Broadcast)
Name Symbolic name of a parameter
Nibble Set of 4 bits
Object Dictionary Local storage of all Communication Objects recognised
by a device
Object List List of all accessible objects
Parameter Value that can be accessed as Object, e.g. variable,
constant, signal
Parameter Number Parameter address
Parameter/Process Special object that contains Parameter and Process
Data Object Data
Process Data Data that contains Control Word and Reference value
or Status Word and Actual value. May also contain
other (user-definable) control information.
Profile Adaptation of the protocol for certain application field,
e.g. drives
Request Label Coded information specifying the required service for
the parameter part sent from master to slave
Response Label Coded information specifying the required service for
the parameter part sent from slave to master
Slave Passive bus participant. In PROFIBUS terminology,
slave stations (or slaves) are also called passive
stations. Also referred to as node.
Status Word 16-bit word from slave to master with bit-coded status
messages

109
Warning Signal caused by an existing alarm which does not lead

to tripping of the device
PROFIBUS abbreviations
The text in italics is the original German term.
.con Confirmation
.ind Indication
.req Request
.res Response
ACT Actual Value
Istwert
AK Request Label/Response Label
Auftragskennung/Antwortkennung
ALI Application Layer Interface
CR Communication Reference
Kommunikationsreferenz (Kommunikationsbeziehung)
DP Decentralised Periphery
Dezentrale Peripherie
DP-ALI Application Layer Interface for DP
DP-V1 PROFIBUS DP Extensions to the EN 50170 standard,
including e.g. acyclic data exchange
FDL Fieldbus Data Link
FMS Fieldbus Message Specification
FSU Manufacturer Specific Interface
Firmenspezifischer Umsetzer
HIW Main Actual Value
Hauptistwert
HSW Main Reference
Hauptsollwert

110
ISW see ACT

KR (KB) see CR
PA Process Automation
Prozessautomatisierung
PD Process Data
Prozessdaten
PKE Parameter Identification
Parameter-Kennung
PKW Parameter Identification Value
Parameter-Kennung-Wert
PNU Parameter Number
Parameternummer
PPO Parameter/Process Data Object
Parameter-/Prozessdaten-Objekt
PWE Parameter Value
Parameter-Wert
PZD see PD
PZDO Process Data Object
Prozessdatenobjekt
SAP Service Access Point
SOW Reference
Sollwert
SPM Request Signal
Spontanmeldung
STW Control Word
Steuerwort
ZSW Status Word
Zustandswort

111
Technical data
RPBA-01
Enclosure:
34 mm
95 mm
20 62 mm
mm
Mounting: Into the option slot on the control board of the drive.
Degree of protection: IP20
Ambient conditions: The applicable ambient conditions specified
for the drive in its Hardware Manual are in effect.
Hardware settings:
• Rotary switches for node address selection (address range
00 to 99)
• DIP switch for bus termination selection
Technical data
112
Software settings:
• Input/Output/User Parameter data/Diagnostics format
• Maximum cyclic I/O data size: 28 bytes in, max 28 bytes out,
max. 56 bytes total
• Maximum acyclic I/O data size: 240 bytes in, max. 240 bytes
out, max. 480 bytes total
• Maximum User Parameter data/Diagnostics length: 26 bytes
Connectors:
• 34-pin parallel bus connector
• 9-pin female DSUB connector
Current consumption:
• 350 mA max. (5 V), supplied by the control board of the drive
General:
• Estimated min. lifetime: 100 000 h
• All materials UL/CSA-approved
• Complies with EMC standards EN 50081-2 and EN 50082-2
Technical data
113
PROFIBUS link
Compatible devices: All devices compatible with the PROFIBUS
DP protocol
Size of the link: 127 stations including repeaters (31 stations and
1 repeater per segment)
Medium: Shielded, twisted pair RS-485 cable
• Termination: built in the module
• Specifications:
Line A Line B
Parameter Unit
PROFIBUS DP DIN 19245 Part 1
Impedance 135 to 165 100 to 130 W
(3 to 20 MHz) (f > 100 kHz)
Capacitance < 30 < 60 pF/m
Resistance < 110 – Ω /km
Wire gauge > 0.64 > 0.53 mm

Conductor area > 0.34 > 0.22 mm2
• Maximum bus length:

Transfer rate
≤ 93.75 187.5 500 1500 3000 6000 12000
(kbit/s)
Line A (m) 1200 1000 400 200 100 100 100
Line B (m) 1200 600 200 – – – –
Topology: Multi-drop
Serial communication type: Asynchronous, half Duplex
Transfer rate: 9.6 kbit/s, 19.2 kbit/s, 45.45 kbit/s, 93.75 kbit/s,
187.5 kbit/s, 500 kbit/s, 1.5 Mbit/s, 3 Mbit/s, 6 Mbit/s, or 12 Mbit/s
(automatically detected by RPBA-01)
Protocol: PROFIBUS DP
Technical data
114
Technical data
3AFE64504215 REV F EN
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
Fax +358 10 22 22681 Telephone 262 785-3200
Internet http://www.abb.com 800-HELP-365
Fax 262 780-5135
NOV PART NO.:
3AFE64527592
Technical Manual
ABB - Firmware Manual
ACS800 Standard Control Program 7.x

3AFE64527592 I
www.nov.com
Revision I
Page 2
REVISION HISTORY

www.nov.com
ACS800
Firmware Manual
Firmware Manual
3AFE64527592 REV I
EN

5
Table of Contents
Table of Contents
Introduction to the manual

Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Start-up and control through the I/O

How to start-up the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
How to perform the guided start-up (covers all essential settings) . . . . . . . . . . . . . . . . . . . . . . . 15
How to perform the limited start-up (covers only the basic settings) . . . . . . . . . . . . . . . . . . . . . 17
How to control the drive through the I/O interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
How to perform the ID Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ID Run Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Control panel
Overview of the panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Panel operation mode keys and displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Status row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Drive control with the panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
How to start, stop and change direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
How to set speed reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Actual signal display mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
How to select actual signals to the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
How to display the full name of the actual signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
How to view and reset the fault history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
How to display and reset an active fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
About the fault history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Parameter mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
How to select a parameter and change the value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
How to adjust a source selection (pointer) parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Function mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
How to enter an assistant, browse and exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
How to upload data from a drive to the panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table of Contents
6
How to download data from the panel to a drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

How to set the contrast of the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Drive selection mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
How to select a drive and change its panel link ID number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Reading and entering packed boolean values on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Program features
Start-up Assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
The default order of the tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
List of tasks and the relevant drive parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Contents of the assistant displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Local control vs. external control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Local control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
External control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Block diagram: start, stop, direction source for EXT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Block diagram: reference source for EXT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Reference types and processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Reference trimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Programmable analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Update cycles in the Standard Control Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Programmable analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Programmable digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Programmable relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Actual signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Motor identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Power loss ride-through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Automatic Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Table of Contents
7
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
DC Magnetising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
DC Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Flux Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Flux Optimisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Acceleration and deceleration ramps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Critical speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Constant speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Speed controller tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Speed control performance figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Torque control performance figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Scalar control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
IR compensation for a scalar controlled drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Hexagonal motor flux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Programmable protection functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
AI<Min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Panel Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
External Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Motor Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Motor temperature thermal model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Use of the motor thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Stall Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Underload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Motor Phase Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Earth Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Communication Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Supervision of optional IO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Preprogrammed faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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Overcurrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
DC overvoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
DC undervoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Drive temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Enhanced drive temperature monitoring for ACS800-U2, -U4 and -U7, frame sizes R7 and R8 65
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Input phase loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Control board temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Overfrequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Internal fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Operation limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Power limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Automatic resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Supervisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Parameter lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Process PID control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Block diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Sleep function for the process PID control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Motor temperature measurement through the standard I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Motor temperature measurement through an analogue I/O extension . . . . . . . . . . . . . . . . . . . . . . 73
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Adaptive Programming using the function blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
DriveAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Control of a mechanical brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Operation time scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
State shifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Master/Follower use of several drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Settings and diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Reduced Run function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
User load curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Application macros
Overview of macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Factory macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Default control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Hand/Auto macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
PID Control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Connection example, 24 VDC / 4…20 mA two-wire sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Torque Control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Sequential Control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Operation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
User macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Actual signals and parameters

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
01 ACTUAL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
02 ACTUAL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
03 ACTUAL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
04 ACTUAL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
09 ACTUAL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10 START/STOP/DIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
11 REFERENCE SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
12 CONSTANT SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
13 ANALOGUE INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
14 RELAY OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
15 ANALOGUE OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
16 SYST CTRL INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
20 LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
21 START/STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
22 ACCEL/DECEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
23 SPEED CTRL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
24 TORQUE CTRL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
25 CRITICAL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
26 MOTOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
27 BRAKE CHOPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
30 FAULT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
31 AUTOMATIC RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
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32 SUPERVISION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
33 INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
34 PROCESS VARIABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
35 MOT TEMP MEAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
40 PID CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
42 BRAKE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
50 ENCODER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
51 COMM MODULE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
52 STANDARD MODBUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
60 MASTER/FOLLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
70 DDCS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
72 USER LOAD CURVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
83 ADAPT PROG CTRL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
84 ADAPTIVE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
85 USER CONSTANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
90 D SET REC ADDR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
92 D SET TR ADDR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
95 HARDWARE SPECIF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
96 EXTERNAL AO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
98 OPTION MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
99 START-UP DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Fieldbus control
Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Redundant fieldbus control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Setting up communication through a fieldbus adapter module . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Setting up communication through the Standard Modbus Link . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Modbus addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Setting up communication through Advant controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Drive control parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
The fieldbus control interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
The Control Word and the Status Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Fieldbus reference selection and correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Reference handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Actual Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Block diagram: Control data input from fieldbus when a type Rxxx fieldbus adapter is used . 200
Block diagram: Actual value selection for fieldbus when a type Rxxx fieldbus adapter is used 201
Block diagram: Control data input from fieldbus when a type Nxxx fieldbus adapter is used . 202
Block Diagram: Actual value selection for fieldbus when a type Nxxx fieldbus adapter is used 203
Communication profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
ABB Drives communication profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
03.01 MAIN CONTROL WORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
03.02 MAIN STATUS WORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Fieldbus reference scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Generic Drive communication profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Drive commands supported by the Generic Drive communication profile . . . . . . . . . . . . . 210
Fieldbus reference scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Table of Contents
11
CSA 2.8/3.0 communication profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

CONTROL WORD for the CSA 2.8/3.0 communication profile . . . . . . . . . . . . . . . . . . . . . . 212
STATUS WORD for the CSA 2.8/3.0 communication profile . . . . . . . . . . . . . . . . . . . . . . . . 212
Diverse status, fault, alarm and limit words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
03.03 AUXILIARY STATUS WORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
03.04 LIMIT WORD 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
03.05 FAULT WORD 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
03.06 FAULT WORD 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
03.07 SYSTEM FAULT WORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
03.08 ALARM WORD 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
03.09 ALARM WORD 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
03.13 AUXILIARY STATUS WORD 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
03.14 AUXILIARY STATUS WORD 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
03.15 FAULT WORD 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
03.16 ALARM WORD 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
03.17 FAULT WORD 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
03.18 ALARM WORD 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
03.19 INT INIT FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
03.30 LIMIT WORD INV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
03.31 ALARM WORD 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
03.32 EXT IO STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
04.01 FAULTED INT INFO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
04.02 INT SC INFO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Fault tracing
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Warning and fault indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
How to reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Fault history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Warning messages generated by the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Warning messages generated by the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Fault messages generated by the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Analogue Extension Module

Speed control through the analogue extension module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Basic checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Settings of the analogue extension module and the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Parameter settings: bipolar input in basic speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Parameter settings: bipolar input in joystick mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Additional data: actual signals and parameters

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Fieldbus addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Table of Contents
12
Rxxx adapter modules (such as RPBA-01, RDNA-01, etc.) . . . . . . . . . . . . . . . . . . . . . . . . . . 247

Nxxx adapter modules (such as NPBA-12, NDNA-02, etc.) . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Actual signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Control block diagrams

Reference control chain, sheet 1: FACTORY, HAND/AUTO, SEQ CTRL and T CTRL macros
(continued on the next page …) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Reference control chain sheet 1: PID CTRL macro (continued on the next page …) . . . . . . . . . 262
Reference control chain sheet 2: All macros (continued on the next page …) . . . . . . . . . . . . . . 264
Handling of Start, Stop, Run Enable and Start Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Handling of Reset and On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Index
Table of Contents
13
Chapter overview
The chapter includes a description of the contents of the manual. In addition it
contains information about the compatibility, safety, intended audience, and related
publications.
Compatibility
The manual is compatible with Standard Control Program version ASXR7320. See
parameter 33.01 SOFTWARE VERSION.
Safety instructions
Follow all safety instructions delivered with the drive.
• Read the complete safety instructions before you install, commission, or use
the drive. The complete safety instructions are given at the beginning of the
Hardware Manual.
• Read the software function specific warnings and notes before changing the
default settings of the function. For each function, the warnings and notes are
given in this manual in the section describing the related user-adjustable
parameters.
Reader
The reader of the manual is expected to know the standard electrical wiring
practices, electronic components, and electrical schematic symbols.
Contents
The manual consists of the following chapters:
• Start-up and control through the I/O instructs in setting up the application
program, and how to start, stop and regulate the speed of the drive.
• Control panel gives instructions for using the panel.
• Program features contains the feature descriptions and the reference lists of the
user settings and diagnostic signals.
• Application macros contains a short description of each macro together with a
connection diagram.
• Actual signals and parameters describes the actual signals and parameters of the
drive.
• Fault tracing lists the warning and fault messages with the possible causes and
remedies.

14
• Fieldbus control describes the communication through the serial communication

links.
• Analogue Extension Module, describes the communication between the drive and
the analogue I/O extension (optional).
• Additional data: actual signals and parameters contains more information on the
actual signals and parameters.
Product and service inquiries

Address any inquiries about the product to your local ABB representative, quoting
the type code and serial number of the unit in question. A listing of ABB sales,
support and service contacts can be found by navigating to www.abb.com/drives and
selecting Drives – Sales, Support and Service network on the right pane.
Product training
For information on ABB product training, navigate to www.abb.com/drives and select
Drives – Training courses on the right pane.
Providing feedback on ABB Drives manuals

Your comments on our manuals are welcome. Go to www.abb.com/drives, then
select successively Drives – Document Library – Manuals feedback form (LV AC
drives) on the right pane.

15
Chapter overview
The chapter instructs how to:
• do the start-up
• start, stop, change the direction of rotation, and adjust the speed of the motor
through the I/O interface
• perform an Identification Run for the drive.
How to start-up the drive

There are two start-up methods between which the user can select: Run the Start-up
Assistant, or perform a limited start-up. The Assistant guides the user through all
essential settings to be done. In the limited start-up, the drive gives no guidance:
The user goes through the very basic settings by following the instructions given in
the manual.
• If you want to run the Assistant, follow the instructions given in section How to
perform the guided start-up (covers all essential settings) on page 15.
• If you want to perform the limited start-up, follow the instructions given in
section How to perform the limited start-up (covers only the basic settings) on
page 17.
How to perform the guided start-up (covers all essential settings)

Before you start, ensure you have the motor nameplate data on hand.
SAFETY
The start-up may only be carried out by a qualified electrician.
The safety instructions must be followed during the start-up procedure. See the
appropriate hardware manual for safety instructions.
Check the installation. See the installation checklist in the appropriate hardware/installation
manual.
Check that the starting of the motor does not cause any danger.
De-couple the driven machine if:
- there is a risk of damage in case of incorrect direction of rotation, or
- a Standard ID Run needs to be performed during the drive start-up. (ID Run is essential only
in applications which require the ultimate in motor control accuracy.)

16
POWER-UP
Apply mains power. The control panel first shows the panel CDP312 PANEL Vx.xx
identification data … .......
… then the Identification Display of the drive … ACS800

ID NUMBER 1
… then the Actual Signal Display … 1 -> 0.0 rpm O

FREQ 0.00 Hz
CURRENT 0.00 A
POWER 0.00 %
…after which the display suggests starting the Language Selection. 1 -> 0.0 rpm O
*** INFORMATION ***
(If no key is pressed for a few seconds, the display starts to alternate between the
Press FUNC to start
Actual Signal Display and the suggestion on selecting the language.)
Language Selection
The drive is now ready for the start-up.
SELECTING THE LANGUAGE
Press the FUNC key. Language Selection 1/1
LANGUAGE ?
[ENGLISH]
ENTER:OK ACT:EXIT
Scroll to the desired language by the arrow keys ( or ) and 1 -> 0.0 rpm O
press ENTER to accept. *** INFORMATION ***
Press FUNC to start
(The drive loads the selected language into use, shifts back to the Actual Signal guided Motor Setup
Display and starts to alternate between the Actual Signal Display and the
suggestion on starting the guided motor set-up.)
STARTING THE GUIDED MOTOR SET-UP

Press FUNC to start the guided motor set-up. Motor Setup 1/10
ENTER: Ok/Continue
(The display shows which general command keys to use when stepping through
ACT: Exit
the assistant.)
FUNC: More Info
Press ENTER to step forward. Motor Setup 2/10

MOTOR NAMEPLATE DATA
Follow the instructions given on the display. AVAILABLE?
ENTER:Yes FUNC:Info

17
How to perform the limited start-up (covers only the basic settings)
Before you start, ensure you have the motor nameplate data at your hand.
SAFETY
The start-up may only be carried out by a qualified electrician.
The safety instructions must be followed during the start-up procedure. See the
appropriate hardware manual for safety instructions.
Check the installation. See the installation checklist in the appropriate hardware/installation
manual.
Check that the starting of the motor does not cause any danger.
De-couple the driven machine if:
- there is a risk of damage in case of incorrect direction of rotation, or
- a Standard ID Run needs to be performed during the drive start-up. (ID Run is essential
only in applications which require the ultimate in motor control accuracy.)
POWER-UP
Apply mains power. The control panel first shows the panel CDP312 PANEL Vx.xx
identification data … .......
… then the Identification Display of the drive … ACS800

ID NUMBER 1
… then the Actual Signal Display … 1 -> 0.0 rpm O

FREQ 0.00 Hz
CURRENT 0.00 A
POWER 0.00 %
…after which the display suggests starting the Language Selection. 1 -> 0.0 rpm O
*** INFORMATION ***
(If no key is pressed for a few seconds, the display starts to alternate between the
Press FUNC to start
Actual Signal Display and the suggestion on starting the Language Selection.)
Language Selection
Press ACT to remove the suggestion on starting the language 1 -> 0.0 rpm O
selection. FREQ 0.00 Hz
CURRENT 0.00 A
The drive is now ready for the limited start-up. POWER 0.00 %
MANUAL START-UP DATA ENTERING (parameter group 99)

Select the language. The general parameter setting procedure is 1 -> 0.0 rpm O
described below. 99 START-UP DATA
01 LANGUAGE
The general parameter setting procedure: ENGLISH
- Press PAR to select the Parameter Mode of the panel.
- Press the double-arrow keys ( or ) to scroll the parameter groups.
1 -> 0.0 rpm O
- Press the arrow keys ( or ) to scroll parameters within a group.
99 START-UP DATA
- Activate the setting of a new value by ENTER. 01 LANGUAGE
- Change the value by the arrow keys ( or ), fast change by the double- [ENGLISH]
arrow keys ( or ).
- Press ENTER to accept the new value (brackets disappear).

18
Select the Application Macro. The general parameter setting 1 -> 0.0 rpm O
procedure is given above. 99 START-UP DATA
02 APPLICATION MACRO
The default value FACTORY is suitable in most cases. [ ]
Select the motor control mode. The general parameter setting 1 -> 0.0 rpm O
procedure is given above. 99 START-UP DATA
04 MOTOR CTRL MODE
DTC is suitable in most cases. The SCALAR control mode is recommended [DTC]
- for multimotor drives when the number of the motors connected to the drive is
variable
- when the nominal current of the motor is less than 1/6 of the nominal current of
the inverter
- when the inverter is used for test purposes with no motor connected.
Enter the motor data from the motor nameplate: Note: Set the motor data to
exactly the same value as
on the motor nameplate.
ABB Motors For example, if the motor
3 motor M2AA 200 MLA 4
nominal speed is 1440 rpm
IEC 200 M/L 55
No on the nameplate, setting
Ins.cl. F IP 55 the value of parameter
V Hz kW r/min A cos IA/IN t E/s 99.08 MOTOR NOM
690 Y 50 30 1475 32.5 0.83
400 D 50 30 1475 56 0.83 SPEED to 1500 rpm
660 Y 50 30 1470 34 0.83 380 V results in the wrong
380 D 50 30 1470 59 0.83 mains operation of the drive.
415 D 50 30 1475 54 0.83
440 D 60 35 1770 59 0.83
voltage
Cat. no 3GAA 202 001 - ADA
6312/C3 6210/C3 180

IEC 34-1
- motor nominal voltage 1 -> 0.0 rpm O

99 START-UP DATA
Allowed range: 1/2 · UN … 2 · UN of ACS800. (UN refers to the highest voltage in
05 MOTOR NOM VOLTAGE
each of the nominal voltage ranges: 415 VAC for 400 VAC units, 500 VAC for 500
[ ]
VAC units and 690 VAC for 600 VAC units.)
- motor nominal current 1 -> 0.0 rpm O

99 START-UP DATA
Allowed range: approx. 1/6 · I2hd … 2 · I2hd of ACS800 (0 … 2 · I2hd if parameter
06 MOTOR NOM CURRENT
99.04 = SCALAR))
[ ]
- motor nominal frequency 1 -> 0.0 rpm O

99 START-UP DATA
Range: 8 … 300 Hz
07 MOTOR NOM FREQ
[ ]
- motor nominal speed 1 -> 0.0 rpm O

99 START-UP DATA
Range: 1 …18000 rpm
08 MOTOR NOM SPEED
[ ]
-motor nominal power 1 -> 0.0 rpm O

99 START-UP DATA
Range: 0 …9000 kW
09 MOTOR NOM POWER
[ ]

19
When the motor data has been entered, two displays (warning and 1 -> 0.0 rpm O
information) start to alternate. Move to next step without pressing ACS800
** WARNING **
any key.
ID MAGN REQ
1 L-> 0.0 rpm I

*** Information ***
Press green button
to start ID MAGN
Select the motor identification method.

The default value ID MAGN (ID Magnetisation) is suitable for most applications. It is applied
in this basic start-up procedure. If your selection is ID Magnetisation, move to next step
without pressing any key.
The ID Run (STANDARD or REDUCED) should be selected if:
- The operation point is near zero speed, and/or
- Operation at torque range above the motor nominal torque within a wide speed range and
without any measured speed feedback is required.
If your selection is ID Run, continue by following the separate instructions given a few pages
ahead in section How to perform the ID Run on page 22.
IDENTIFICATION MAGNETISATION (with Motor ID Run selection ID MAGN)
Press the LOC/REM key to change to local control (L shown on the 1 L -> 1242.0 rpm I
first row). ** WARNING **
MOTOR STARTS
Press to start the Identification Magnetisation. The motor is
magnetised at zero speed for 20 to 60 s. Three warnings are 1 L-> 0.0 rpm I
displayed: ** WARNING **
ID MAGN
The first warning is displayed when the magnetisation starts.
The second warning is displayed while the magnetisation is on. 1 L-> 0.0 rpm O
** WARNING **
The third warning is displayed after the magnetisation is completed.
ID DONE

20
DIRECTION OF ROTATION OF THE MOTOR

Check the direction of rotation of the motor. 1 L->[xxx] rpm I
FREQ xxx Hz
- Press ACT to get the status row visible. CURRENT xx A
- Increase the speed reference from zero to a small value by POWER xx %
pressing REF and then the arrow keys ( , , or ).
- Press to start the motor.
- Check that the motor is running in the desired direction.
- Stop the motor by pressing .
To change the direction of rotation of the motor:
- Disconnect mains power from the drive, and wait 5 minutes for the forward
direction
intermediate circuit capacitors to discharge. Measure the voltage
between each input terminal (U1, V1 and W1) and earth with a
multimeter to ensure that the frequency converter is discharged.
reverse
- Exchange the position of two motor cable phase conductors at the direction
motor terminals or at the motor connection box.
- Verify your work by applying mains power and repeating the check
as described above.
SPEED LIMITS AND ACCELERATION/DECELERATION TIMES
Set the minimum speed. 1 L-> 0.0 rpm O
20 LIMITS
01 MINIMUM SPEED
[ ]
Set the maximum speed. 1 L-> 0.0 rpm O

20 LIMITS
02 MAXIMUM SPEED
[ ]
Set the acceleration time 1. 1 L-> 0.0 rpm O

22 ACCEL/DECEL
Note: Check also acceleration time 2, if two acceleration times will 02 ACCELER TIME 1
be used in the application. [ ]
Set the deceleration time 1. 1 L-> 0.0 rpm O

22 ACCEL/DECEL
Note: Set also deceleration time 2, if two deceleration times will be 03 DECELER TIME 1
used in the application. [ ]
The drive is now ready for use.

21
How to control the drive through the I/O interface

The table below instructs how to operate the drive through the digital and analogue
inputs, when:
• the motor start-up is performed, and
• the default (factory) parameter settings are valid.
PRELIMINARY SETTINGS
Ensure the Factory macro is active. See parameter 99.02.
If you need to change the direction of rotation, change the setting of

parameter 10.03 to REQUEST.
Ensure the control connections are wired according to the connection See chapter Application
diagram given for the Factory macro. macros.
Ensure the drive is in external control mode. Press the LOC/REM key to In External control, there is
change between external and local control. no L visible on the first row
of the panel display.
STARTING AND CONTROLLING THE SPEED OF THE MOTOR

Start by switching digital input DI1 on. 1 -> 0.0 rpm I
FREQ 0.00 Hz
CURRENT 0.00 A
POWER 0.00 %
Regulate the speed by adjusting the voltage of analogue input AI1. 1 -> 500.0 rpm I
FREQ 16.66 Hz
CURRENT 12.66 A
POWER 8.33 %
CHANGING THE DIRECTION OF ROTATION OF THE MOTOR

Forward direction: Switch digital input DI2 off. 1 -> 500.0 rpm I
FREQ 16.66 Hz
CURRENT 12.66 A
POWER 8.33 %
Reverse direction: Switch digital input DI2 on. 1 <- 500.0 rpm I
FREQ 16.66 Hz
CURRENT 12.66 A
POWER 8.33 %
STOPPING THE MOTOR

Switch off digital input DI1. 1 -> 500.0 rpm O
FREQ 0.00 Hz
CURRENT 0.00 A
POWER 0.00 %

22
How to perform the ID Run

The drive performs the ID Magnetisation automatically at the first start. In most
applications there is no need to perform a separate ID Run. The ID Run (Standard or
Reduced) should be selected if:
• The operation point is near zero speed, and/or
• Operation at torque range above the motor nominal torque within a wide speed
range and without any measured speed feedback is required.
The Reduced ID Run is to be performed instead of the Standard if it is not possible to
disengage the driven machine from the motor.
ID Run Procedure
Note: If parameter values (Group 10 to 98) are changed before the ID Run, check
that the new settings meet the following conditions:
• 20.01 MINIMUM SPEED < 0 rpm
• 20.02 MAXIMUM SPEED > 80% of motor rated speed
• 20.03 MAXIMUM CURRENT > 100% · Ihd
• 20.04 MAXIMUM TORQUE > 50%
• Ensure that the panel is in the local control mode (L displayed on the status row).
Press the LOC/REM key to switch between modes.
• Change the ID Run selection to STANDARD or REDUCED.
1 L ->1242.0 rpm O
99 START-UP DATA
10 MOTOR ID RUN
[STANDARD]
• Press ENTER to verify selection. The following message will be displayed:
1 L ->1242.0 rpm O
ACS800
**WARNING**
ID RUN SEL
• To start the ID Run, press the key. The Run Enable signal must be active
(see parameter 16.01 RUN ENABLE).
Warning when the ID Run is Warning during the ID Run Warning after a successfully
started completed ID Run
1 L -> 1242.0 rpm I 1 L -> 1242.0 rpm I 1 L -> 1242.0 rpm I

ACS800 ACS800 ACS800
**WARNING** **WARNING** **WARNING**
MOTOR STARTS ID RUN ID DONE

23
In general it is recommended not to press any control panel keys during the ID run.
However:
• The Motor ID Run can be stopped at any time by pressing the control panel stop
key ( ).
• After the ID Run is started with the start key ( ), it is possible to monitor the
actual values by first pressing the ACT key and then a double-arrow key ( ).

24

25
Control panel
Chapter overview
The chapter describes how to use the control panel CDP 312R.
The same control panel is used with all ACS800 series drives, so the instructions
given apply to all ACS800 types. The display examples shown are based on the
Standard Control Program; displays produced by other application programs may
differ slightly.
Overview of the panel
The LCD type display has 4 lines of 20 characters.

The language is selected at start-up (parameter 99.01).
The control panel has four operation modes:
- Actual Signal Display Mode (ACT key)
- Parameter Mode (PAR key)
1 L -> 1242.0 rpm I
FREQ 45.00 Hz - Function Mode (FUNC key)
CURRENT 80.00 A
POWER 75.00 % - Drive Selection Mode (DRIVE key)
The use of single arrow keys, double arrow keys and
ENTER depend on the operation mode of the panel.
ACT PAR FUNC DRIVE The drive control keys are:
No. Use
1 Start
ENTER
2 Stop
3 Activate reference setting

7 6 3 1
LOC RESET REF 4 Forward direction of rotation
REM
5 Reverse direction of rotation

I 0 6 Fault reset
4 5 2
7 Change between Local / Remote (external)
control
Control panel
26
Panel operation mode keys and displays

The figure below shows the mode selection keys of the panel, and the basic
operations and displays in each mode.
Actual Signal Display Mode
Act. signal / Fault history Status row

ACT selection
1 L -> 1242.0 rpm O
FREQ 45.00 Hz Actual signal names
CURRENT 80.00 A and values
Act. signal / Fault message
scrolling POWER 75.00 %
Enter selection mode
ENTER Accept new signal
Parameter Mode
Group selection 1 L -> 1242.0 rpm O Status row

PAR Fast value change
10 START/STOP/DIR Parameter group
01 EXT1 STRT/STP/DIR Parameter
Parameter selection
Slow value change DI1,2 Parameter value
Enter change mode

ENTER Accept new value
Function Mode
1 L -> 1242.0 rpm O Status row

FUNC Row selection
Motor Setup
Page selection
Application Macro List of functions
Speed Control EXT1
ENTER Function start
Drive Selection Mode
Drive selection ACS800 Device type

DRIVE ID number change
Enter change mode ASXR7260 xxxxxx SW loading package

ENTER Accept new value name and ID number
ID NUMBER 1
Status row
The figure below describes the status row digits.
Drive ID number Drive status

1 L -> 1242.0 rpm I I = Running
Drive control status
O = Stopped
L = Local control Direction of rotation Drive reference “ “ = Run disabled
R = Remote control -> = Forward
“ “ = External control <- = Reverse
Control panel
27
Drive control with the panel

The user can control the drive with the panel as follows:
• start, stop, and change direction of the motor
• give the motor speed reference or torque reference
• give a process reference (when the process PID control is active)
• reset the fault and warning messages
• change between local and external drive control.
The panel can be used for control of the drive control always when the drive is under
local control and the status row is visible on the display.
How to start, stop and change direction

Step Action Press Key Display
1. To show the status row. 1 ->1242.0 rpm I

ACT PAR
FREQ 45.00 Hz
CURRENT 80.00 A
FUNC
POWER 75.00 %
2. To switch to local control. 1 L ->1242.0 rpm I

LOC
(only if the drive is not under local control, i.e. there is no L FREQ 45.00 Hz
REM
on the first row of the display.) CURRENT 80.00 A
POWER 75.00 %
3. To stop 1 L ->1242.0 rpm O

FREQ 45.00 Hz
CURRENT 80.00 A
POWER 75.00 %
4. To start 1 L ->1242.0 rpm I

FREQ 45.00 Hz
CURRENT 80.00 A
POWER 75.00 %
5. To change the direction to reverse. 1 L <-1242.0 rpm I

0 FREQ 45.00 Hz
CURRENT 80.00 A
POWER 75.00 %
6. To change the direction to forward. 1 L ->1242.0 rpm I

I FREQ 45.00 Hz
CURRENT 80.00 A
POWER 75.00 %
Control panel
28
How to set speed reference

1. To show the status row. 1 ->1242.0 rpm I

ACT PAR
FREQ 45.00 Hz
CURRENT 80.00 A
FUNC
POWER 75.00 %
2. To switch to local control. 1 L ->1242.0 rpm I

LOC
(Only if the drive is not under local control, i.e. there is no L FREQ 45.00 Hz
REM
on the first row of the display.) CURRENT 80.00 A
POWER 75.00 %
3. To enter the Reference Setting function. REF

1 L ->[1242.0 rpm]I
FREQ 45.00 Hz
CURRENT 80.00 A
POWER 75.00 %
4. To change the reference. 1 L ->[1325.0 rpm]I

(slow change) FREQ 45.00 Hz
CURRENT 80.00 A
POWER 75.00 %
(fast change)
5. To save the reference. 1 L -> 1325.0 rpm I

ENTER
(The value is stored in the permanent memory; it is FREQ 45.00 Hz
restored automatically after power switch-off.) CURRENT 80.00 A
POWER 75.00 %
Control panel
29
Actual signal display mode

In the Actual Signal Display Mode, the user can:
• show three actual signals on the display at a time
• select the actual signals to display
• view the fault history
• reset the fault history.
The panel enters the Actual Signal Display Mode when the user presses the ACT
key, or if he does not press any key within one minute.
How to select actual signals to the display

Step Action Press key Display
1. To enter the Actual Signal Display Mode. 1 L -> 1242.0 rpm I

ACT FREQ 45.00 Hz
CURRENT 80.00 A
POWER 75.00 %
2. To select a row (a blinking cursor indicates the selected 1 L -> 1242.0 rpm I
row). FREQ 45.00 Hz
CURRENT 80.00 A
POWER 75.00 %
3. To enter the actual signal selection function. ENTER

1 L -> 1242.0 rpm I
1 ACTUAL SIGNALS
04 CURRENT
80.00 A
4. To select an actual signal. 1 L -> 1242.0 rpm I

1 ACTUAL SIGNALS
05 TORQUE 70.00 %
To change the actual signal group.
5.a To accept the selection and to return to the Actual Signal 1 L -> 1242.0 rpm I
ENTER
Display Mode. FREQ 45.00 Hz
TORQUE 70.00 %
POWER 75.00 %
5.b To cancel the selection and keep the original selection. 1 L -> 1242.0 rpm I
ACT PAR
FREQ 45.00 Hz
CURRENT 80.00 A
The selected keypad mode is entered.
FUNC DRIVE
POWER 75.00 %
Control panel
30
How to display the full name of the actual signals

1. To display the full name of the three actual signals. Hold 1 L -> 1242.0 rpm I
FREQUENCY
ACT CURRENT
POWER
2. To return to the Actual Signal Display Mode. Release 1 L -> 1242.0 rpm I
FREQ 45.00 Hz
ACT CURRENT 80.00 A
POWER 75.00 %
How to view and reset the fault history
Note: The fault history cannot be reset if there are active faults or warnings.
1. To enter the Actual Signal Display Mode. 1 L -> 1242.0 rpm I

ACT FREQ 45.00 Hz
CURRENT 80.00 A
POWER 75.00 %
2. To enter the Fault History Display. 1 L -> 1242.0 rpm I

1 LAST FAULT
+OVERCURRENT
6451 H 21 MIN 23 S
3. To select the previous (UP) or the next fault/warning 1 L -> 1242.0 rpm I
(DOWN). 2 LAST FAULT
+OVERVOLTAGE
1121 H 1 MIN 23 S
To clear the Fault History. RESET

1 L -> 1242.0 rpm I
2 LAST FAULT
H MIN S
4. To return to the Actual Signal Display Mode. 1 L -> 1242.0 rpm I

FREQ 45.00 Hz
CURRENT 80.00 A
POWER 75.00 %
Control panel
31
How to display and reset an active fault
WARNING! If an external source for start command is selected and it is ON, the
drive will start immediately after fault reset. If the cause of the fault has not been
removed, the drive will trip again.
1. To display an active fault. 1 L -> 1242.0 rpm

ACT ACS800
** FAULT **
ACS800 TEMP
2. To reset the fault. RESET 1 L -> 1242.0 rpm O

FREQ 45.00 Hz
CURRENT 80.00 A
POWER 75.00 %
About the fault history

The fault history restores information on the latest events (faults, warnings and
resets) of the drive. The table below shows how the events are stored in the fault
history.
Event Information on display

Drive detects a fault and Sequential number of the event and
A Fault History View generates a fault message LAST FAULT text.
Sign Name and Name of the fault and a “+” sign in front
code of the name.
Sequential number Power- Total power-on time.

(1 is the most recent event) on time User resets the fault message. Sequential number of the event and
LAST FAULT text.
1 L -> 1242.0 rpm I -RESET FAULT text.
2 LAST FAULT Total power-on time.
+DC OVERVOLT (3210)
1121 H 1 MIN 23 S Drive generates a warning Sequential number of the event and
message. LAST WARNING text.
Name of the warning and a “+” sign in
front of the name.
Total power-on time.
Drive deactivates the warning Sequential number of the event and
message. LAST WARNING text.
Name of the warning and a “-” sign in
front of the name.
Total power-on time.
Control panel
32
Parameter mode
In the Parameter Mode, the user can:
• view the parameter values
• change the parameter settings.
The panel enters the Parameter Mode when the user presses the PAR key.
How to select a parameter and change the value

1. To enter the Parameter Mode. 1 L -> 1242.0 rpm O

PAR 10 START/STOP/DIR
01 EXT1 STRT/STP/DIR
DI1,2
2. To select a group. 1 L -> 1242.0 rpm O

11 REFERENCE SELECT
01 KEYPAD REF SEL
REF1 (rpm)
3. To select a parameter within a group. 1 L -> 1242.0 rpm O

11 REFERENCE SELECT
03 EXT REF1 SELECT
AI1
4. To enter the parameter setting function. ENTER 1 L -> 1242.0 rpm O

11 REFERENCE SELECT
03 EXT REF1 SELECT
[AI1]
5. To change the parameter value. 1 L -> 1242.0 rpm O

- (slow change for numbers and text) 11 REFERENCE SELECT
03 EXT REF1 SELECT
[AI2]
- (fast change for numbers only)
6a. To save the new value. ENTER 1 L -> 1242.0 rpm O

11 REFERENCE SELECT
03 EXT REF1 SELECT
AI2
6b. To cancel the new setting and keep the original value, 1 L -> 1242.0 rpm O
ACT PAR
press any of the mode selection keys. 11 REFERENCE SELECT
The selected mode is entered. 03 EXT REF1 SELECT
FUNC DRIVE
AI1
Control panel
33
How to adjust a source selection (pointer) parameter

Most parameters define values that are used directly in the drive application
program. Source selection (pointer) parameters are exceptions: They point to the
value of another parameter. The parameter setting procedure differs somewhat from
that of the other parameters.
1. See the table above to 1 L ->1242.0 rpm O

- enter the Parameter Mode PAR 84 ADAPTIVE PROGRAM
06 INPUT1
- select the correct parameter group and parameter
[±000.000.00]
- enter the parameter setting mode
ENTER
2. To scroll between the inversion, group, index and bit 1 L ->1242.0 rpm O
fields.1) 84 ADAPTIVE PROGRAM
06 INPUT1
[±000.000.00]
3. To adjust the value of a field. 1 L ->1242.0 rpm O

84 ADAPTIVE PROGRAM
06 INPUT1
[±000.018.00]
4. To accept the value.

ENTER
1)
1 L ->1242.0 rpm O Inversion field inverts the selected parameter

84 ADAPTIVE PROGRAM value. Plus sign (+): no inversion, minus (-) sign:
06 INPUT1 inversion.
[±001.018.00] Bit field selects the bit number (relevant only if the
Inversion field parameter value is a packed boolean word).
Group field Index field selects the parameter index.
Index field
Group field selects the parameter group.
Bit field
Note: Instead of pointing to another parameter, it is also possible to define a

constant by the source selection parameter. Proceed as follows:
- Change the inversion field to C. The appearance of the row changes. The rest of
the line is now a constant setting field.
- Give the constant value to the constant setting field.
- Press Enter to accept.
Control panel
34
Function mode
In the Function Mode, the user can:
• start a guided procedure for adjusting the drive settings (assistants)
• upload the drive parameter values and motor data from the drive to the panel.
1)
• download group 1 to 97 parameter values from the panel to the drive.
• adjust the contrast of the display.
The panel enters the Function Mode when the user presses the FUNC key.
1) The parameter groups 98, 99 and the results of the motor identification are not included by default. The restriction
prevents downloading of unfit motor data. In special cases it is, however, possible to download all. For more information,
please contact your local ABB representative.
Control panel
35
How to enter an assistant, browse and exit

The table below shows the operation of the basic keys which lead the user through
an assistant. The Motor Setup task of the Start-up Assistant is used as an example.
The Start-up Assistant is not available in Scalar mode or when the parameter lock is
on. (99.04 MOTOR CTRL MODE = SCALAR or 16.02 PARAMETER LOCK =
LOCKED or 16.10 ASSIST SEL = OFF)
1. To enter the Function Mode. 1 L -> 1242.0 rpm O

FUNC Motor Setup
Application Macro
Speed Control EXT1
2. To select a task or function from the list (a flashing cursor 1 L -> 1242.0 rpm O
indicates the selection). Motor Setup
Double arrows: To change page to see more assistants/ Application Macro
functions. Speed Control EXT 1
3. To enter the task. ENTER Motor Setup 1/10

ENTER: Ok/Continue
ACT: Exit
FUNC: More Info
4. To accept and continue. ENTER Motor Setup 2/10

MOTOR NAMEPLATE DATA
AVAILABLE?
ENTER:Yes FUNC:Info
5. To accept and continue. ENTER Motor Setup 3/10

MOTOR NOM VOLTAGE?
[0 V]
ENTER:Ok RESET:Back
6. a. To adjust the requested drive parameter. Motor Setup 3/10

MOTOR NOM VOLTAGE?
[415 V]
ENTER:Ok RESET:back
b. To ask for information on the requested value. FUNC INFO P99.05

(To scroll the information displays Set as given on the
( )
motor nameplate.
and return to the task).
FUNC, ACT
7. a. To accept a value and step forward. ENTER Motor Setup 4/10

MOTOR NOM CURRENT?
[0.0 A]
ENTER:Ok RESET:Back
b. To cancel the setting and take one step back. RESET Motor Setup 3/10
MOTOR NOM VOLTAGE?
[415 V]
ENTER:Ok RESET:back
Control panel
36
8. To cancel and exit. 2 x ACT 1 L -> 0.0 rpm O

Note: 1 x ACT returns to the first display of the task. FREQ 0.00 Hz
CURRENT 0.00 A
POWER 0.00 %
How to upload data from a drive to the panel
Note:
• Upload before downloading.
• Ensure the firmware of the destination drive is the same (e.g. standard firmware).
• Before removing the panel from a drive, ensure the panel is in remote operating
mode (change with the LOC/REM key).
• Stop the drive before downloading.
Before upload, repeat the following steps in each drive:

• Setup the motors.
• Activate the communication to the optional equipment. (See parameter group 98
OPTION MODULES.)
Before upload, do the following in the drive from which the copies are to be taken:
• Set the parameters in groups 10 to 97 as preferred.
• Proceed to the upload sequence (below).
1. Enter the Function Mode. 1 L -> 1242.0 rpm O

FUNC Motor Setup
Application Macro
Speed Control EXT1
2. Enter the page that contains the upload, download and 1 L -> 1242.0 rpm O
contrast functions. UPLOAD <=<=
DOWNLOAD =>=>
CONTRAST 4
3. Select the upload function (a flashing cursor indicates the 1 L -> 1242.0 rpm O
selected function). UPLOAD <=<=
DOWNLOAD =>=>
CONTRAST 4
4. Enter the upload function. ENTER 1 L -> 1242.0 rpm O

UPLOAD <=<=
5. Switch to external control. 1 -> 1242.0 rpm O

LOC
(No L on the first row of the display.) UPLOAD <=<=
REM
DOWNLOAD =>=>
CONTRAST 4
Control panel
37
6. Disconnect the panel and reconnect it to the drive into

which the data will be downloaded.
How to download data from the panel to a drive

Consider the notes in section How to upload data from a drive to the panel on page
36.
1. Connect the panel containing the uploaded data to the

drive.
2. Ensure the drive is in local control (L shown on the first row 1 L -> 1242.0 rpm I
LOC
of the display). If necessary, press the LOC/REM key to FREQ 45.00 Hz
REM
change to local control. CURRENT 80.00 A
POWER 75.00 %

FUNC Motor Setup
Application Macro
Speed Control EXT1
DOWNLOAD =>=>
CONTRAST 4
5. Select the download function (a flashing cursor indicates 1 L -> 1242.0 rpm O
the selected function). UPLOAD <=<=
DOWNLOAD =>=>
CONTRAST 4
6. Start the download. ENTER 1 L -> 1242.0 rpm O

DOWNLOAD =>=>
Control panel
38
How to set the contrast of the display


FUNC Motor Setup
Application Macro
Speed Control EXT1
DOWNLOAD =>=>
CONTRAST 4
3. Select a function (a flashing cursor indicates the selected 1 L -> 1242.0 rpm O
function). UPLOAD <=<=
DOWNLOAD =>=>
CONTRAST 4
4. Enter the contrast setting function. ENTER 1 L -> 1242.0 rpm O

CONTRAST [4]
5. Adjust the contrast. 1 L -> 1242.0 rpm

CONTRAST [6]
6.a Accept the selected value. ENTER 1 L -> 1242.0 rpm O

UPLOAD <=<=
DOWNLOAD =>=>
CONTRAST 6
6.b Cancel the new setting and retain the original value by 1 L -> 1242.0 rpm I
pressing any of the mode selection keys. ACT PAR FREQ 45.00 Hz
CURRENT 80.00 A
POWER 75.00 %
The selected mode is entered. FUNC DRIVE
Control panel
39
Drive selection mode

In normal use the features available in the Drive Selection Mode are not needed; the
features are reserved for applications where several drives are connected to one
panel link. (For more information, see the Installation and Start-up Guide for the
Panel Bus Connection Interface Module, NBCI, [3AFY58919748 (English)].
In the Drive Selection Mode, the user can:
• Select the drive with which the panel communicates through the panel link.
• Change the identification number of a drive connected to the panel link.
• View the status of the drives connected on the panel link.
The panel enters the Drive Selection Mode when the user presses the DRIVE key.
Each on-line station must have an individual identification number (ID). By default,
the ID number of the drive is 1.
Note: The default ID number setting of the drive should not be changed unless the
drive is to be connected to the panel link with other drives on-line.
How to select a drive and change its panel link ID number

1. To enter the Drive Selection Mode. ACS800

DRIVE
ASAAA5000 xxxxxx
ID NUMBER 1
2. To select the next drive/view. ACS800

The ID number of the station is changed by first pressing
ENTER (the brackets round the ID number appear) and ASAAA5000 xxxxxx
then adjusting the value with arrow buttons. The new value
ID NUMBER 1
is accepted with ENTER. The power of the drive must be
switched off to validate its new ID number setting.
The status display of all devices connected to the Panel 1o

Link is shown after the last individual station. If all stations
do not fit on the display at once, press the double-arrow up
Status Display Symbols:
to view the rest of them.
o = Drive stopped, direction
forward
= Drive running, direction
reverse
F = Drive tripped on a fault
3. To connect to the last displayed drive and to enter another 1 L -> 1242.0 rpm I
mode, press one of the mode selection keys. ACT PAR FREQ 45.00 Hz
CURRENT 80.00 A
FUNC
POWER 75.00 %
The selected mode is entered.
Control panel
40
Reading and entering packed boolean values on the display

Some actual values and parameters are packed boolean, i.e. each individual bit has
a defined meaning (explained at the corresponding signal or parameter). On the
control panel, packed boolean values are read and entered in hexadecimal format.
In this example, bits 1, 3 and 4 of the packed boolean value are ON:
Bit 15 Bit 0
Boolean 0000 0000 0001 1010

Hex 0 0 1 A
Control panel
41
Program features
Chapter overview
The chapter describes program features. For each feature, there is a list of related
user settings, actual signals, and fault and warning messages.
Start-up Assistant
Introduction
The assistant guides the user through the start-up procedure, helping the user to
feed the requested data (parameter values) to the drive. The assistant also check
that the entered values are valid, i.e. within the allowed range. At the first start, the
drive suggests entering the first task of the assistant, Language Select,
automatically.
The Start-up Assistant is divided into tasks. The user may activate the tasks either
one after the other as the Start-up Assistant suggests, or independently. The user
may also adjust the drive parameters in the conventional way without using the
assistant at all.
See chapter Control panel on how to start the assistant, browse and exit.
The default order of the tasks

Depending on the selection made in the Application task (parameter 99.02), the
Start-up Assistant decide which consequent tasks it suggests. The default tasks are
shown in the table below.
Application Default Tasks
Selection
FACTORY, SEQ Language Select, Motor Set-up, Application, Option Modules, Speed Control EXT1, Start/Stop
CTRL Control, Protections, Output Signals
HAND/AUTO Language Select, Motor Set-up, Application, Option Modules, Speed Control EXT2, Start/Stop
Control, Speed Control 1, Protections, Output Signals
T CTRL Language Select, Motor Set-up, Application, Option Modules, Torque Control, Start/Stop Control,
Speed Control EXT1, Protections, Output Signals
PID CTRL Language Select, Motor Set-up, Application, Option Modules, PID Control, Start/Stop Control, Speed
Control EXT1, Protections, Output Signals
Program features
42
List of tasks and the relevant drive parameters

Name Description Set parameters
Language Select Selecting the language 99.01
Motor Set-up Setting the motor data 99.05, 99.06, 99.09, 99.07, 99.08,
99.04
Performing the motor identification. (If the speed limits are not in 99.10 (20.8, 20.07)
the allowed range: Setting the limits).
Application Selecting the application macro 99.02, parameters associated to
the macro
Option Modules Activating the option modules Group 98, 35, 52
Speed Control Selecting the source for the speed reference 11.03
EXT1 (If AI1 is used: Setting analogue input AI1 limits, scale, (13.01, 13.02, 13.03, 13.04,
inversion) 13.05, 30.01)
Setting the reference limits 11.04, 11.05
Setting the speed (frequency) limits 20.02, 20.01, (20.08, 20.07)
Setting acceleration and deceleration times 22.02, 22.03
(Setting up the brake chopper if activated by parameter 27.01) (Group 27, 20.05, 14.01)
(If 99.02 is not SEQ CTRL: Setting constant speeds) (Group 12)
Speed Control Setting the source for the speed reference 11.06
EXT2 (If AI1 is used: Setting analogue input AI1 limits, scale, (13.01, 13.02, 13.03, 13.04,
inversion) 13.05, 30.01)
Torque Control Selecting the source for the torque reference 11.06
(If AI1 is used: Setting analogue input AI1 limits, scale, (13.01, 13.02, 13.03, 13.04,
inversion) 13.05, 30.01)
Setting the torque ramp up and ramp down times 24.01, 24.02
PID Control Selecting the source for the process reference 11.06
(If AI1 is used: Setting analogue input AI1 limits, scale, (13.01, 13.02, 13.03, 13.04,
inversion) 13.05, 30.01)
Setting the speed (reference) limits 20.02, 20.01 (20.08, 20.07)
Setting the source and limits for the process actual value 40.07, 40.09, 40.10
Start/Stop Control Selecting the source for start and stop signals of the two external 10.01, 10.02
control locations, EXT1 and EXT2
Selecting between EXT1 and EXT2 11.02
Defining the direction control 10.03
Defining the start and stop modes 21.01, 21.02, 21.03
Selecting the use of Run Enable signal 16.01, 21.07
Setting the ramp time for the Run Enable function 22.07
Protections Setting the torque and current limits 20.03, 20.04
Output Signals Selecting the signals indicated through the relay outputs RO1, Group 14
RO2, RO3 and optional RO’s (if installed)
Selecting the signals indicated through the analogue output 15.01, 15.02, 15.03, 15.04, 15.05,
AO1, AO2 and optional AO’s (if installed). Setting the minimum, (Group 96)
maximum, scaling and inversion.
Program features
43
Contents of the assistant displays

There are two types of displays in the Start-up Assistant: The main displays and the
information displays. The main displays prompt the user to feed in information or
answer a question. The assistant steps through the main displays. The information
displays contain help texts for the main displays. The figure below shows a typical
example of both and explanations of the contents.
Main Display Information Display

1 Motor Setup 3/10 INFO P99.05
2 MOTOR NOM VOLTAGE? Set as given on the motor
3 [0 V] nameplate.
4 ENTER:Ok RESET:Back
1 Name of the assistant, step Text INFO, index of parameter to

number / total number of steps be set
2 Request/question Help text …
3 Feed-in field … help text continued
4 Commands: accept value and double arrow symbol (indicates
step forward or cancel and step that the text continues)
backwards
Local control vs. external control

The drive can receive start, stop and direction commands and reference values from
the control panel or through digital and analogue inputs. An optional fieldbus adapter
enables control over an open fieldbus link. A PC equipped with DriveWindow can
also control the drive.
Local control ACS800 External control
Standard I/O
Control panel Fieldbus Slot 1

adapter
RTAC/RDIO/RAIO Slot 1 or Slot 2

module
RDCO CH0 Fieldbus adapter

CH3 module (DDCS) Nxxx
DriveWindow
(DDCS) or
Advant controller
(e.g. AC 80, AC 800M)
CH1 AIMA-01 I/O RTAC/RDIO/RAIO

(DDCS) adapter module module
Program features
44
Local control
The control commands are given from the control panel keypad when the drive is in
local control. L indicates local control on the panel display.
1 L ->1242 rpm I
The control panel always overrides the external control signal sources when used in
local mode.
External control
When the drive is in external control, the commands are given through the standard
I/O terminals (digital and analogue inputs), optional I/O extension modules and/or
the fieldbus interface. In addition, it is also possible to set the control panel as the
source for the external control.
External control is indicated by a blank on the panel display or with an R in those
special cases when the panel is defined as a source for external control.
1 ->1242 rpm I 1 R ->1242 rpm I
External Control through the Input/ External Control by control panel

Output terminals, or through the
fieldbus interfaces
The user can connect the control signals to two external control locations, EXT1 or
EXT2. Depending on the user selection, either one is active at a time. This function
operates on a 12 ms time level.
Settings
Panel key Additional information
LOC/REM Selection between local and external control
Parameter
11.02 Selection between EXT1 and EXT2
10.01 Start, stop, direction source for EXT1
11.03 Reference source for EXT1
10.02 Start, stop, direction source for EXT2
11.06 Reference source for EXT2
Group 98 OPTION Activation of the optional I/O and serial communication
MODULES
Diagnostics
Actual signals Additional information
01.11, 01.12 EXT1 reference, EXT2 reference
03.02 EXT1/EXT2 selection bit in a packed boolean word
Program features
45
Block diagram: start, stop, direction source for EXT1

The figure below shows the parameters that select the interface for start, stop, and
direction for external control location EXT1.
Select
DI1 / Std IO DI1
DI6 EXT1
DI6 / Std IO Start/stop/
DI7 to DI9 direction
DI1 / DIO ext 1 10.01
I/O Extensions
DI2 / DIO ext 1
See group 98
DI1 / DIO ext 2 OPTION
DI2 / DIO ext 2 MODULES.
Fb. selection
Fieldbus adapter slot 1 See chapter COMM.
CH0 / RDCO board Fieldbus control. CW
Standard Modbus Link
KEYPAD
Control panel
DI1 / Std IO = Digital input DI1 on the standard I/O terminal block
DI1 / DIO ext 1 = Digital input DI1 on the digital I/O extension module 1
Block diagram: reference source for EXT1

The figure below shows the parameters that select the interface for the speed
reference of external control location EXT1.
AI1 / Std IO AI1, AI2, AI3, DI3, DI4 Select

AI2 / Std IO
AI3 / Std IO EXT1
AI5, AI6
DI3 / Std IO Reference
DI4 / Std IO DI11, DI12
REF1 (rpm)
11.03
AI1 / AIO ext I/O Extensions
AI2 / AIO ext See parameter
group 98 OPTION
DI1 / DIO ext 3
MODULES.
DI2 / DIO ext 3
Fieldbus adapter slot 1 Fb. selection
See chapter COMM.
CH0 / RDCO board REF
Fieldbus control.
Standard Modbus Link
Control panel KEYPAD
AI1 / Std IO = Analogue input AI1 on the standard I/O terminal block
AI1 / AIO ext = Analogue input AI1 on the analogue I/O extension module
Program features
46
Reference types and processing

The drive can accept a variety of references in addition to the conventional analogue
input signal and control panel signals.
• The drive reference can be given with two digital inputs: One digital input
increases the speed, the other decreases it.
• The drive accepts a bipolar analogue speed reference. This feature allows both
the speed and direction to be controlled with a single analogue input. The
minimum signal is full speed reversed and the maximum signal is full speed
forward.
• The drive can form a reference out of two analogue input signals by using
mathematical functions: Addition, subtraction, multiplication, minimum selection,
and maximum selection.
• The drive can form a reference out of an analogue input signal and a signal
received through a serial communication interface by using mathematical
functions: addition and multiplication.
It is possible to scale the external reference so that the signal minimum and
maximum values correspond to a speed other than the minimum and maximum
speed limits.
Settings
Parameter Additional information
Group 11 REFERENCE External reference source, type and scaling
SELECT
Group 20 LIMITS Operating limits
Group 22 ACCEL/DECEL Speed reference acceleration and deceleration ramps
Group 24 TORQUE CTRL Torque reference ramp times
Group 32 SUPERVISION Reference supervision
Diagnostics
Actual signal Additional information
01.11, 01.12 Values of external references
Group 02 ACTUAL SIGNALS The reference values in different stages of the reference processing
chain.
Parameter
Group 14 RELAY OUTPUTS Active reference / reference loss through a relay output
Group 15 ANALOGUE Reference value
OUTPUTS
Program features
47
Reference trimming
In reference trimming, the external %-reference (External reference REF2) is
corrected depending on the measured value of a secondary application variable.
The block diagram below illustrates the function.
Switch Select
max.freq
Select
DIRECT (3)
max.speed max.torque
%ref PROPOR. (2)
Select 99.04 (DTC) 40.18
1 OFF (1)
AI1 Add
AI2 40.14 %ref
... Mul. %ref’
40.16
PID Mul.
40.15 40.17
tref
40.01 k
Actual Values 40.02 ti
40.03 td
40.05 .
. i
. Filter 40.04 dFiltT
40.07 40.05 errVInv
AI1 40.13 rInt
AI2 PIDmax oh1
AI3 PIDmin ol1
AI5
AI6 40.19
IMOT
%ref= The drive reference before trimming

%ref’ = The drive reference after trimming
max. speed= Par. 20.02 (or 20.01 if the absolute value is greater)
max. freq = Par. 20.08 (or 20.07 if the absolute value is greater)
max. torq = Par. 20.14 (or 20.13 if the absolute value is greater)
Settings
40.14…40.18 Trimming function settings
40.01…40.13, 40.19 PID control block settings
Group 20 LIMITS Drive operation limits
Program features
48
Example
The drive runs a conveyor line. It is speed-controlled but the line tension also needs
to be taken into account: If the measured tension exceeds the tension setpoint, the
speed will be slightly decreased, and vice versa.
To accomplish the desired speed correction, the user:
• activates the trimming function and connects the tension setpoint and the
measured tension to it
• tunes the trimming to a suitable level.
Speed controlled conveyor line
Drive rollers (pull)

Tension measurement
Simplified block diagram

Add
Speed reference Trimmed
speed reference
PID
Tension
measurement
Tension
setpoint
Program features
49
Programmable analogue inputs

The drive has three programmable analogue inputs: one voltage input (0/2 to 10 V or
-10 to 10 V) and two current inputs (0/4 to 20 mA). Two extra inputs are available if
an optional analogue I/O extension module is used. Each input can be inverted and
filtered, and the maximum and minimum values can be adjusted.
Update cycles in the Standard Control Program

Input Cycle
AI / standard 6 ms
AI / extension 6 ms (100 ms 1))
1) Update cycle in the motor temperature measurement function. See group 35 MOT TEMP MEAS.
Settings
Group 11 REFERENCE AI as a reference source
SELECT
Group 13 ANALOGUE Processing of the standard inputs
INPUTS
30.01 Supervision of AI loss
Group 40 PID AI as a PID process control reference or actual values
CONTROL
35.01 AI in a motor temperature measurement
40.15 AI in a drive reference trimming
42.07 AI in a mechanical brake control function
98.06 Activation of optional analogue inputs
98.13 Optional AI signal type definition (bipolar or unipolar)
98.14 Optional AI signal type definition (bipolar or unipolar)
Diagnostics
Actual value Additional information
01.18, 01.19, 01.20 Values of standard inputs
01.38, 01.39 Value of optional inputs
Group 09 ACTUAL Scaled analogue input values (integer values for function block
SIGNALS programming)
Program features
50
Programmable analogue outputs

Two programmable current outputs (0/4 to 20 mA) are available as standard, and
two outputs can be added by using an optional analogue I/O extension module.
Analogue output signals can be inverted and filtered.
The analogue output signals can be proportional to motor speed, process speed
(scaled motor speed), output frequency, output current, motor torque, motor power,
etc.
It is possible to write a value to an analogue output through a serial communication
link.

Output Cycle
AO / standard 24 ms
AO / extension 24 ms (1000 ms 1) )
1) Update cycle in the motor temperature measurement function. See group 35 MOT TEMP MEAS.
Settings
Group 15 ANALOGUE AO value selection and processing (standard outputs)
OUTPUTS
30.20 Operation of an externally controlled AO in a communication break
30.22 Supervision of the use of optional AO
Group 35 MOT TEMP AO in motor temperature measurement
MEAS
Group 96 EXTERNAL Optional AO value selection and processing
AO
Group 98 OPTION Activation of optional I/O
MODULES
Diagnostics
01.22, 01.23 Values of the standard outputs
01.28, 01.29 Values of the optional outputs
Warning
IO CONFIG (FF8B) Improper use of optional I/O
Program features
51
Programmable digital inputs

The drive has six programmable digital inputs as a standard. Six extra inputs are
available if optional digital I/O extension modules are used.

Input Cycle
DI / standard 6 ms
DI / extension 12 ms
Settings
Group 10 START/STOP/ DI as start, stop, direction
DIR
Group 11 REFERENCE DI in reference selection, or reference source
SELECT
Group 12 CONSTANT DI in constant speed selection
SPEEDS
Group 16 SYST CTRL DI as external Run Enable, fault reset or user macro change signal
INPUTS
22.01 DI as acceleration and deceleration ramp selection signal
30.03 DI as external fault source
30.05 DI in motor overtemperature supervision function
30.22 Supervision of optional I/O use
40.20 DI as sleep function activation signal (in PID process control)
42.02 DI as mechanical brake acknowledgement signal
98.03…96.05 Activation of the optional digital I/O extension modules
98.09…98.11 Naming of the optional digital inputs in the application program
Diagnostics
01.17 Values of the standard digital inputs
01.40 Values of the optional digital inputs
Warning
IO CONFIG (FF8B) Improper use of optional I/O
Fault
I/O COMM ERR (7000) Communication loss to I/O
Program features
52
Programmable relay outputs

As standard there are three programmable relay outputs. Six outputs can be added
by using the optional digital I/O extension modules. By means of a parameter setting
it is possible to choose which information to indicate through the relay output: ready,
running, fault, warning, motor stall, etc.
It is possible to write a value to a relay output through a serial communication link.

Output Cycle
RO / standard 100 ms
RO / extension 100 ms
Settings
Group 14 RELAY RO value selections and operation times
OUTPUTS
30.20 Operation of an externally controlled relay output on a communication break
Group 42 BRAKE RO in a mechanical brake control
CONTROL
Group 98 OPTION Activation of optional relay outputs
MODULES
Diagnostics
01.21 Standard relay output states
01.41 Optional relays output states
Program features
53
Actual signals
Several actual signals are available:
• Drive output frequency, current, voltage and power
• Motor speed and torque
• Mains voltage and intermediate circuit DC voltage
• Active control location (Local, EXT1 or EXT2)
• Reference values
• Drive temperature
• Operating time counter (h), kWh counter
• Digital I/O and Analogue I/O status
• PID controller actual values (if the PID Control macro is selected)
Three signals can be shown simultaneously on the control panel display. It is also
possible to read the values through the serial communication link or through the
analogue outputs.
Settings
Group 15 ANALOGUE Selection of an actual signal to an analogue output
OUTPUTS
Group 92 D SET TR Selection of an actual signal to a data set (serial communication)
ADDR
Diagnostics
Group 01 ACTUAL Lists of actual signals
SIGNALS … 09
ACTUAL SIGNALS
Motor identification
The performance of Direct Torque Control is based on an accurate motor model
determined during the motor start-up.
A motor Identification Magnetisation is automatically done the first time the start
command is given. During this first start-up, the motor is magnetised at zero speed
for several seconds to allow the motor model to be created. This identification
method is suitable for most applications.
In demanding applications a separate Identification Run can be performed.
Settings
Parameter 99.10.
Program features
54
Power loss ride-through

If the incoming supply voltage is cut off, the drive will continue to operate by utilising
the kinetic energy of the rotating motor. The drive will be fully operational as long as
the motor rotates and generates energy to the drive. The drive can continue the
operation after the break if the main contactor remained closed.
Umains
TM fout UDC
(Nm) (Hz) (V d.c.) UDC
160 80 520
120 60 390
fout
80 40 260
TM
40 20 130
t(s)
1.6 4.8 8 11.2 14.4
UDC= Intermediate circuit voltage of the drive, fout = output frequency of the drive,
TM = Motor torque
Loss of supply voltage at nominal load (fout = 40 Hz). The intermediate circuit DC voltage drops to the
minimum limit. The controller keeps the voltage steady as long as the mains is switched off. The drive
runs the motor in generator mode. The motor speed falls but the drive is operational as long as the
motor has enough kinetic energy.
Note: Cabinet assembled units equipped with main contactor option have a “hold
circuit” that keeps the contactor control circuit closed during a short supply break.
The allowed duration of the break is adjustable. The factory setting is five seconds.
Automatic Start
Since the drive can detect the state of the motor within a few milliseconds, the
starting is immediate under all conditions. There is no restart delay. E.g. the starting
of turbining pumps or windmilling fans is easy.
Settings
Parameter 21.01.
Program features
55
DC Magnetising
When DC Magnetising is activated, the drive automatically magnetises the motor
before starting. This feature guarantees the highest possible breakaway torque, up
to 200% of motor nominal torque. By adjusting the premagnetising time, it is possible
to synchronise the motor start and e.g. a mechanical brake release. The Automatic
Start feature and DC Magnetising cannot be activated at the same time.
Settings
Parameters 21.01 and 21.02.
DC Hold
By activating the motor DC Hold feature it is possible to Motor
Speed
lock the rotor at zero speed. When both the reference DC Hold
and the motor speed fall below the preset DC hold
speed, the drive stops the motor and starts to inject DC DC hold
speed
into the motor. When the reference speed again exceeds t
the DC hold speed, the normal drive operation resumes. Speed
Reference
Settings
DC hold
Parameters 21.04, 21.05, and 21.06. speed
t
Flux Braking
The drive can provide greater deceleration by raising the level of magnetisation in
the motor. By increasing the motor flux, the energy generated by the motor during
braking can be converted to motor thermal energy. This feature is useful in motor
power ranges below 15 kW.
Motor TBr
Speed TN (%)
TBr = Braking Torque
No Flux Braking 60 TN = 100 Nm
40
Flux Braking
20
Flux Braking No Flux Braking
t (s) f (Hz)
50 HZ / 60 Hz
Program features
56
Braking Torque (%)

120
1 No Flux Braking
80
Rated Motor Power

40
2
1 2.2 kW 4 3
2 15 kW 0 5
f (Hz)
3 37 kW 5 10 20 30 40 50
4 75 kW 120
5 250 kW
1 Flux Braking
80
2
40 3
4
5
0 f (Hz)
5 10 20 30 40 50
The drive monitors the motor status continuously, also during the Flux Braking.
Therefore, Flux Braking can be used both for stopping the motor and for changing
the speed. The other benefits of Flux Braking are:
• The braking starts immediately after a stop command is given. The function does
not need to wait for the flux reduction before it can start the braking.
• The cooling of the motor is efficient. The stator current of the motor increases
during the Flux Braking, not the rotor current. The stator cools much more
efficiently than the rotor.
Settings
Parameter 26.02.
Flux Optimisation
Flux Optimisation reduces the total energy consumption and motor noise level when
the drive operates below the nominal load. The total efficiency (motor and the drive)
can be improved by 1% to 10%, depending on the load torque and speed.
Settings
Parameter 26.01.
Program features
57
Acceleration and deceleration ramps

Two user-selectable acceleration and deceleration ramps are available. It is possible
to adjust the acceleration/deceleration times and the ramp shape. Switching
between the two ramps can be controlled via a digital input.
Motor speed
The available ramp shape alternatives are Linear
and S-curve.
Linear: Suitable for drives requiring steady or slow Linear
acceleration/deceleration. S-curve
S-curve: Ideal for conveyors carrying fragile loads,

or other applications where a smooth transition is
required when changing the speed.
Settings 2 t (s)
Parameter group 22 ACCEL/DECEL.
Critical speeds
A Critical Speeds function is available for applications where it is necessary to avoid
certain motor speeds or speed bands because of e.g. mechanical resonance
problems.
Settings
Parameter group 25 CRITICAL SPEEDS.
Constant speeds
It is possible to predefine 15 constant speeds. Constant speeds are selected with
digital inputs. Constant speed activation overrides the external speed reference.
This function operates on a 6 ms time level.
Settings
Parameter group 12 CONSTANT SPEEDS.
Program features
58
Speed controller tuning

During the motor identification, the speed controller is automatically tuned. It is,
however, possible to manually adjust the controller gain, integration time and
derivation time, or let the drive perform a separate speed controller Autotune Run. In
Autotune Run, the speed controller is tuned based on the load and inertia of the
motor and the machine. The figure below shows speed responses at a speed
reference step (typically, 1 to 20%).
n
nN
%
A B C D
A: Undercompensated t
B: Normally tuned (autotuning)
C: Normally tuned (manually). Better dynamic performance than with B
D: Overcompensated speed controller
The figure below is a simplified block diagram of the speed controller. The controller
output is the reference for the torque controller.
Derivative
acceleration
compensation
Proportional,
integral + Torque
Speed + Error +
reference - value + reference
Derivative
Calculated actual speed
Settings
Parameter group 23 SPEED CTRL and 20 LIMITS.
Diagnostics
Actual signal 01.02.
Program features
59
Speed control performance figures

The table below shows typical performance figures for speed control when Direct
Torque Control is used.
T (%)
TN
Speed Control No Pulse With Pulse Tload
100
Encoder Encoder
Static speed error, + 0.1 to 0.5% + 0.01%
% of nN (10% of nominal
slip) t (s)
Dynamic speed 0.4 %sec.* 0.1 %sec.* 0.1 - 0.4 %sec
nact-nref
error
nN
*Dynamic speed error depends on speed controller tuning. TN = rated motor torque
nN = rated motor speed
nact = actual speed
nref = speed reference
Torque control performance figures

The drive can perform precise torque control without any speed feedback from the
motor shaft. The table below shows typical performance figures for torque control,
when Direct Torque Control is used.
T (%)
TN
Torque Control No Pulse With Pulse Tref
Encoder Encoder 100
Tact
90
Linearity error + 4%* + 3%
Repeatability + 3%* + 1%
error
Torque rise time 1 to 5 ms 1 to 5 ms
*When operated around zero frequency, the error may be

greater.
10
< 5 ms t(s)
TN = rated motor torque
Tref = torque reference
Tact = actual torque
Program features
60
Scalar control
It is possible to select Scalar Control as the motor control method instead of Direct
Torque Control (DTC). In the Scalar Control mode, the drive is controlled with a
frequency reference. The outstanding performance of the default motor control
method, Direct Torque Control, is not achieved in Scalar Control.
It is recommended to activate the Scalar Control mode in the following special
applications:
• In multimotor drives: 1) if the load is not equally shared between the motors, 2) if
the motors are of different sizes, or 3) if the motors are going to be changed after
the motor identification
• If the nominal current of the motor is less than 1/6 of the nominal output current of
the drive
• If the drive is used without a motor connected (e.g. for test purposes)
• The drive runs a medium voltage motor via a step-up transformer.
In the Scalar Control mode, some standard features are not available.
Settings
Parameter 99.04.
IR compensation for a scalar controlled drive

IR Compensation is active only when the motor Motor Voltage
control mode is Scalar (see section Scalar control
on page 60). When IR Compensation is IR Compensation
activated, the drive gives an extra voltage boost
to the motor at low speeds. IR Compensation is
useful in applications that require high breakaway
torque. In Direct Torque Control, no IR No compensation
Compensation is possible/needed. f (Hz)
Settings
Parameter 26.03.
Program features
61
Hexagonal motor flux

Typically the drive controls the motor flux in such a way that the rotating flux vector
follows a circular pattern. This is ideal in most applications. When operated above
the field weakening point (FWP, typically 50 or 60 Hz), it is, however, not possible to
reach 100% of the output voltage. The peak load capacity of the drive is lower than
with the full voltage.
If hexagonal flux control is selected, the motor flux is controlled along a circular
pattern below the field weakening point, and along a hexagonal pattern in the field
weakening range. The applied pattern is changed gradually as the frequency
increases from 100% to 120% of the FWP. Using the hexagonal flux pattern, the
maximum output voltage can be reached; The peak load capacity is higher than with
the circular flux pattern but the continuous load capacity is lower in the frequency
range of FWP to 1.6 · FWP, due to increased losses.
Settings
Parameter 26.05.
Programmable protection functions
AI<Min
AI<Min function defines the drive operation if an analogue input signal falls below the
preset minimum limit.
Settings
Parameter 30.01.
Panel Loss
Panel Loss function defines the operation of the drive if the control panel selected as
control location for the drive stops communicating.
Settings
Parameter 30.02.
External Fault
External Faults can be supervised by defining one digital input as a source for an
external fault indication signal.
Settings
Parameter 30.03.
Program features
62
Motor Thermal Protection

The motor can be protected against overheating by activating the Motor Thermal
Protection function and by selecting one of the motor thermal protection modes
available.
The Motor Thermal Protection modes are based either on a motor temperature
thermal model or on an overtemperature indication from a motor thermistor.
Motor temperature thermal model
The drive calculates the temperature of the motor on the basis of the following
assumptions:
1) The motor is at the estimated temperature (value of 01.37 MOTOR TEMP EST
saved at power switch off) when power is applied to the drive. When power is
applied for the first time, the motor is at the ambient temperature (30°C).
2) Motor temperature is calculated using either the user-adjustable or automatically
calculated motor thermal time and motor load curve (see the figures below). The
load curve should be adjusted in case the ambient temperature exceeds 30°C.
Motor Motor Break point

Load Current 150
100% (%) Motor load curve
100
50
Temp. t Zero speed load
Rise
Speed
100%
63%
t
Motor thermal time
Use of the motor thermistor

It is possible to detect motor overtemperature by connecting a motor thermistor
(PTC) between the +24 VDC voltage supply offered by the drive and digital input
DI6. In normal motor operation temperature, the thermistor resistance should be less
than 1.5 kohm (current 5 mA). The drive stops the motor and gives a fault indication
if the thermistor resistance exceeds 4 kohm. The installation must meet the
regulations for protecting against contact.
Settings
Note: It is also possible to use the motor temperature measurement function. See
sections Motor temperature measurement through the standard I/O on page 71 and
Motor temperature measurement through an analogue I/O extension on page 73.
Program features
63
Stall Protection
The drive protects the motor in a stall situation. It is possible to adjust the supervision
limits (torque, frequency, time) and choose how the drive reacts to a motor stall
condition (warning indication / fault indication & stop the drive / no reaction).
The torque and current limits, which define the stall limit, must be set according to
the maximum load of the used application. Note: Stall limit is restricted by internal
current limit 03.04 TORQ_INV_CUR_LIM.
When the application reaches the stall limit and the output frequency of the drive is
below the stall frequency: Fault is activated after the stall time delay.
Settings
Parameters 20.03, 20.13 and 20.14 (Define the stall limit.)
Underload Protection
Loss of motor load may indicate a process malfunction. The drive provides an
underload function to protect the machinery and process in such a serious fault
condition. Supervision limits - underload curve and underload time - can be chosen
as well as the action taken by the drive upon the underload condition (warning
indication / fault indication & stop the drive / no reaction).
Settings
Motor Phase Loss

The Phase Loss function monitors the status of the motor cable connection. The
function is useful especially during the motor start: the drive detects if any of the
motor phases is not connected and refuses to start. The Phase Loss function also
supervises the motor connection status during normal operation.
Settings
Parameter 30.16.
Program features
64
Earth Fault Protection

The Earth Fault Protection detects earth faults in the motor or motor cable. The
protection is based on sum current measurement.
• An earth fault in the mains does not activate the protection.
• In an earthed (grounded) supply, the protection activates in 200 microseconds.
• In floating mains, the mains capacitance should be 1 microfarad or more.
• The capacitive currents due to screened copper motor cables up to 300 metres
do not activate the protection.
• Earth fault protection is deactivated when the drive is stopped.
Note: With parallel connected inverter modules, the earth fault indication is
CUR UNBAL xx. See chapter Fault tracing.
Settings
Parameter 30.17.
Communication Fault
The Communication Fault function supervises the communication between the drive
and an external control device (e.g. a fieldbus adapter module).
Settings
Supervision of optional IO
The function supervises the use of the optional analogue and digital inputs and
outputs in the application program, and warns if the communication to the input/
output is not operational.
Settings
Parameter 30.22.
Preprogrammed faults
Overcurrent
The overcurrent trip limit for the drive is 1.65 to 2.17 · Imax depending on the drive
type.
DC overvoltage
The DC overvoltage trip limit is 1.3 ·U1max, where U1max is the maximum value of the
mains voltage range. For 400 V units, U1max is 415 V. For 500 V units, U1max is 500
V. For 690 V units, U1max is 690 V. The actual voltage in the intermediate circuit
corresponding to the mains voltage trip level is 728 VDC for 400 V units, 877 VDC
for 500 V units, and 1210 VDC for 690 V units.
Program features
65
DC undervoltage
The DC undervoltage trip limit is 0.6 · U1min, where U1min is the minimum value of
the mains voltage range. For 400 V and 500 V units, U1min is 380 V. For 690 V units,
U1min is 525 V. The actual voltage in the intermediate circuit corresponding to the
mains voltage trip level is 307 VDC for 400 V and 500 V units, and 425 VDC for
690 V units.
Drive temperature
The drive supervises the inverter module temperature. There are two supervision
limits: warning limit and fault trip limit.
Enhanced drive temperature monitoring for ACS800-U2, -U4 and -U7, frame sizes
R7 and R8
Traditionally, drive temperature monitoring is based on the power semiconductor
(IGBT) temperature measurement which is compared with a fixed maximum IGBT
temperature limit. However, certain abnormal conditions such as cooling fan failure,
insufficient cooling air flow or excessive ambient temperature might cause
overheating inside the converter module, which the traditional temperature
monitoring alone does not detect. The Enhanced drive temperature monitoring
improves the protection in these situations.
The function monitors the converter module temperature by checking cyclically that
the measured IGBT temperature is not excessive considering the load current,
ambient temperature, and other factors that affect the temperature rise inside the
converter module. The calculation uses an experimentally defined equation that
simulates the normal temperature changes in the module depending on the load.
Drive generates a warning when the temperature exceeds the limit, and trips when
temperature exceeds the limit by 5°C.
Note: The monitoring is available only for ACS800-U2, -U4 and -U7, frame sizes R7
and R8 with Standard Control Program version ASXR730U (and later versions).
Types to which the enhanced drive temperature monitoring is available:

ACS800-Ux -0080-2
-0100-2
-0120-2
-0140-2/3/7
-0170-2/3/5/7
-0210-2/3/5/7
-0230-2
-0260-2/3/5/7
-0270-5
-0300-2/5
-0320-3/5/7
-0400-3/5/7
-0440-3/5/7
Program features
66
-0490-3/5/7
-0550-5/7
-0610-5/7
Settings
95.10 TEMP INV AMBIENT Ambient temperature
Diagnostics
Warning/Fault Additional information
INV OVERTEMP Excessive converter module temperature
Short circuit
There are separate protection circuits for supervising the motor cable and the
inverter short circuits. If a short circuit occurs, the drive will not start and a fault
indication is given.
Input phase loss

Input phase loss protection circuits supervise the mains cable connection status by
detecting intermediate circuit ripple. If a phase is lost, the ripple increases. The drive
is stopped and a fault indication is given if the ripple exceeds 13%.
Control board temperature

The drive supervises the control board temperature. A fault indication CTRL B TEMP
is given, if the temperature exceeds 88°C.
Overfrequency
If the drive output frequency exceeds the preset level, the drive is stopped and a
fault indication is given. The preset level is 50 Hz over the operating range absolute
maximum speed limit (Direct Torque Control mode active) or frequency limit (Scalar
Control active).
Internal fault
If the drive detects an internal fault, the drive is stopped and a fault indication is
given.
Operation limits
ACS800 has adjustable limits for speed, current (maximum), torque (maximum) and
DC voltage.
Settings
Parameter group 20 LIMITS.
Program features
67
Power limit
Power limitation is used to protect the input bridge and the DC intermediate circuit.
If the maximum allowed power is exceeded, the drive torque is automatically limited.
Maximum overload and continuous power limits depend on the drive hardware.
For specific values refer to the appropriate hardware manual.
Automatic resets
The drive can automatically reset itself after overcurrent, overvoltage, undervoltage
and “analogue input below a minimum” faults. The Automatic Resets must be
activated by the user.
Settings
Parameter group 31 AUTOMATIC RESET.
Supervisions
The drive monitors whether certain user selectable variables are within the user-
defined limits. The user may set limits for speed, current etc.
The supervision functions operate on a 100 ms time level.
Settings
Parameter group 32 SUPERVISION.
Diagnostics
Actual Signals Additional information
03.02 Supervision limit indicating bits in a packed boolean word
Group 14 RELAY Supervision limit indication through a relay output
OUTPUTS
Parameter lock
The user can prevent parameter adjustment by activating the parameter lock.
Settings
Parameters 16.02 and 16.03.
Program features
68
Process PID control

There is a built-in PID controller in the drive. The controller can be used to control
process variables such as pressure, flow or fluid level.
When the process PID control is activated, a process reference (setpoint) is
connected to the drive instead of a speed reference. An actual value (process
feedback) is also brought back to the drive. The process PID control adjusts the
drive speed in order to keep the measured process quantity (actual value) at the
desired level (reference).
The control operates on a 24 ms time level.
Block diagrams
The block diagram below right illustrates the process PID control.
The figure on the left shows an application example: The controller adjusts the
speed of a pressure boost pump according to the measured pressure and the set
pressure reference.
Example: PID Control Block Diagram

Pressure boost pump PID
%ref ref
A C S 6 0 0
40.01 k
ACS800 40.02 ti Switch
Actual Values Frequency
A C T P A R F U N C D R IV E
40.03 td
40.06 .
E N T E R
reference
L O C R E S E T R E F
i
R E M
.. 40.04 dFiltT
3
40.12 Filter
AI1
40.05 errVInv Speed
40.13 rInt
2 0 ...1 0 b a r AI2 PIDmax
reference
4 ...2 0 m A oh1
AI3 PIDmin ol1 99.04 = 0
AI5
(DTC)
AI6 40.19
3
IMOT
%ref = external reference EXT REF2 (see

parameter 11.06)
Program features
69
Settings
Parameter Purpose
99.02 Process PID control activation
40.01...40.13, 40.19, The settings of the process PID controller
40.25...40.27
32.13...32.18 The supervision limits for the process reference REF2 and the variables
ACT1 and ACT2
Diagnostics
Actual Signals Purpose
01.12, 01.24, 01.25, PID process controller reference, actual values and error value
01.26 and 01.34
Group 14 RELAY Supervision limit exceeded indication through a relay output
OUTPUTS
Group 15 ANALOGUE PID process controller values through standard analogue outputs
OUTPUTS
Group 96 EXTERNAL PID process controller values through optional analogue outputs
AO
Sleep function for the process PID control

The sleep function operates on a 100 ms time level.
The block diagram below illustrates the sleep function enable/disable logic. The
sleep function can be put into use only when the process PID control is active.
Compare
Mot.speed 1 Select
0
Delay
And
1<2 INTERNAL Set/Reset
DI1 t S
40.21 2 ..
.
%refActive
PIDCtrlActive & 1)
40.20 modulating
40.22
S/R
R
Or
03.02 (B1)
1)
<1 Or 1 = Activate
03.02 (B2)
sleeping
Compare
StartRq
<1 0 = Deactivate
01.34
sleeping
1 Select Delay
0
1<2 INTERNAL t
DI1
40.23 2 ...
40.20 40.24
Mot.speed: Actual speed of the motor

%refActive: The % reference (EXT REF2) is in use. See parameter 11.02.
PIDCtrlActive: 99.02 is PID CTRL
modulating: The inverter IGBT control is operating
Program features
70
Example
The time scheme below visualises the operation of the sleep function.
Motor Speed
td = Sleep delay, parameter 40.22

t<td td
Sleep level
Par. 40.21 Text on display
SLEEP MODE
Time
Actual Value STOP START
No inversion, i.e. par. 40.05 is NO.
twd
Wake-up level
Parameter 42.23
Time
twd = Wake-up delay, parameter 40.24
Actual Value
Inverted, i.e. par. 40.05 is YES.
Parameter 42.23
Wake-up level
twd
Time
Sleep function for a PID controlled pressure boost pump: The water consumption
falls at night. As a consequence, the PID process controller decreases the motor
speed. However, due to natural losses in the pipes and the low efficiency of the
centrifugal pump at low speeds, the motor does not stop but keeps rotating. The
sleep function detects the slow rotation, and stops the unnecessary pumping after
the sleep delay has passed. The drive shifts into sleep mode, still monitoring the
pressure. The pumping restarts when the pressure falls under the allowed minimum
level and the wake-up delay has passed.
Settings
99.02 Process PID control activation
40.05 Inversion
40.20...40.24 Sleep function settings
Diagnostics
Warning SLEEP MODE on the panel display.
Program features
71
Motor temperature measurement through the standard I/O

This section describes the temperature measurement of one motor when the drive
control board RMIO is used as the connection interface.
RMIO board
One sensor
AI1+
Motor
AI1-
T
AO1+
AO1-
10 nF The minimum voltage
(> 630 VAC) of the capacitor must
be 630 VAC.
Three sensors RMIO board
AI1+
Motor AI1-
T T T
AO1+
AO1-
10 nF
(> 630 VAC)
WARNING! According to IEC 664, the connection of the motor temperature sensor
to the RMIO board, requires double or reinforced insulation between motor live parts
and the sensor. Reinforced insulation entails a clearance and creepage distance of
8 mm (400 / 500 VAC equipment). If the assembly does not fulfil the requirement:
• The RMIO board terminals must be protected against contact and they may not
be connected to other equipment.
Or
• The temperature sensor must be isolated from the RMIO board terminals.
See also section Motor Thermal Protection on page 62.
Program features
72
Settings
15.01 Analogue output in a motor 1 temperature measurement. Set to M1 TEMP
MEAS.
35.01…35.03 Settings of motor 1 temperature measurement
Other
Parameters 13.01 to 13.05 (AI1 processing) and 15.02 to 15.05 (AO1 processing) are not effective.
At the motor end the cable shield should be earthed through a 10 nF capacitor. If this is not possible,
the shield is to be left unconnected.
Diagnostics
Actual values Additional information
01.35 Temperature value
Warnings
MOTOR 1 TEMP (4312) Measured motor temperature has exceeded the set alarm limit.
T MEAS ALM (FF91) Motor temperature measurement is out of acceptable range.
Faults
MOTOR 1 TEMP (4312) Measured motor temperature has exceeded the set fault limit.
Program features
73
Motor temperature measurement through an analogue I/O extension

This section describes the motor temperature measurement of one motor when an
optional analogue I/O extension module RAIO is used as the connection interface.
RAIO module
One sensor
AI1+
Motor
AI1-
T
AO1+
AO1-
10 nF
(> 630 VAC)
SHLD
The minimum voltage

Three sensors RAIO module of the capacitor must
be 630 VAC.
AI1+
Motor AI1-
T T T
AO1+
AO1-
10 nF
(> 630 VAC)
SHLD
WARNING! According to IEC 664, the connection of the motor temperature sensor
to the RAIO module, requires double or reinforced insulation between motor live
parts and the sensor. Reinforced insulation entails a clearance and creepage
distance of 8 mm (400 / 500 VAC equipment). If the assembly does not fulfil the
requirement:
• The RAIO module terminals must be protected against contact and they may not
be connected to other equipment.
Or
• The temperature sensor must be isolated from the RAIO module terminals.
See also section Motor Thermal Protection on page 62.
Program features
74
Settings
35.01 … 35.03 Settings of motor 1 temperature measurement
98.12 Activation of optional analogue I/O for motor temperature measurement
Other
Parameters 13.16 to 13.20 (AI1 processing) and 96.01 to 96.05 (AO1 signal selection and processing)
are not effective.
At the motor end the cable shield should be earthed through a 10 nF capacitor. If this is not possible,
the shield is to be left unconnected.
Diagnostics
Actual values Additional information
01.35 Temperature value
Warnings
MOTOR 1 TEMP (4312) Measured motor temperature has exceeded the set alarm limit
T MEAS ALM (FF91) Motor temperature measurement is out of acceptable range.
Faults
MOTOR 1 TEMP (4312) Measured motor temperature has exceeded the set fault limit
Adaptive Programming using the function blocks

Conventionally, the user can control the operation of the drive by parameters. Each
parameter has a fixed set of choices or a setting range. The parameters make the
programming easy, but the choices are limited. The user cannot customise the
operation any further. The Adaptive Program makes freer customising possible
without the need of a special programming tool or language:
• The program is built of standard function blocks included in the drive application
program.
• The control panel is the programming tool.
• The user can document the program by drawing it on block diagram template
sheets.
The maximum size of the Adaptive Program is 15 function blocks. The program may
consist of several separate functions.
For more information, see the Application Guide for Adaptive Program
[3AFE64527274 (English)].
DriveAP
DriveAP is a Windows based tool for Adaptive Programming. With DriveAP it is
possible to upload the Adaptive Program from the drive and edit it with PC.
For more information, see the DriveAP User’s Manual [3AFE64540998 (English)].
Program features
75
Control of a mechanical brake

The mechanical brake is used for holding the motor and driven machinery at zero
speed when the drive is stopped, or not powered.
Example
The figure below shows a brake control application example.
WARNING! Make sure that the machinery into which the drive with brake control
function is integrated fulfils the personnel safety regulations. Note that the frequency
converter (a Complete Drive Module or a Basic Drive Module, as defined in IEC
61800-2), is not considered as a safety device mentioned in the European
Machinery Directive and related harmonised standards. Thus, the personnel safety
of the complete machinery must not be based on a specific frequency converter
feature (such as the brake control function), but it has to be implemented as defined
in the application specific regulations.
Brake control logic is integrated in Brake control RMIO board

the drive application program. The hardware X25
brake control hardware and wirings
230 VAC
needs to be done by the user. 1 RO1
- Brake on/off control through relay 2 RO1
output RO1. 3 RO1
- Brake supervision through digital
input DI5 (optional). Emergency
- Emergency brake switch in the brake X22
brake control circuit.
5 DI5
7 +24 V
Motor Mechanical brake
Program features
76
Operation time scheme

The time scheme below illustrates the operation of the brake control function. See
also the state machine on the following page.
1 5
Start command
External speed
reference
Inverter modulating 7
2
Motor magnetised tmd
tcd
Open brake
command
4
Internal speed
reference (actual tod 3 6
motor speed) ncs
Torque reference
Ts
time
Ts Start torque at brake release (Parameter 42.07 and 42.08)

tmd Motor magnetising delay
tod Brake open delay (Parameter 42.03)
ncs Brake close speed (Parameter 42.05)
tcd Brake close delay (Parameter 42.04)
Program features
77
State shifts
From any state
1) (rising edge)
NO
MODULATION 0/0/1
2)
OPEN
BRAKE 1/1/1
3)
A
5)
RELEASE RFG
INPUT 1/1/0
4)
RFG INPUT
TO ZERO 1/1/1
7)
10)
6)
11) CLOSE
BRAKE 0/1/1
RFG = Ramp Function 12)
A
Generator in the speed 13)
control loop (reference 8) 9)
handling).
BRAKE
ACK FAULT 0/0/1
State (Symbol NN )
X/Y/Z
- NN: State name
- X/Y/Z: State outputs/operations
X=1 Open the brake. The relay output set to brake on/off control energises.
Y=1 Forced start. The function keeps the internal Start on until the brake is closed in spite of the
status of the external Start signal.
Z=1 Ramp in zero. Forces the used speed reference (internal) to zero along a ramp.
State change conditions (Symbol )

1) Brake control active 0 -> 1 OR Inverter is modulating = 0
2) Motor magnetised = 1 AND Drive running = 1
3) Brake acknowledgement = 1 AND Brake open delay passed AND Start = 1
4) Start = 0
5) Start = 0
6) Start = 1
7) Actual motor speed < Brake close speed AND Start = 0
8) Start = 1
9) Brake acknowledgement = 0 AND Brake close delay passed = 1 AND Start = 0
Only if parameter 42.02 = OFF:
10) Brake acknowledgement = 0 AND Brake open delay passed =1
11) Brake acknowledgement = 0
12) Brake acknowledgement = 0
13) Brake acknowledgement = 1 AND Brake close delay passed = 1
Program features
78
Settings
14.01 Relay output for the brake control (set to BRAKE CTRL)
Group 42 BRAKE CONTROL Brake function settings
Diagnostics
03.01 Ramp in zero bit
03.13 The state of bit “brake open/close command”
Warnings
BRAKE ACKN (FF74) Unexpected state of brake acknowledge signal
Faults
BRAKE ACKN (FF74) Unexpected state of brake acknowledge signal
Master/Follower use of several drives

In a Master/Follower application, the system is run by several drives, the motor
shafts of which are coupled to each other. The master and follower drives
communicate via a fibre optic link. The figures below illustrate two basic application
types.
M/F Application, Overview

Solidly coupled motor shafts: Flexibly coupled motor shafts:
- Speed-controlled Master - Speed-controlled Master
- Follower follows the torque reference - Follower follows the speed reference
of the Master of the Master
External control
External control
signals
signals
n 3 n 3
Supply Supply
3 3
Master/
Follower fault 2 2 Follower Link Follower fault 2 2 Master/Follower
supervision supervision Link
3 3
Supply Supply
3 3
Settings and diagnostics

Group 60 MASTER/ Master/Follower parameters
FOLLOWER
Other
Master/Follower Application Guide [3AFE64590430 (English)] explains the functionality in further
detail.
Program features
79
Jogging
The jogging function is typically used to control a cyclical movement of a machine
section. One push button controls the drive through the whole cycle: When it is on,
the drive starts, accelerates to a preset speed at a preset rate. When it is off, the
drive decelerates to zero speed at a preset rate.
The figure and table below describe the operation of the drive. They also represent
how the drive shifts to normal operation (= jogging inactive) when the drive start
command is switched on. Jog cmd = State of the jogging input, Start cmd = State of
the drive start command.
The function operates on a 100 ms time level.
Speed
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Time
Phase Jog Start Description

cmd cmd
1-2 1 0 Drive accelerates to the jogging speed along the acceleration ramp of the jogging function.
2-3 1 0 Drive runs at the jogging speed.
3-4 0 0 Drive decelerates to zero speed along the deceleration ramp of the jogging function.
4-5 0 0 Drive is stopped.
5-6 1 0 Drive accelerates to the jogging speed along the acceleration ramp of the jogging function.
7-8 x 1 Normal operation overrides the jogging. Drive accelerates to the speed reference along the
active acceleration ramp.
8-9 x 1 Normal operation overrides the jogging. Drive follows the speed reference.
9-10 0 0 Drive decelerates to zero speed along the active deceleration ramp.
10-11 0 0 Drive is stopped.
11-12 x 1 Normal operation overrides the jogging. Drive accelerates to the speed reference along the
active acceleration ramp.
12-13 x 1 Normal operation overrides the jogging. Drive follows he speed reference.
13-14 1 0 Drive decelerates to the jogging speed along the deceleration ramp of the jogging function.
15-16 0 0 Drive decelerates to zero speed along the deceleration ramp of the jogging function.
x = State can be either 1 or 0.
Program features
80
Note: The jogging is not operational when:

• the drive start command is on, or
• the drive is in local control (L visible on the first row of the panel display).
Note: The jogging speed overrides the constant speeds.
Note: The ramp shape time is set to zero during the jogging.
Settings
10.06 Input for the on/off control of the jogging.
12.15 Jogging speed
21.10 Switch off delay for the inverter IGBT control. A delay keeps the inverter
modulation live over a short standstill period enabling a smooth restart.
22.04, 22.05 Acceleration and deceleration times used during the jogging.
22.06 Acceleration and deceleration ramp shape time: Set to zero during the
jogging.
Reduced Run function

Reduced Run function is available for parallel connected inverters. Reduced Run
function makes it possible to continue the operation with limited current if an inverter
module(s) is out of order. If one of the modules is broken, it must be removed.
Parameter change is needed to continue the run with reduced current (95.03 INT
CONFIG USER). For instructions on how to remove and reconnect an inverter
module, see the appropriate drive hardware manual.
Settings
95.03 INT CONFIG Number of existing parallel connected inverters
USER
Diagnostics
04.01 INT board fault
Faults
INT CONFIG Number of inverter modules is not equal to original number of inverters.
Program features
81
User load curve

Motor temperature rise can be limited by limiting the drive output current. The user
can define a load curve (output current as a function of frequency). The load curve is
defined by eight points by parameters 72.02...72.17. If the load curve is exceeded,
a fault / warning / current limitation is activated.
T/Tn
Normal motor load capacity
User load curve

Frequency
0 Hz 50 Hz 100 Hz
Overload
Overload supervision can be applied to the user load curve by setting parameters
72.18 LOAD CURRENT LIMIT... 72.20 COOLING TIME according to the overload
values defined by the motor manufacturer.
The supervision is based on an integrator, ∫I2dt. Whenever the drive output current
exceeds the user load curve, the integrator is started. When the integrator has
reached the overload limit defined by parameters 72.18 and 72.19, the drive reacts
as defined by parameter 72.01 OVERLOAD FUNC. The output of the integrator is
set to zero if the current stays continuously below the user load curve for the cooling
time defined by parameter 72.20 COOLING TIME.
If the overload time 72.19 LOAD THERMAL TIME is set to zero, the drive output
current is limited to the user load curve.
Current
72.20
COOLING TIME
Overload Iuser curve
Ioutput
Frequency / Time
Program features
82
Settings
Group 72 USER LOAD User load curve
CURVE
Diagnostics
02.20 Measured motor current in percent of the user load curve current
Warnings Additional information
USER L CURVE Integrated motor current has exceeded load curve.
Faults
USER L CURVE Integrated motor current has exceeded load curve.
Program features
83
Application macros
Chapter overview
This chapter describes the intended use, operation and the default control
connections of the standard application macros. It also describes how to save a user
macro, and how to recall it.
Overview of macros
Application macros are preprogrammed parameter sets. While starting up the drive,
the user typically selects one of the macros - the one that is best suited to his needs
- by parameter 99.02, makes the essential changes and saves the result as a user
macro.
There are five standard macros and two user macros. The table below contains a
summary of the macros and describes suitable applications.
Macro Suitable Applications
Factory Ordinary speed control applications where no, one, two or three constant speeds
are used:
- Conveyors
- Speed-controlled pumps and fans
- Test benches with predefined constant speeds
Hand/Auto Speed control applications. Switching between two external control devices is
possible.
PID Control Process control applications e.g. different closed loop control systems such as
pressure control, level control, and flow control. For example:
- pressure boost pumps of municipal water supply systems
- level controlling pumps of water reservoirs
- pressure boost pumps of district heating systems
- material flow control on a conveyor line.
It is also possible to switch between process and speed control.
Torque Torque control applications. Switching between torque and speed control is
Control possible.
Sequential Speed control applications in which speed reference, seven constant speeds and
Control two acceleration and deceleration ramps can be used.
User The user can save the customised standard macro i.e. the parameter settings
including group 99, and the results of the motor identification into the permanent
memory, and recall the data at a later time. Two user macros are essential when
switching between two different motors is required
Application macros
84
Factory macro
All drive commands and reference settings can be given from the control panel or
from an external control location. The active control location is selected with the
LOC/REM key of the panel. The drive is speed-controlled.
In external control, the control location is EXT1. The reference signal is connected to
analogue input AI1 and Start/Stop and Direction signals are connected to digital
inputs DI1 and DI2. By default, the direction is fixed to FORWARD (parameter
10.03). DI2 does not control the direction of rotation unless parameter 10.03 is
changed to REQUEST.
Three constant speeds are selected by digital inputs DI5 and DI6. Two acceleration/
deceleration ramps are preset. The acceleration and deceleration ramps are used
according to the state of digital input DI4.
Two analogue signals (speed and current) and three relay output signals (ready,
running and inverted fault) are available.
The default signals on the display of the control panel are FREQUENCY, CURRENT
and POWER.
Application macros
85
Default control connections

The figure below shows the external control connections for the Factory macro. The
markings of the standard I/O terminals on the RMIO board are shown.
1) Effective only if parameter 10.03 is

X20
switched to REQUEST by the user. 1 VREF Reference voltage -10 VDC
2 GND 1 kohm < RL < 10 kohm
2)
The US default settings differ as X21
follows: 1 VREF Reference voltage 10 VDC
DI1 Start (Pulse: 0->1)
3 AI1+ Speed reference 0(2) … 10 V, Rin > 200 kohm
DI2 Stop (Pulse: 1->0) 4 AI1-
DI3 Forward/Reverse 5 AI2+ By default, not in use. 0(4) … 20 mA, Rin =
6 AI2- 100 ohm
3) 7 AI3+ By default, not in use. 0(4) … 20 mA, Rin =
0 = ramp times according to par.
8 AI3- 100 ohm
22.02 and 22.03. 1 = ramp times
according to par. 22.04 and 22.05. rpm 9 AO1+ Motor speed 0(4) … 20 mA = 0 … motor nom.
10 AO1- speed, RL < 700 ohm
A 11 AO2+ Output current 0(4) … 20 mA = 0 … motor
4)
See parameter group 12 12 AO2- nom. current, RL < 700 ohm
CONSTANT SPEEDS:
X22
DI5 DI6 Operation 1 DI1 Stop/Start 2)
0 0 Set speed through AI1 2 DI2 Forward/reverse 1, 2)
1 0 Speed 1 3 DI3 By default, not in use. 2)
0 1 Speed 2 4 DI4 Acceleration & deceleration select 3)
5 DI5 Constant speed select 4)
1 1 Speed 3
7 +24 V +24 VDC, max. 100 mA
5)
See parameter 21.09. 8 +24 V
9 DGND1 Digital ground
11 DI IL Start interlock (0 = stop) 5)
X23
1 +24 V Auxiliary voltage output, non-isolated,
2 GND 24 VDC, 250 mA
X25
1 RO11 Relay output 1
2 RO12 Ready
3 RO13
X26
2 RO22 Running
3 RO23
X27
1 R031 Relay output 3
Fault 2 R032 Inverted fault
3 R033
Application macros
86
Hand/Auto macro
Start/Stop and Direction commands and reference settings can be given from one of
two external control locations, EXT1 (Hand) or EXT2 (Auto). The Start/Stop/Direction
commands of EXT1 (Hand) are connected to digital inputs DI1 and DI2, and the
reference signal is connected to analogue input AI1. The Start/Stop/Direction
commands of EXT2 (Auto) are connected to digital inputs DI5 and DI6, and the
reference signal is connected to analogue input AI2. The selection between EXT1
and EXT2 is dependent on the status of digital input DI3. The drive is speed
controlled. Speed reference and Start/Stop and Direction commands can be given
from the control panel keypad also. One constant speed can be selected through
digital input DI4.
Speed reference in Auto Control (EXT2) is given as a percentage of the maximum
speed of the drive.
Two analogue and three relay output signals are available on terminal blocks. The
default signals on the display of the control panel are FREQUENCY, CURRENT and
CTRL LOC.
Application macros
87

The figure below shows the external control connections for the Hand/Auto macro.
The markings of the standard I/O terminals on the RMIO board are shown.
1) Selection between two external

X20
control locations, EXT1 and EXT2. 1 VREF Reference voltage -10 VDC
2)
See parameter 21.09. X21
1 VREF Reference voltage 10 VDC, kohm < RL <
2 GND 10 kohm
3 AI1+ Speed reference (Hand control). 0(2) … 10 V,
4 AI1- Rin > 200 kohm
5 AI2+ Speed reference (Auto control). 0(4) …
6 AI2- 20 mA, Rin = 100 ohm
7 AI3+ By default, not in use. 0(4) … 20 mA,
8 AI3- Rin = 100 ohm.
rpm 9 AO1+ Motor speed 0(4) … 20 mA = 0 … motor nom.
12 AO2- nom. current, RL < 700 ohm
X22
1 DI1 Stop/Start (Hand control)
2 DI2 Forward/Reverse (Hand control)
3 DI3 Hand/Auto control select 1)
4 DI4 Constant speed 4: Par. 12.05
5 DI5 Forward/Reverse (Auto control)
6 DI6 Stop/Start (Auto control)
7 +24 V +24 VDC, max. 100 mA
8 +24 V
X23
X25
2 RO12 Ready
3 RO13
X26
2 RO22 Running
3 RO23
X27
3 R033
Application macros
88
PID Control macro

The PID Control macro is used for controlling a process variable – such as pressure
or flow – by controlling the speed of the driven motor.
Process reference signal is connected to analogue input AI1 and process feedback
signal to analogue input AI2.
Alternatively, a direct speed reference can be given to the drive through analogue
input AI1. Then the PID controller is bypassed and the drive no longer controls the
process variable. Selection between the direct speed control and the process
variable control is done with digital input DI3.
default signals on the display of the control panel are SPEED, ACTUAL VALUE1 and
CONTROL DEVIATION.
Connection example, 24 VDC / 4…20 mA two-wire sensor
X21 / RMIO board

4…20 mA 5 AI2+ Process actual value measurement. 0(4) …
P
I 6 AI2- 20 mA, Rin = 100 ohm
…
X23 / RMIO board
Note: The sensor is supplied through its current output. Thus the output signal must
be 4…20 mA, not 0…20 mA.
Application macros
89

The figure below shows the external control connections for the PID Control macro.
The markings of the standard I/O terminals on the RMIO board are shown.
1) Selection between two external

X20
control locations, EXT1 and EXT2 1 VREF Reference voltage -10 VDC
2) In use only when the speed control X21
is active (DI3 = 0) 1 VREF Reference voltage 10 VDC
3) Off = Run Enable off. Drive will not 3 AI1+ Speed ref. (speed cntrl) or process ref.
4 AI1- (process cntrl). 0(2) … 10 V, Rin > 200 kohm
start or stops. On = Run Enable on.
Normal operation. PT
5 AI2+ Process actual value measurement. 0(4) …
6 AI2- 20 mA, Rin = 100 ohm
5)
4)
7 AI3+ By default, not in use. 0(4) … 20 mA, Rin =
See parameter 21.09. 8 AI3- 100 ohm.
rpm 9 AO1+ Motor speed 0(4) … 20 mA =
5)The sensor needs to be powered. 10 AO1- 0 … motor nom. speed, RL < 700 ohm
See the manufacturer’s instructions. A 11 AO2+ Output current 0(4) … 20 mA =
A connection example of a two-wire 12 AO2- 0 … motor nom. current, RL < 700 ohm
24 VDC / 4…20 mA sensor is shown X22
on previous page. 1 DI1 Stop/Start (speed control)
2 DI2 By default, not in use.
3 DI3 Speed / process control select 1)
4 DI4 Constant speed 4: Par. 12.05 2)
5 DI5 Run Enable. 3)
6 DI6 Stop/Start (process control)
7 +24 V +24 VDC, max. 100 mA
8 +24 V
X23
X25
2 RO12 Ready
3 RO13
X26
2 RO22 Running
3 RO23
X27
3 R033
Application macros
90
Torque Control macro

Torque Control macro is used in applications in which torque control of the motor is
required. Torque reference is given through analogue input AI2 as a current signal.
By default, 0 mA corresponds to 0 %, and 20 mA to 100 % of the rated motor torque.
The Start/Stop/Direction commands are given through digital inputs DI1 and DI2.
The Run Enable signal is connected to DI6.
Through digital input DI3 it is possible to select speed control instead of torque
control. It is also possible to change the external control location to local (i.e. to
control panel) by pressing the LOC/REM key. The panel controls the speed by
default. If torque control with panel is required, the value of parameter 11.01 should
be changed to REF2 (%).
default signals on the display of the control panel are SPEED, TORQUE and CTRL
LOC.
Application macros
91

The figure below shows the external control connections for the Torque Control
macro. The markings of the standard I/O terminals on the RMIO board are shown.
1) Selection between external control

X20
locations EXT1 and EXT2 1 VREF Reference voltage -10 VDC
2) In use only when the speed control X21
is active (DI3 = 0) 1 VREF Reference voltage 10 VDC
3) 3 AI1+ Speed reference. 0(2) … 10 V, Rin >
Off = Ramp times according to par.
4 AI1- 200 kohm
22.02 and 22.03. On = Ramp times
according to par. 22.04 and 22.05. 5 AI2+ Torque reference. 0(4) … 20 mA, Rin = 100
6 AI2- ohm
4) Off = Run Enable off. Drive will not
8 AI3- 100 ohm
start or stops. On = Run Enable on.
rpm 9 AO1+ Motor speed 0(4) … 20 mA = 0 … motor nom.
Normal operation.
5) See parameter 21.09. 12 AO2- nom. current, RL < 700 ohm
X22
1 DI1 Stop/Start
2 DI2 Forward/Reverse
3 DI3 Speed / torque control select 1)
4 DI4 Constant speed 4: Par. 12.05 2)
5 DI5 Acceleration & deceleration select 3)
6 DI6 Run Enable 4)
7 +24 V +24 VDC, max. 100 mA
8 +24 V
X23
X25
2 RO12 Ready
3 RO13
X26
2 RO22 Running
3 RO23
X27
3 R033
Application macros
92
Sequential Control macro

This macro offers seven preset constant speeds which can be activated by digital
inputs DI4 to DI6. Two acceleration/deceleration ramps are preset. The acceleration
and deceleration ramps are applied according to the state of digital input DI3. The
Start/Stop and Direction commands are given through digital inputs DI1 and DI2.
External speed reference can be given through analogue input AI1. The reference is
active only when all of the digital inputs DI4 to DI6 are 0 VDC. Giving operational
commands and setting reference is possible also from the control panel.
Two analogue and three relay output signals are available on terminal blocks.
Default stop mode is ramp. The default signals on the display of the control panel are
FREQUENCY, CURRENT and POWER.
Operation diagram
The figure below shows an example of the use of the macro.
Speed
Speed 3
Stop with
Speed 2 deceleration
ramp
Speed 1
Time
Accel1 Accel1 Accel2 Decel2
Start/Stop
Accel1/Decel1
Speed 1
Speed 2
Accel2/Decel2
Speed 3
Application macros
93

The figure below shows the external control connections for the Sequential Control
macro. The markings of the standard I/O terminals on the RMIO board are shown.
1) Off = Ramp times according to par.

X20
22.02 and 22.03. On = Ramp times 1 VREF Reference voltage -10 VDC
according to par. 22.04 and 22.05. 2 GND 1 kohm < RL < 10 kohm
X21
2)
See parameter group 12 1 VREF Reference voltage 10 VDC
CONSTANT SPEEDS: 2 GND 1 kohm < RL < 10 kohm
3 AI1+ External speed reference 0(2) … 10 V, Rin >
DI4 DI5 DI6 Operation
4 AI1- 200 kohm
0 0 0 Set speed through AI1
1 0 0 Speed 1 6 AI2- 100 ohm
0 1 0 Speed 2 7 AI3+ By default, not in use. 0(4) … 20 mA, Rin =
1 1 0 Speed 3 8 AI3- 100 ohm
0 0 1 Speed 4 rpm 9 AO1+ Motor speed 0(4) … 20 mA = 0 … motor nom.
1 0 1 Speed 5 10 AO1- speed, RL < 700 ohm
0 1 1 Speed 6 A 11 AO2+ Output current 0(4) … 20 mA = 0 … motor
1 1 1 Speed 7 12 AO2- nom. current, RL < 700 ohm
X22
1 DI1 Stop/Start
3)
See parameter 21.09. 2 DI2 Forward/Reverse
3 DI3 Acceleration & deceleration selection 1)
7 +24 V +24 VDC, max. 100 mA
8 +24 V
X23
X25
2 RO12 Ready
3 RO13
X26
2 RO22 Running
3 RO23
X27
3 R033
Application macros
94
User macros
In addition to the standard application macros, it is possible to create two user
macros. The user macro allows the user to save the parameter settings including
Group 99, and the results of the motor identification into the permanent memory, and
recall the data at a later time. The panel reference is also saved, if the macro is
saved and loaded in Local control mode. Remote control location setting is saved
into the user macro, but Local control location setting is not.
To create User Macro 1:
• Adjust the parameters. Perform the motor identification if not performed yet.
• Save the parameter settings and the results of the motor identification by
changing parameter 99.02 to USER 1 SAVE (press ENTER). The storing takes 20
s to 1 min.
Note: If user macro save function is executed several times, drive memory fills up
and file compression starts. File compression can last up to 10 minutes. Macro
saving will be completed after the file compression. (Operation is indicated on the
last row of the control panel display by blinking dots).
To recall the user macro:
• Change parameter 99.02 to USER 1 LOAD.
• Press ENTER to load.
The user macro can also be switched via digital inputs (see parameter 16.05).
Note: User macro load restores also the motor settings in group 99 START-UP
DATA and the results of the motor identification. Check that the settings correspond
to the motor used.
Example: The user can switch the drive between two motors without having to
adjust the motor parameters and to repeat the motor identification every time the
motor is changed. The user needs only to adjust the settings and perform the motor
identification once for both motors and then to save the data as two user macros.
When the motor is changed, only the corresponding User macro needs to be loaded,
and the drive is ready to operate.
Application macros
95
Chapter overview
The chapter describes the actual signals and parameters and gives the fieldbus
equivalent values for each signal/parameter. More data is given in chapter Additional
data: actual signals and parameters.
Terms and abbreviations

Term Definition
Absolute Maximum Value of 20.08, or 20.07 if the absolute value of the minimum limit is
Frequency greater than the maximum limit.
Absolute Maximum Value of parameter 20.02, or 20.01 if the absolute value of the minimum
Speed limit is higher than the maximum limit.
Actual signal Signal measured or calculated by the drive. Can be monitored by the
user. No user setting possible.
FbEq Fieldbus equivalent: The scaling between the value shown on the panel
and the integer used in serial communication.
Parameter A user-adjustable operation instruction of the drive.

96
No. Name/Value Description FbEq

01 ACTUAL SIGNALS Basic signals for monitoring of the drive.
01.01 PROCESS VARIABLE Process variable based on settings in parameter group 34 PROCESS 1=1
VARIABLE.
01.02 SPEED Calculated motor speed in rpm. Filter time setting by parameter 34.04. -20000 =
-100% 20000
= 100% of
motor abs.
max. speed
01.03 FREQUENCY Calculated drive output frequency. -100 = -1 Hz
100 = 1 Hz
01.04 CURRENT Measured motor current. 10 = 1 A
01.05 TORQUE Calculated motor torque. 100 is the motor nominal torque. Filter time -10000 =
setting by parameter 34.05. -100% 10000
= 100% of
motor nom.
torque
01.06 POWER Motor power. 100 is the nominal power. -1000 =
-100% 1000 =
100% of motor
nom. power
01.07 DC BUS VOLTAGE V Measured intermediate circuit voltage. 1=1V
01.08 MAINS VOLTAGE Calculated supply voltage. 1=1V
01.09 OUTPUT VOLTAGE Calculated motor voltage. 1=1V
01.10 ACS800 TEMP Calculated IGBT temperature. 10 = 1%
01.11 EXTERNAL REF 1 External reference REF1 in rpm. (Hz if value of parameter 99.04 is 1 = 1 rpm
SCALAR.)
01.12 EXTERNAL REF 2 External reference REF2. Depending on the use, 100% is the motor 0 = 0% 10000
maximum speed, motor nominal torque, or maximum process reference. = 100% 1)
01.13 CTRL LOCATION Active control location. (1,2) LOCAL; (3) EXT1; (4) EXT2. See section See descr.
Local control vs. external control on page 43.
01.14 OP HOUR COUNTER Elapsed time counter. Runs when the control board is powered. 1=1h
01.15 KILOWATT HOURS kWh counter. Counts inverter output kWh during operation (motor side - 1 = 100 kWh
generator side).
01.16 APPL BLOCK OUTPUT Application block output signal. E.g. the process PID controller output 0 = 0% 10000
when the PID Control macro is active. = 100%
01.17 DI6-1 STATUS Status of digital inputs. Example: 0000001 = DI1 is on, DI2 to DI6 are off.
01.18 AI1 [V] Value of analogue input AI1. 1 = 0.001 V
01.19 AI2 [mA] Value of analogue input AI2. 1 = 0.001 mA
01.20 AI3 [mA] Value of analogue input AI3. 1 = 0.001 mA
01.21 RO3-1 STATUS Status of relay outputs. Example: 001 = RO1 is energised, RO2 and
RO3 are de-energised.
01.22 AO1 [mA] Value of analogue output AO1. 1 =0.001 mA

97

01.23 AO2 [mA] Value of analogue output AO2. 1 = 0.001 mA
01.24 ACTUAL VALUE 1 Feedback signal for the process PID controller. Updated only when 0 = 0% 10000
parameter 99.02 = PD CTRL = 100%
01.25 ACTUAL VALUE 2 Feedback signal for the process PID controller. Updated only when 0 = 0% 10000
parameter 99.02 = PID CTRL. = 100%
01.26 CONTROL DEVIATION Deviation of the process PID controller, i.e. the difference between the -10000 =
reference value and the actual value. Updated only when parameter -100% 10000
99.02 = PID CTRL. = 100%
01.27 APPLICATION MACRO Active application macro (value of parameter 99.02). See 99.02
01.28 EXT AO1 [mA] Value of output 1 of the analogue I/O extension module (optional). 1 = 0.001 mA
01.29 EXT AO2 [mA] Value of output 2 of the analogue I/O extension module (optional). 1 = 0.001 mA
01.30 PP 1 TEMP Measured heatsink temperature in inverter no. 1. 1 = 1°C
01.31 PP 2 TEMP Measured heatsink temperature in inverter no. 2 (used only in high power 1 = 1°C
units with parallel inverters).
01.34 ACTUAL VALUE Process PID controller actual value. See parameter 40.06. 0 = 0%
10000 = 100%
01.35 MOTOR 1 TEMP Measured temperature of motor 1. See parameter 35.01. 1 = 1°C/ohm
01.36 MOTOR 2 TEMP Measured temperature of motor 2. See parameter 35.04. 1 = 1°C/ohm
01.37 MOTOR TEMP EST Estimated motor temperature. Signal value is saved at power switch off. 1 = 1°C
01.38 AI5 [mA] Value of analogue input AI5 read from AI1 of the analogue I/O extension 1 = 0.001 mA
module (optional). A voltage signal is also displayed in mA (instead of V).
01.39 AI6 [mA] Value of analogue input AI6 read from AI2 of the analogue I/O extension 1 = 0.001 mA
module (optional). A voltage signal is also displayed in mA (instead of V).
01.40 DI7-12 STATUS Status of digital inputs DI7 to DI12 read from the digital I/O extension 1=1
modules (optional). E.g. value 000001: DI7 is on, DI8 to DI12 are off.
01.41 EXT RO STATUS Status of the relay outputs on the digital I/O extension modules (optional). 1 = 1
E.g. value 0000001: RO1 of module 1 is energised. Other relay outputs
are de-energised.
01.42 PROCESS SPEED REL Motor actual speed in percent of the Absolute Maximum Speed. If 1=1
parameter 99.04 is SCALAR, the value is the relative actual output
frequency.
01.43 MOTOR RUN TIME Motor run time counter. The counter runs when the inverter modulates. 1 = 10 h
Can be reset by parameter 34.06.
01.44 FAN ON-TIME Running time of the drive cooling fan. 1 = 10 h
Note: Resetting of the counter is recommended when the fan is replaced.
For more information, contact your local ABB representative.
01.45 CTRL BOARD TEMP Control board temperature. 1 = 1°C
02 ACTUAL SIGNALS Speed and torque reference monitoring signals.
02.01 SPEED REF 2 Limited speed reference. 100% corresponds to the Absolute Maximum 0 = 0% 20000
Speed of the motor. = 100% of
motor
absolute max.
speed

98

02.02 SPEED REF 3 Ramped and shaped speed reference. 100% corresponds to the 20000 = 100%
Absolute Maximum Speed of the motor.
02.09 TORQUE REF 2 Speed controller output. 100% corresponds to the motor nominal torque. 0 = 0% 10000
= 100% of
motor nominal
torque
02.10 TORQUE REF 3 Torque reference. 100% corresponds to the motor nominal torque. 10000 = 100%
02.13 TORQ USED REF Torque reference after frequency, voltage and torque limiters. 100% 10000 = 100%
corresponds to the motor nominal torque.
02.14 FLUX REF Flux reference in percent. 10000 = 100%
02.17 SPEED ESTIMATED Estimated motor speed. 100% corresponds to the Absolute Maximum 20000 = 100%
Speed of the motor.
02.18 SPEED MEASURED Measured motor actual speed (zero when no encoder is used). 100% 20000 = 100%
corresponds to the Absolute Maximum Speed of the motor.
02.19 MOTOR ACCELERATIO Calculated motor acceleration from signal 01.02 MOTOR SPEED. 1=1 rpm/s.
02.20 USER CURRENT Measured motor current in percent of the user load curve current. User 10 = 1%
load curve current is defined by parameters 72.02...72.09. See section
User load curve on page 81.
03 ACTUAL SIGNALS Data words for monitoring of fieldbus communication (each signal is a 16- 2)
bit data word).
03.01 MAIN CTRL WORD A 16-bit data word. See section 03.01 MAIN CONTROL WORD on page
205.
03.02 MAIN STATUS WORD A 16-bit data word. See section 03.02 MAIN STATUS WORD on page
206.
03.03 AUX STATUS WORD A 16-bit data word. See section 03.03 AUXILIARY STATUS WORD on
page 213.
03.04 LIMIT WORD 1 A 16-bit data word. See section 03.04 LIMIT WORD 1 on page 214.
03.05 FAULT WORD 1 A 16-bit data word. See section 03.05 FAULT WORD 1 on page 214.
03.07 SYSTEM FAULT A 16-bit data word. See section 03.07 SYSTEM FAULT WORD on page
216.
03.08 ALARM WORD 1 A 16-bit data word. See section 03.08 ALARM WORD 1 on page 216.
03.11 FOLLOWER MCW A 16-bit data word. For the contents, see Master/Follower Application
Guide [3AFE64590430 (English)].
03.13 AUX STATUS WORD 3 A 16-bit data word. See section 03.13 AUXILIARY STATUS WORD 3 on
page 217.
03.14 AUX STATUS WORD 4 A 16-bit data word. See section 03.14 AUXILIARY STATUS WORD 4 on
page 218.
03.19 INT INIT FAULT A 16-bit data word. See section 03.19 INT INIT FAULT on page 220.
03.20 LATEST FAULT Fieldbus code of the latest fault. See chapter Fault tracing for the codes.
03.21 2.LATEST FAULT Fieldbus code of the 2nd latest fault.

99

03.22 3.LATEST FAULT Fieldbus code of the 3rd latest fault.
03.23 4.LATEST FAULT Fieldbus code of the 4th latest fault.
03.24 5.LATEST FAULT Fieldbus code of the 5th latest fault.
03.25 LATEST WARNING Fieldbus code of the latest warning.
03.26 2.LATEST WARNING Fieldbus code of the 2nd latest warning.
03.27 3.LATEST WARNING Fieldbus code of the 3rd latest warning.
03.28 4.LATEST WARNING Fieldbus code of the 4th latest warning.
03.29 5.LATEST WARNING Fieldbus code of the 5th latest warning.
03.30 LIMIT WORD INV A 16-bit data word. See section 03.30 LIMIT WORD INV on page 221.
03.32 EXT IO STATUS Status of emergency stop and step up modules. See section 03.32 EXT
IO STATUS on page 222.
04 ACTUAL SIGNALS Signals for parallel connected inverters 2)
04.01 FAULTED INT INFO A 16-bit data word. See section 04.01 FAULTED INT INFO on page 223.
04.02 INT SC INFO A 16-bit data word. See section 04.02 INT SC INFO on page 224.
09 ACTUAL SIGNALS Signals for the Adaptive Program
09.01 AI1 SCALED Value of analogue input AI1 scaled to an integer value. 20000 = 10 V
09.02 AI2 SCALED Value of analogue input AI2 scaled to an integer value. 20000 = 20
mA
mA
mA
mA
09.06 DS MCW Control Word (CW) of the Main Reference data set received from the 0 ... 65535
master station through the fieldbus interface (Decimal)
09.07 MASTER REF1 Reference 1 (REF1) of the Main Reference data set received from the -32768 …
master station through the fieldbus interface 32767
09.08 MASTER REF2 Reference 2 (REF2) of the Main Reference data set received from the -32768 …
master station through the fieldbus interface 32767
09.09 AUX DS VAL1 Auxiliary data set value 1 received from the master station through the -32768 …
fieldbus interface 32767
09.12 LCU ACT SIGNAL1 Line-side converter signal selected by parameter 95.08. A 16-bit data
word.
09.13 LCU ACT SIGNAL2 Line-side converter signal selected by parameter 95.09. A 16-bit data
word.
1) Percent of motor maximum speed / nominal torque / maximum process reference (depending on the
ACS800 macro selected).
2) The contents of these data words are detailed in chapter Fieldbus control.

100
Index Name/Selection Description FbEq

10 START/STOP/DIR The sources for external start, stop and direction control
10.01 EXT1 STRT/STP/DIR Defines the connections and the source of the start, stop and direction
commands for external control location 1 (EXT1).
NOT SEL No start, stop and direction command source. 1
DI1 Start and stop through digital input DI1. 0 = stop; 1 = start. Direction is fixed 2
according to parameter 10.3 DIRECTION.
WARNING! After a fault reset, the drive will start if the start signal is
on.
DI1,2 Start and stop through digital input DI1. 0 = stop, 1 = start. Direction through 3
digital input DI2. 0 = forward, 1 = reverse. To control direction, parameter 10.03
DIRECTION must be REQUEST.
WARNING! After a fault reset, the drive will start if the start signal is
on.
DI1P,2P Pulse start through digital input DI1. 0 -> 1: Start. Pulse stop through digital 4
input DI2. 1 -> 0: Stop. Direction of rotation is fixed according to parameter
10.03 DIRECTION.
DI1P,2P,3 Pulse start through digital input DI1. 0 -> 1: Start. Pulse stop through digital 5
input DI2. 1 -> 0: Stop. Direction through digital input DI3. 0 = forward, 1 =
reverse. To control direction, parameter 10.03 DIRECTION must be
REQUEST.
DI1P,2P,3P Pulse start forward through digital input DI1. 0 -> 1: Start forward. Pulse start 6
reverse through digital input DI2. 0 -> 1: Start reverse. Pulse stop through
digital input DI3. 1 -> ”0”: stop. To control the direction, parameter 10.03
DIRECTION must be REQUEST.
DI6 See selection DI1. 7
DI6,5 See selection DI1,2. DI6: Start/stop, DI5: direction. 8
KEYPAD Control panel. To control the direction, parameter 10.03 DIRECTION must be 9
REQUEST.
COMM.CW Fieldbus Control Word. 10
DI7,8 See selection DI1,2. DI7: start/stop, DI8: direction. 12
DI7P,8P See selection DI1P,2P. 13
DI7P,8P,9 See selection DI1P,2P,3. 14
DI7P,8P,9P See selection DI1P,2P,3P. 15
PARAM 10.04 Source selected by 10.04. 16
DI1 F, DI2 R Start, stop and direction commands through digital inputs DI1 and DI2. 17
DI1 DI2 Operation

0 0 Stop
1 0 Start forward
0 1 Start reverse
1 1 Stop
Note: Parameter 10.03 DIRECTION must be REQUEST.

10.02 EXT2 STRT/STP/DIR Defines the connections and the source of the start, stop and direction
commands for external control location 2 (EXT2).
NOT SEL See parameter 10.01. 1

101

DI1 See parameter 10.01. 2
DI1,2 See parameter 10.01. 3
DI1P,2P See parameter 10.01. 4
DI1P,2P,3 See parameter 10.01. 5
DI1P,2P,3P See parameter 10.01. 6
KEYPAD See parameter 10.01. 9
COMM.CW See parameter 10.01. 10
DI7P,8P See parameter 10.01. 13
DI7P,8P,9 See parameter 10.01. 14
DI7P,8P,9P See parameter 10.01. 15
DI1 F, DI2 R See parameter 10.01. 17
10.03 REF DIRECTION Enables the control of rotation direction of the motor, or fixes the direction.
FORWARD Fixed to forward 1
REVERSE Fixed to reverse 2
REQUEST Direction of rotation control allowed 3
10.04 EXT 1 STRT PTR Defines the source or constant for value PAR 10.04 of parameter 10.01.
-255.255.31 … Parameter index or a constant value: -
+255.255.31 / C.- - Parameter pointer: Inversion, group, index and bit fields. The bit number is
32768 … C.32767 effective only for blocks handling boolean inputs.
- Constant value: Inversion and constant fields. Inversion field must have value
C to enable the constant setting.
10.05 EXT 2 STRT PTR Defines the source or constant for value PAR 10.05 of parameter 10.02.
-255.255.31 … Parameter index or a constant value. See parameter 10.04 for information on -
+255.255.31 / C.- the difference.
32768 … C.32767
10.06 JOG SPEED SELECT Defines the signal that activates jogging function. The operation of the jogging
is explained in section Jogging on page 79.
NOT SEL Not selected. 1
DI3 Digital input DI3. 0 = Jogging is inactive. 1 = Jogging is active. 2

102

10.07 NET CONTROL When active, fieldbus overrides the selection of parameter 10.01. Fieldbus
Control Word (except bit 11) is enabled when EXT1 is selected as the active
control location.
Note: Only visible with the Generic Drive communication profile selected
(98.07).
Note: The setting is not saved in the permanent memory (will reset to zero
when power is switched off).
0 Inactive 0
1 Active 1
10.08 NET REFERENCE When active, fieldbus overrides the selection of parameter 11.03. Fieldbus
reference REF1 is enabled when EXT1 is selected as the active control
location.
Note: Only visible with the Generic Drive communication profile selected
(98.07).
Note: The setting is not saved in the permanent memory (will reset to zero
when power is switched off).
0 Inactive 0
1 Active 1
11 REFERENCE Panel reference type, external control location selection and external reference
SELECT sources and limits
11.01 KEYPAD REF SEL Selects the type of the reference given from panel.
REF1 (rpm) Speed reference in rpm. (Frequency reference (Hz) if parameter 99.04 is 1
SCALAR.)
REF2 (%) %-reference. The use of REF2 vary depending on the application macro. For 2
example, if the Torque Control macro is selected, REF2 is the torque
reference.
11.02 EXT1/EXT2 SELECT Defines the source from which the drive reads the signal that selects between
the two external control locations, EXT1 or EXT2.
DI1 Digital input DI1. 0 = EXT1, 1 = EXT2. 1
EXT1 EXT1 active. The control signal sources are defined by parameter 10.01 and 7
11.03.
EXT2 EXT2 active. The control signal sources are defined by parameter 10.02 and 8
11.06.
COMM.CW Fieldbus Control Word, bit 11. 9
PARAM 11.09 Source selected by parameter 11.09. 16

103

11.03 EXT REF1 SELECT Selects the signal source for external reference REF1
KEYPAD Control panel. The first line on the display shows the reference value. 1
AI1 Analogue input AI1. 2
Note: If the signal is bipolar (±10 VDC), use the selection AI1 BIPOLAR. (The
selection AI1 ignores the negative signal range.)
AI1/JOYST Unipolar analogue input AI1 as joystick. The minimum input signal runs the 5
motor at the maximum reference in the reverse direction, the maximum input at
the maximum reference in the forward direction.
Note: Parameter 10.03 must have the value REQUEST.
WARNING! Minimum reference for joystick must be higher than 0.5 V.
Set parameter 13.01 to 2 V or to a value higher than 0.5 V and
analogue signal loss detection parameter 30.01 to FAULT. The drive
will stop in case the control signal is lost.
Speed Reference (REF1)
11.05
11.04
0
AI1
-11.04
-11.05
2 6 10
Par. 13.01 = 2 V, Par 13.02 = 10 V
Note: If the signal is bipolar (±10 VDC), use the selection AI1 BIPOLAR. The
selection AI1/JOYST ignores the negative signal range.
AI2/JOYST See selection AI1/JOYST. 6
AI1+AI3 Summation of analogue input AI1 and AI3 7
AI2+AI3 Summation of analogue input AI2 and AI3 8
AI1-AI3 Subtraction of analogue input AI1 and AI3 9
AI2-AI3 Subtraction of analogue input AI2 and AI3 10
AI1*AI3 Multiplication of analogue input AI1 and AI3 11
AI2*AI3 Multiplication of analogue input AI2 and AI3 12
MIN(AI1,AI3) Minimum of analogue input AI1 and AI3 13
MIN(AI2,AI3) Minimum of analogue input AI2 and AI3 14
MAX(AI1,AI3) Maximum of analogue input AI1 and AI3 15
MAX(AI2,AI3) Maximum of analogue input AI2 and AI3 16
DI3U,4D(R) Digital input 3: Reference increase. Digital input DI4: Reference decrease. 17
Stop command or power switch off resets the reference to zero. Parameter
22.04 defines the rate of the reference change.

104

DI3U,4D Digital input 3: Reference increase. Digital input DI4: Reference decrease. The 18
program stores the active speed reference (not reset by a stop command or
power switch-off). Parameter 22.04 defines the rate of the reference change.
DI5U,6D See selection DI3U,4D. 19
COMM. REF Fieldbus reference REF1 20
COM.REF1+AI1 Summation of fieldbus reference REF1 and analogue input AI1 21
COM.REF1*AI1 Multiplication of fieldbus reference REF1 and analogue input AI1 22
FAST COMM As with the selection COMM. REF, except the following differences: 23
- shorter communication cycle time when transferring the reference to the core
motor control program (6 ms -> 2 ms)
- the direction cannot be controlled through interfaces defined by parameters
10.01 or 10.02, nor with the control panel
- parameter group 25 CRITICAL SPEEDS is not effective
Note: If any of the following selections is true, the selection is not effective.
Instead, the operation is according to COMM. REF.
- parameter 99.02 is PID
- parameter 99.04 is SCALAR
- parameter 40.14 has value PROPORTIONAL or DIRECT
COM.REF1+AI5 See selection COM.REF1+AI1 (AI5 used instead of AI1). 24
COM.REF1*AI5 See selection COM.REF1*AI1 (AI5 used instead of AI1). 25
AI5 Analogue input AI5 26
AI5+AI6 Summation of analogue input AI5 and AI6. 30
AI5-AI6 Subtraction of analogue input AI5 and AI6. 31
AI5*AI6 Multiplication of analogue input AI5 and AI6. 32
MIN(AI5,AI6) Lower of analogue input AI5 and AI6. 33
MAX(AI5,AI6) Higher of analogue input AI5 and AI6. 34
DI11U,12D(R) See selection DI3U,4D(R). 35
DI11U,12D See selection DI3U,4D. 36

105

AI1 BIPOLAR Bipolar analogue input AI1 (-10 … 10 V). The figure below illustrates the use of 38
the input as the speed reference.
Operation Range
scaled
maxREF1
10.03 DIRECTION =
FORWARD or
REQUEST
Speed Reference
minREF1
-minREF1
10.03 DIRECTION =
REVERSE or
REQUEST
-scaled
maxREF1
-maxAI1 -minAI1 minAI1 maxAI1
Analogue Input Signal
minAI1 = 13.01 MINIMUM AI1

maxAI1 = 13.02 MAXIMUM AI1
scaled maxREF1 = 13.03 SCALE AI1 x 11.05 EXT REF1 MAXIMUM
minREF1 = 11.04 EXT REF1 MINIMUM
11.04 EXT REF1 MINIMUM Defines the minimum value for external reference REF1 (absolute value).
Corresponds to the minimum setting of the source signal used.
0 … 18000 rpm Setting range in rpm. (Hz if parameter 99.04 is SCALAR.) 1 … 18000
Example: Analogue input AI1 is selected as the reference source (value of
parameter 11.03 is AI1). The reference minimum and maximum correspond
the AI minimum and maximum settings as follows:
EXT REF1 Range
2’
1 parameter 13.01
2 parameter 13.02
1’ parameter 11.04
2’ parameter 11.05
1’
AI1 Range
1 2
Note: If the reference is given through fieldbus, the scaling differs from that of
an analogue signal. See chapter Fieldbus control for more information.

106

11.05 EXT REF1 MAXIMUM Defines the maximum value for external reference REF1 (absolute value).
Corresponds to the maximum setting of the used source signal.
0 … 18000 rpm Setting range. (Hz if value of parameter 99.04 is SCALAR.) 1 … 18000
See parameter 11.04.
11.06 EXT REF2 SELECT Selects the signal source for external reference REF2. REF2 is a
- speed reference in percent of the Absolute Maximum Speed if parameter
99.02 = FACTORY, HAND/AUTO or SEQ CTRL.
- torque reference in percent of the motor nominal torque if parameter 99.02 =
TORQUE.
- process reference in percent of the maximum process quantity if parameter
99.02 = PID CTRL.
- frequency reference in percent of the Absolute Maximum Frequency if
parameter 99.04 = SCALAR.
KEYPAD See parameter 11.03. 1
AI1 See parameter 11.03. 2
Note: If the signal is bipolar (±10 VDC), use the selection AI1 BIPOLAR. The
selection AI1 ignores the negative signal range.
AI1/JOYST See parameter 11.03. 5
AI1+AI3 See parameter 11.03. 7
AI1-AI3 See parameter 11.03. 9
AI1*AI3 See parameter 11.03. 11
MIN(AI1,AI3) See parameter 11.03. 13
MAX(AI1,AI3) See parameter 11.03. 15
DI3U,4D(R) See parameter 11.03. 17
DI3U,4D See parameter 11.03. 18
COMM. REF See parameter 11.03. 20
COM.REF2+AI1 See parameter 11.03. 21
COM.REF2*AI1 See parameter 11.03. 22
FAST COMM See parameter 11.03. 23
COM.REF2+AI5 See parameter 11.03. 24
COM.REF2*AI5 See parameter 11.03. 25

107

DI11U,12D(R) See parameter 11.03. 35
AI1 BIPOLAR See parameter 11.03. 38
11.07 EXT REF2 MINIMUM Defines the minimum value for external reference REF2 (absolute value).
Corresponds to the minimum setting of the source signal used.
0 … 100% Setting range in percent. Correspondence to the source signal limits: 0 … 10000
- Source is an analogue input: See example for parameter 11.04.
- Source is a serial link: See chapter Fieldbus control.
11.08 EXT REF2 MAXIMUM Defines the maximum value for external reference REF2 (absolute value).
Corresponds to the maximum setting of the source signal used.
0 … 600% Setting range. Correspondence to the source signal limits: 0 … 6000
- Source is an analogue input: See parameter 11.04.
- Source is a serial link: See chapter Fieldbus control.
11.09 EXT 1/2 SEL PTR Defines the source or constant for value PAR 11.09 of parameter 11.02.
32768 … C.32767
11.10 EXT 1 REF PTR Defines the source or constant for value PAR 11.10 of parameter 11.03.
32768 … C.32767
11.11 EXT 2 REF PTR Defines the source or constant for value PAR 11.11 of parameter 11.06.
32768 … C.32767
12 CONSTANT SPEEDS Constant speed selection and values. An active constant speed overrides the
drive speed reference. See section Constant speeds on page 57.
Note: If parameter 99.04 is SCALAR, only speeds 1 to 5 and speed 15 are in
use.
12.01 CONST SPEED SEL Activates the constant speeds or selects the activation signal.
NOT SEL No constant speeds in use 1
DI1(SPEED1) Speed defined by parameter 12.02 is activated through digital input DI1. 2
1 = active, 0 = inactive.

108

DI1,2 Constant speed selection through digital input DI1 and DI2. 8
DI1 DI2 Constant speed in use

0 0 No constant speed
1 0 Speed defined by parameter 12.02
DI3,4 See selection DI1,2. 9

DI1,2,3 Constant speed selection through digital input DI1, DI2 and DI3. 11
DI1 DI2 DI3 Constant speed in use

0 0 0 No constant speed
1 0 0 Speed defined by parameter 12.02
DI3,4,5 See selection DI1,2,3. 12

DI4,5,6 See selection DI1,2,3. 13
DI3,4,5,6 Constant speed selection through digital input DI3, 4, 5 and 6 14
DI1 DI2 DI3 DI4 Constant speed in use

0 0 0 0 No constant speed
1 0 0 0 Speed defined by parameter 12.02

109

DI12 (SPEED6) Speed defined by parameter 12.07 is activated through digital input DI12. 20
12.02 CONST SPEED 1 Defines speed 1. An absolute value. Does not include the direction information.
0 … 18000 rpm Setting range 0 … 18000
12.11 CONST SPEED 10 Defines speed 10. An absolute value. Does not include the direction
information.
information.
information.
Note: If inching is in use, the parameter defines the inching 1 speed. The sign
is taken into account. See chapter Fieldbus control.
-18000 … 18000 rpm Setting range -18000 …
18000

110

information.
Note: If inching is in use, the parameter defines the inching 2 speed. The sign
is taken into account. See chapter Fieldbus control.
18000
information.
Note: If the jogging function is in use, the parameter defines the jogging speed.
The sign is not taken into account. See section Jogging on page 79.
12.16 CONST SPEED 15 Defines speed 15 or Fault speed. The program considers the sign when used
as a fault speed by parameter 30.01 and 30.02.
18000
13 ANALOGUE INPUTS The analogue input signal processing. See section Programmable analogue
inputs on page 49.
13.01 MINIMUM AI1 Defines the minimum value for analogue input AI1. When used as a reference,
the value corresponds to the reference minimum setting.
Example: If AI1 is selected as the source for external reference REF1, this
value corresponds to the value of parameter 11.04.
0V Zero volts. Note: The program cannot detect a loss of analogue input signal. 1
2V Two volts 2
TUNED VALUE The value measured by the tuning function. See the selection TUNE. 3
TUNE The value measurement triggering. Procedure: 4
- Connect the minimum signal to input.
- Set the parameter to TUNE.
Note: The readable range in tuning is 0 … 10 V.
13.02 MAXIMUM AI1 Defines the maximum value for analogue input AI1. When used as a reference,
the value corresponds to the reference maximum setting.
Example: If AI1 is selected as the source for external reference REF1, this
value corresponds to the value of parameter 11.05.
10 V Ten volts (DC). 1
TUNED VALUE The value measured by the tuning function. See the selection TUNE. 2
TUNE Triggering of the tuning function. Procedure: 3
- Connect the maximum signal to input.
- Set the parameter to TUNE.
Note: The readable range in tuning is 0 … 10 V.

111

13.03 SCALE AI1 Scales analogue input AI1.
Example: The effect on speed reference REF1 when:
- REF1 source selection (parameter 11.03) = AI1+AI3
- REF1 maximum value setting (parameter 11.05) = 1500 rpm
- Actual AI1 value = 4 V (40% of the full scale value)
- Actual AI3 value = 12 mA (60% of the full scale value)
- AI1 scaling = 100%, AI3 scaling = 10%
AI1 AI3 AI1 + AI3
10 V 1500 rpm 20 mA 150 rpm 1500 rpm
60% 90 rpm
690 rpm
40% 600 rpm
0V 0 mA 0 rpm
0 … 1000% Scaling range 0 … 32767

13.04 FILTER AI1 Defines the filter time constant for analogue input AI1.
%
Unfiltered Signal O = I · (1 - e-t/T)
100
I = filter input (step)
63 O = filter output
Filtered Signal
t = time
T = filter time constant
t
T
Note: The signal is also filtered due to the signal interface hardware (10 ms
time constant). This cannot be changed by any parameter.
0.00 … 10.00 s Filter time constant 0 … 1000
13.05 INVERT AI1 Activates/deactivates the inversion of analogue input AI1.
NO No inversion 0
YES Inversion active. The maximum value of the analogue input signal corresponds 65535
to the minimum reference and vice versa.
13.06 MINIMUM AI2 See parameter 13.01.
0 mA See parameter 13.01. 1
TUNED VALUE See parameter 13.01. 3
TUNE See parameter 13.01. 4
13.07 MAXIMUM AI2 See parameter 13.02.

112

13.08 SCALE AI2 See parameter 13.03.
0 … 1000% See parameter 13.03. 0 … 32767
13.09 FILTER AI2 See parameter 13.04.
0.00 … 10.00 s See parameter 13.04. 0 … 1000
13.10 INVERT AI2 See parameter 13.05.
NO See parameter 13.05. 0
YES See parameter 13.05. 65535
0 … 1000% See parameter 13.03. 0 … 32767
0.00 … 10.00 s See parameter 13.04. 0 … 1000
Note: If RAIO-01 is used with voltage input signal, 20 mA corresponds to 10 V.

0 … 1000% See parameter 13.03. 0 … 32767
0.00 … 10.00 s See parameter 13.04. 0 … 1000

113

0 … 1000% See parameter 13.03. 0 … 32767
0.00 … 10.00 s See parameter 13.04. 0 … 1000
14 RELAY OUTPUTS Status information indicated through the relay outputs, and the relay operating
delays. See section Programmable relay outputs on page 52.
14.01 RELAY RO1 OUTPUT Selects a drive status indicated through relay output RO1. The relay energises
when the status meets the setting.
NOT USED Not used. 1
READY Ready to function: Run Enable signal on, no fault. 2
RUNNING Running: Start signal on, Run Enable signal on, no active fault. 3
FAULT Fault 4
FAULT(-1) Inverted fault. Relay is de-energised on a fault trip. 5
FAULT(RST) Fault. Automatic reset after the autoreset delay. See parameter group 31 6
AUTOMATIC RESET.
STALL WARN Warning by the stall protection function. See parameter 30.10. 7
STALL FLT Fault trip by the stall protection function. See parameter 30.10. 8
MOT TEMP WRN Warning trip of the motor temperature supervision function. See parameter 9
30.04.
MOT TEMP FLT Fault trip of the motor temperature supervision function. See parameter 30.04. 10
ACS TEMP WRN Warning by the drive temperature supervision function. The warning limit 11
depends on the used inverter type.
ACS TEMP FLT Fault trip by the drive temperature supervision function. Trip limit is 100%. 12
FAULT/WARN Fault or warning active 13
WARNING Warning active 14
REVERSED Motor rotates in reverse direction. 15

114

EXT CTRL Drive is under external control. 16
REF 2 SEL External reference REF 2 is in use. 17
CONST SPEED A constant speed is in use. See parameter group 12 CONSTANT SPEEDS. 18
DC OVERVOLT The intermediate circuit DC voltage has exceeded the overvoltage limit. 19
DC UNDERVOLT The intermediate circuit DC voltage has fallen below the undervoltage limit. 20
SPEED 1 LIM Motor speed at supervision limit 1. See parameters 32.01 and 32.02. 21
SPEED 2 LIM Motor speed at supervision limit 2. See parameters 32.03 and 32.04. 22
CURRENT LIM Motor current at the supervision limit. See parameters 32.05 and 32.06. 23
REF 1 LIM External reference REF1 at the supervision limit. See parameters 32.11 and 24
32.12.
REF 2 LIM External reference REF2 at the supervision limit. See parameters 32.13 and 25
32.14.
TORQUE 1 LIM Motor torque at supervision limit 1. See parameters 32.07 and 32.08. 26
TORQUE 2 LIM Motor torque at supervision limit 2. See parameters 32.09 and 32.10. 27
STARTED The drive has received the start command. 28
LOSS OF REF The drive has no reference. 29
AT SPEED The actual value has reached the reference value. In speed control, the speed 30
error is less or equal to 10% of the nominal motor speed.
ACT 1 LIM Process PID controller variable ACT1 at the supervision limit. See parameters 31
32.15 and 32.16.
ACT 2 LIM Process PID controller variable ACT2 at the supervision limit. See parameters 32
32.17 and 32.18.
COMM.REF3(13) The relay is controlled by fieldbus reference REF3. See chapter Fieldbus 33
control.
BRAKE CTRL On/Off control of a mechanical brake. See parameter group 42 BRAKE 35
CONTROL and section Control of a mechanical brake on page 75.
BC SHORT CIR Drive trips on a brake chopper fault. See chapter Fault tracing. 36
14.02 RELAY RO2 OUTPUT Selects the drive status to be indicated through relay output RO2. The relay
energises when the status meets the setting.
NOT USED See parameter 14.01. 1
READY See parameter 14.01. 2
RUNNING See parameter 14.01. 3
FAULT See parameter 14.01. 4
FAULT(-1) See parameter 14.01. 5
FAULT(RST) See parameter 14.01. 6
STALL WARN See parameter 14.01. 7
STALL FLT See parameter 14.01. 8
MOT TEMP WRN See parameter 14.01. 9
MOT TEMP FLT See parameter 14.01. 10
ACS TEMP WRN See parameter 14.01. 11
ACS TEMP FLT See parameter 14.01. 12
FAULT/WARN See parameter 14.01. 13
WARNING See parameter 14.01. 14

115

REVERSED See parameter 14.01. 15
EXT CTRL See parameter 14.01. 16
REF 2 SEL See parameter 14.01. 17
CONST SPEED See parameter 14.01. 18
DC OVERVOLT See parameter 14.01. 19
DC UNDERVOLT See parameter 14.01. 20
SPEED 1 LIM See parameter 14.01. 21
CURRENT LIM See parameter 14.01. 23
REF 1 LIM See parameter 14.01. 24
TORQUE 1 LIM See parameter 14.01. 26
STARTED See parameter 14.01. 28
LOSS OF REF See parameter 14.01. 29
AT SPEED See parameter 14.01. 30
ACT 1 LIM See parameter 14.01. 31
ACT 2 LIM See parameter 14.01. 32
COMM. REF3(14) See parameter 14.01. 33
BRAKE CTRL See parameter 14.01. 35
BC SHORT CIR See parameter 14.01. 36
14.03 RELAY RO3 OUTPUT Selects the drive status to be indicated through relay output RO3. The relay
energises when the status meets the setting.
FAULT(-1) See parameter 14.01. 5
FAULT(RST) See parameter 14.01. 6
STALL WARN See parameter 14.01. 7
STALL FLT See parameter 14.01. 8
MOT TEMP WRN See parameter 14.01. 9
MOT TEMP FLT See parameter 14.01. 10
ACS TEMP WRN See parameter 14.01. 11
ACS TEMP FLT See parameter 14.01. 12
FAULT/WARN See parameter 14.01. 13
REVERSED See parameter 14.01. 15
EXT CTRL See parameter 14.01. 16
CONST SPEED See parameter 14.01. 18

116

DC OVERVOLT See parameter 14.01. 19
DC UNDERVOLT See parameter 14.01. 20
CURRENT LIM See parameter 14.01. 23
STARTED See parameter 14.01. 28
LOSS OF REF See parameter 14.01. 29
MAGN READY The motor is magnetised and ready to give nominal torque (nominal 31
magnetising of the motor has been reached).
USER 2 SEL User Macro 2 is in use. 32
COMM. REF3(15) See parameter 14.01. 33
BRAKE CTRL See parameter 14.01. 35
BC SHORT CIR See parameter 14.01. 36
14.04 RO1 TON DELAY Defines the operation delay for the relay RO1.
0.0 … 3600.0 s Setting range. The figure below illustrates the operation (on) and release (off) 0 … 36000
delays for relay output RO1.
1
Drive status
0
1
RO1 status
0
time
tOn tOff tOn tOff
tOn 14.04
tOff 14.05
14.05 RO1 TOFF DELAY Defines the release delay for relay output RO1.
0.0 … 3600.0 s See parameter 14.04. 0 … 36000
14.06 RO2 TON DELAY Defines the operation delay for relay output RO2.
0.0 … 3600.0 s See parameter 14.04. 0 … 36000
14.07 RO2 TOFF DELAY Defines the release delay for relay output RO2.
0.0 … 3600.0 s See parameter 14.04. 0 … 36000
14.08 RO3 TON DELAY Defines the operation delay for relay output RO3.
0.0 … 3600.0 s See parameter 14.04. 0 … 36000
14.09 RO3 TOFF DELAY Defines the release delay of relay output RO3.
0.0 … 3600.0 s See parameter 14.04. 0 … 36000

117

14.10 DIO MOD1 RO1 Selects the drive status indicated through relay output RO1 of digital I/O
extension module 1 (optional, see parameter 98.03).

118

extension module no. 3 (optional, see parameter 98.05).
14.16 RO PTR1 Defines the source or constant for value PAR 14.16 of parameter 14.01.
32768 … C.32767
32768 … C.32767
32768 … C.32767
32768 … C.32767
32768 … C.32767
32768 … C.32767
32768 … C.32767
32768 … C.32767
32768 … C.32767

119

15 ANALOGUE Selection of the actual signals to be indicated through the analogue outputs.
OUTPUTS Output signal processing. See section Programmable analogue outputs on
page 50.
15.01 ANALOGUE Connects a drive signal to analogue output AO1.
OUTPUT1
NOT USED Not in use 1
P SPEED Value of a user-defined process quantity derived from the motor speed. See 2
parameter group 34 PROCESS VARIABLE for scaling and unit selection (%;
m/s; rpm). The updating interval is 100 ms.
SPEED Motor speed (signal 01.02 SPEED). 20 mA = motor nominal speed. The 3
updating interval is 24 ms. The value is filtered with the filter time constant
defined by parameter 34.04 MOTOR SP FILT TIM.
FREQUENCY Output frequency. 20 mA = motor nominal frequency. The updating interval is 4
24 ms.
CURRENT Output current. 20 mA = motor nominal current. The updating interval is 24 ms. 5
TORQUE Motor torque. 20 mA = 100% of motor nominal rating. The updating interval is 6
24 ms.
POWER Motor power. 20 mA = 100% of motor nominal rating. The updating interval is 7
100 ms.
DC BUS VOLT DC bus voltage. 20 mA = 100% of the reference value. The reference value is 8
540 VDC. (= 1.35 · 400 V) for 380...415 VAC supply voltage rating and
675 VDC (= 1.35 · 500 V) for 380...500 VAC supply. The updating interval is
24 ms.
OUTPUT VOLT Motor voltage. 20 mA = motor rated voltage. The updating interval is 100 ms. 9
APPL OUTPUT The reference which is given as an output from the application. For example, if 10
the PID Control macro is in use, this is the output of the process PID controller.
The updating interval is 24 ms.
REFERENCE Active reference that the drive is currently following. 20 mA = 100 % of the 11
active reference. The updating interval is 24 ms.
CONTROL DEV The difference between the reference and the actual value of the process PID 12
controller. 0/4 mA = -100%, 10/12 mA = 0%, 20 mA = 100%. The updating
interval is 24 ms.
ACTUAL 1 Value of variable ACT1 used in the process PID control. 20 mA = value of 13
parameter 40.10. The updating interval is 24 ms.
ACTUAL 2 Value of variable ACT2 used in the process PID control. 20 mA = value of 14
parameter 40.12. The updating interval is 24 ms.
COMM.REF4 The value is read from fieldbus reference REF4. See chapter Fieldbus control. 15
M1 TEMP MEAS Analogue output is a current source in a motor temperature measuring circuit. 16
Depending on the sensor type, the output is 9.1 mA (Pt 100) or 1.6 mA (PTC).
For more information, see parameter 35.01 and section Motor temperature
measurement through the standard I/O on page 71.
Note: The settings of parameters 15.02 to 15.05 are not effective.
PARAM 15.11 Source selected by 15.11 17
15.02 INVERT AO1 Inverts the analogue output AO1 signal. The analogue signal is at the minimum
level when the indicated drive signal is at its maximum level and vice versa.
NO Inversion off 0
YES Inversion on 65535

120

15.03 MINIMUM AO1 Defines the minimum value of the analogue output signal AO1.
0 mA Zero mA 1
4 mA Four mA 2
15.04 FILTER AO1 Defines the filtering time constant for analogue output AO1.
0.00 … 10.00 s Filter time constant 0 … 1000
%
100
Filtered Signal
t = time
t
T
Note: Even if you select 0 s as the minimum value, the signal is still filtered
with a time constant of 10 ms due to the signal interface hardware. This cannot
be changed by any parameters.
15.05 SCALE AO1 Scales the analogue output AO1 signal.
10 … 1000% Scaling factor. If the value is 100%, the reference value of the drive signal 100 …
corresponds to 20 mA. 10000
Example: The nominal motor current is 7.5 A and the measured maximum
current at maximum load 5 A. The motor current 0 to 5 A needs to be read as 0
to 20 mA analogue signal through AO1. The required settings are:
1. AO1 is set to CURRENT by parameter 15.01.
2. AO1 minimum is set to 0 mA by parameter 15.03.
3. The measured maximum motor current is scaled to correspond to 20 mA
analogue output signal by setting the scaling factor (k) to 150%. The value is
defined as follows: The reference value of the output signal CURRENT is the
motor nominal current i.e. 7.5 A (see parameter 15.01). To make the measured
maximum motor current correspond to 20 mA, it should be scaled equal to the
reference value before it is converted to an analogue output signal. Equation:
k · 5 A = 7.5 A => k = 1.5 = 150%
15.06 ANALOGUE See parameter 15.01.
OUTPUT2
P SPEED See parameter 15.01. 2
SPEED See parameter 15.01. 3
FREQUENCY See parameter 15.01. 4
CURRENT See parameter 15.01. 5
TORQUE See parameter 15.01. 6
POWER See parameter 15.01. 7
DC BUS VOLT See parameter 15.01. 8
OUTPUT VOLT See parameter 15.01. 9
APPL OUTPUT See parameter 15.01. 10
REFERENCE See parameter 15.01. 11
CONTROL DEV See parameter 15.01. 12
ACTUAL 1 See parameter 15.01. 13

121

COMM.REF5 The value is read from fieldbus reference REF5. See chapter Fieldbus control. 15
PARAM 15.12 Source selected by 15.12 16
15.07 INVERT AO2 See parameter 15.02.
15.08 MINIMUM AO2 See parameter 15.03.
15.09 FILTER AO2 See parameter 15.04.
0.00 … 10.00 s See parameter 15.04. 0 … 1000
15.10 SCALE AO2 See parameter 15.05.
10 … 1000% See parameter 15.05. 100 …
10000
15.11 AO1 PTR Defines the source or constant for value PAR 15.11 of parameter 15.01.
-255.255.31 … Parameter index or a constant value. See parameter 10.04 for information on 1000 =
+255.255.31 / C.- the difference. 1 mA
32768 … C.32767
15.12 AO2 PTR Defines the source or constant for value PAR 15.12 of parameter 15.06.
-255.255.31 … Parameter index or a constant value. See parameter 10.04 for information on 1000 =
+255.255.31 / C.- the difference. 1 mA
32768 … C.32767
16 SYST CTRL INPUTS Run Enable, parameter lock etc.
16.01 RUN ENABLE Sets the Run Enable signal on, or selects a source for the external Run Enable
signal. If Run Enable signal is switched off, the drive will not start or stops if it is
running. The stop mode is set by parameter 21.07.
YES Run Enable signal is on. 1
DI1 External signal required through digital input DI1. 1 = Run Enable. 2
COMM.CW External signal required through the Fieldbus Control Word (bit 3). 8

122

16.02 PARAMETER LOCK Selects the state of the parameter lock. The lock prevents parameter changing.
OPEN The lock is open. Parameter values can be changed. 0
LOCKED Locked. Parameter values cannot be changed from the control panel. The lock 65535
can be opened by entering the valid code to parameter 16.03.
16.03 PASS CODE Selects the pass code for the parameter lock (see parameter 16.02).
0 … 30000 Setting 358 opens the lock. The value reverts back to 0 automatically. 0 … 30000
16.04 FAULT RESET SEL Selects the source for the fault reset signal. The signal resets the drive after a
fault trip if the cause of the fault no longer exists.
NOT SEL Fault reset only from the control panel keypad (RESET key). 1
DI1 Reset through digital input DI1 or by control panel: 2
- If the drive is in external control mode: Reset by a rising edge of DI1.
- If the drive is in local control mode: Reset by the RESET key of the control
panel.
COMM.CW Reset through the fieldbus Control Word (bit 7), or by the RESET key of the 8
control panel.
Note: Reset through fieldbus Control Word (bit 7) is enabled automatically and
it is independent of parameter 16.04 setting if parameter 10.01 or 10.02 is set
to COMM.CW.
ON STOP Reset along with the stop signal received through a digital input, or by the 9
RESET key of the control panel.
16.05 USER MACRO IO Enables the change of the User Macro through a digital input. See parameter
CHG 99.02. The change is only allowed when the drive is stopped. During the
change, the drive will not start.
Note: Always save the User Macro by parameter 99.02 after changing any
parameter settings, or reperforming the motor identification. The last settings
saved by the user are loaded into use whenever the power is switched off and
on again or the macro is changed. Any unsaved changes will be lost.
Note: The value of this parameter is not included in the User Macro. A setting
once made remains despite the User Macro change.
Note: Selection of User Macro 2 can be supervised via relay output RO3. See
parameter 14.03 for more information.
NOT SEL User macro change is not possible through a digital input. 1
DI1 Falling edge of digital input DI1: User Macro 1 is loaded into use. Rising edge 2
of digital input DI1: User Macro 2 is loaded into use.

123

16.06 LOCAL LOCK Disables entering local control mode (LOC/REM key of the panel).
WARNING! Before activating, ensure that the control panel is not
needed for stopping the drive!
OFF Local control allowed. 0

ON Local control disabled. 65535
16.07 PARAMETER SAVE Saves the valid parameter values to the permanent memory.
Note: A new parameter value of a standard macro is saved automatically when
changed from the panel but not when altered through a fieldbus connection.
DONE Saving completed 0
SAVE.. Saving in progress 1
16.08 RUN ENA PTR Defines the source or constant for value PAR 16.08 of parameter 16.01
32768 … C.32767
16.09 CTRL BOARD Defines the source of the control board power supply.
SUPPLY Note: If an external supply is used but this parameter has value INTERNAL,
the drive trips on a fault at power switch off.
INTERNAL 24V Internal (default). 1
EXTERNAL 24V External. The control board is powered from an external supply. 2
16.10 ASSIST SEL Enables the Start-up Assistant.
OFF Assistant disabled. 0
ON Assistant enabled. 65535
16.11 FAULT RESET PTR Defines the source or constant for selection PARAM 16.11 of parameter 16.04.
32768 … C.32767

124

20 LIMITS Drive operation limits. See also section Speed controller tuning on page 58.
20.01 MINIMUM SPEED Defines the allowed minimum speed. The limit cannot be set if parameter
99.04 = SCALAR.
Note: The limit is linked to the motor nominal speed setting i.e.
parameter 99.08. If 99.08 is changed, the default speed limit will also
change.
-18000 / (no. of pole Minimum speed limit. 1 = 1 rpm
pairs) … par. 20.02 Note: If the value is positive, the motor cannot be run in the reverse direction.
rpm
20.02 MAXIMUM SPEED Defines the allowed maximum speed. The value cannot be set if parameter
99.04 = SCALAR.
Note: The limit is linked to the motor nominal speed setting i.e.
parameter 99.08. If 99.08 is changed, the default speed limit will also
change.
par. 20.01 … 18000 / Maximum speed limit 1 = 1 rpm
(no. of pole pairs) rpm
20.03 MAXIMUM CURRENT Defines the allowed maximum motor current.

0.0 … x.x A Current limit 0 …10·x.x
20.04 TORQ MAX LIM1 Defines the maximum torque limit 1 for the drive.
0.0 … 600.0% Value of limit in percent of motor nominal torque. 0 … 60000
20.05 OVERVOLTAGE Activates or deactivates the overvoltage control of the intermediate DC link.
CTRL Fast braking of a high inertia load causes the voltage to rise to the overvoltage
control limit. To prevent the DC voltage from exceeding the limit, the
overvoltage controller automatically decreases the braking torque.
Note: If a brake chopper and resistor are connected to the drive, the controller
must be off (selection NO) to allow chopper operation.
OFF Overvoltage control deactivated. 0
ON Overvoltage control activated. 65535
20.06 UNDERVOLTAGE Activates or deactivates the undervoltage control of the intermediate DC link.
CTRL If the DC voltage drops due to input power cut off, the undervoltage controller
will automatically decrease the motor speed in order to keep the voltage above
the lower limit. By decreasing the motor speed, the inertia of the load will cause
regeneration back into the drive, keeping the DC link charged and preventing
an undervoltage trip until the motor coasts to stop. This will act as a power-loss
ride-through functionality in systems with a high inertia, such as a centrifuge or
a fan.
OFF Undervoltage control deactivated. 0
ON Undervoltage control activated. 65535
20.07 MINIMUM FREQ Defines the minimum limit for the drive output frequency. The limit can be set
only parameter 99.04 = SCALAR.
-300.00 … 50 Hz Minimum frequency limit. -30000 …
Note: If the value is positive, the motor cannot be run in the reverse direction. 5000
20.08 MAXIMUM FREQ Defines the maximum limit for the drive output frequency. The limit can be set
only if parameter 99.04 = SCALAR
-50 … 300.00 Hz Maximum frequency limit -5000 …
30000

125

20.11 P MOTORING LIM Defines the allowed maximum power fed by the inverter to the motor.
0 … 600% Power limit in percent of the motor nominal power 0 … 60000
20.12 P GENERATING LIM Defines the allowed maximum power fed by the motor to the inverter.
-600 … 0% Power limit in percent of the motor nominal power -60000 … 0
20.13 MIN TORQ SEL Selects the minimum torque limit for the drive. The update interval is 100 ms.
MIN LIM1 Value of parameter 20.15. 1
DI1 Digital input DI1. 0: Value of parameter 20.15. 1: Value of parameter 20.16. 2
AI1 Analogue input AI1. See parameter 20.20 on how the signal is converted to a 14
torque limit.
AI2 See selection AI1. 15
PARAM 20.18 Limit given by 20.18 19
NEG MAX TORQ Inverted maximum torque limit defined by parameter 20.14 20
20.14 MAX TORQ SEL Defines the maximum torque limit for the drive. The update interval is 100 ms.
MAX LIM1 Value of parameter 20.04. 1
DI1 Digital input DI1. 0: Value of parameter 20.04. 1: Value of parameter 20.17. 2
AI1 Analogue input AI1. See parameter 20.20 on how the signal is converted to a 14
torque limit.

126

PARAM 20.19 Limit given by 20.19 19
20.15 TORQ MIN LIM1 Defines the minimum torque limit 1 for the drive.
-600.0 … 0.0% Value of limit in percent of motor nominal torque -60000 … 0
20.16 TORQ MIN LIM2 Defines the minimum torque limit 2 for the drive.
-600.0 … 0.0% Value of limit in percent of motor nominal torque -60000 … 0
20.17 TORQ MAX LIM2 Defines the maximum torque limit 2 for the drive.
0.0 … 600.0% Value of limit in percent of motor nominal torque 0 … 60000
20.18 TORQ MIN PTR Defines the source or constant for value PAR 20.18 of parameter 20.13
-255.255.31 … Parameter index or a constant value. 100 = 1%
+255.255.31 / C.-
32768 … C.32767
20.19 TORQ MAX PTR Defines the source or constant for value PAR 20.19 of parameter 20.14
-255.255.31 … Parameter index or a constant value. See parameter 10.04 for information on 100 = 1%
+255.255.31 / C.- the difference. FbEq for the torque value is 100 = 1%.
32768 … C.32767
20.20 MIN AI SCALE Defines how an analogue signal (mA or V) is converted to a torque minimum or
maximum limit (%). The figure below illustrate the converting, when analogue
input AI1 has been set the source for a torque limit by parameter 20.13 or
20.14.
Torque limit
20.21 13.01 Minimum setting for AI1

13.02 Maximum setting for AI1
20.20 Minimum torque
20.21 Maximum torque
20.20
13.01 13.02
Analogue signal
0.0 … 600.0% %-value that corresponds to the minimum setting of the analogue input. 100 = 1%
20.21 MAX AI SCALE See parameter 20.20.
0.0 … 600.0% %-value that corresponds to the maximum setting of the analogue input. 100 = 1%
21 START/STOP Start and stop modes of the motor.
21.01 START FUNCTION Selects the motor starting method. See also section Automatic Start on page
54.

127

AUTO Automatic start guarantees optimal motor start in most cases. It includes the 1
flying start function (starting to a rotating machine) and the automatic restart
function (stopped motor can be restarted immediately without waiting the motor
flux to die away). The drive motor control program identifies the flux as well as
the mechanical state of the motor and starts the motor instantly under all
conditions.
Note: If parameter 99.04 = SCALAR, no flying start or automatic restart is
possible by default. The flying start feature needs to be activated separately by
parameter 21.08.
DC MAGN DC magnetising should be selected if a high break-away torque is required. 2
The drive pre-magnetises the motor before the start. The pre-magnetising time
is determined automatically, being typically 200 ms to 2 s depending on the
motor size. DC MAGN guarantees the highest possible break-away torque.
Note: Starting to a rotating machine is not possible when DC magnetising is
selected.
Note: DC magnetising cannot be selected if parameter 99.04 = SCALAR.
CNST DC MAGN Constant DC magnetising should be selected instead of DC magnetising if 3
constant pre-magnetising time is required (e.g. if the motor start must be
simultaneous with a mechanical brake release). This selection also guarantees
the highest possible break-away torque when the pre-magnetising time is set
long enough. The pre-magnetising time is defined by parameter 21.02.
Note: Starting to a rotating machine is not possible when DC magnetising is
selected.
Note: DC magnetising cannot be selected if parameter 99.04 = SCALAR.
WARNING! The drive will start after the set magnetising time has
passed although the motor magnetisation is not completed. Ensure
always in applications where a full break-away torque is essential, that
the constant magnetising time is long enough to allow generation of full
magnetisation and torque.
21.02 CONST MAGN TIME Defines the magnetising time in the constant magnetising mode. See
parameter 21.01. After the start command, the drive automatically pre-
magnetises the motor the set time.
30.0 … 10000.0 ms Magnetising time. To ensure full magnetising, set this value to the same value 30 … 10000
as or higher than the rotor time constant. If not known, use the rule-of-thumb
value given in the table below:
Motor Rated Power Constant Magnetising Time

< 10 kW > 100 to 200 ms
10 to 200 kW > 200 to 1000 ms
200 to 1000 kW > 1000 to 2000 ms
21.03 STOP FUNCTION Selects the motor stop function.

COAST Stop by cutting of the motor power supply. The motor coasts to a stop. 1
WARNING! If the mechanical brake control function is on, the
application program uses ramp stop in spite of the selection COAST
(see parameter group 42 BRAKE CONTROL).
RAMP Stop along a ramp. See parameter group 22 ACCEL/DECEL. 2

128

21.04 DC HOLD Activates/deactivates the DC hold function. DC Hold is not possible if
When both the reference and the speed drop below the value of parameter
21.05, the drive will stop generating sinusoidal current and start to inject DC
into the motor. The current is set by parameter 21.06. When the reference
speed exceeds parameter 21.05, normal drive operation continues.
SPEEDmotor
DC Hold
Ref. t
DC HOLD SPEED
t
Note: DC Hold has no effect if the start signal is switched off.
Note: Injecting DC current into the motor causes the motor to heat up. In
applications where long DC hold times are required, externally ventilated
motors should be used. If the DC hold period is long, the DC hold cannot
prevent the motor shaft from rotating if a constant load is applied to the motor.
See section DC Hold on page 55.
NO Inactive 0
YES Active 65535
21.05 DC HOLD SPEED Defines the DC Hold speed. See parameter 21.04.
0 … 3000 rpm Speed in rpm 0 … 3000
21.06 DC HOLD CURR Defines the DC hold current. See parameter 21.04.
0 … 100% Current in percent of the motor nominal current 0 … 100
21.07 RUN ENABLE FUNC Selects the stop mode applied when the Run Enable signal is switched off. The
Run Enable signal is put into use by parameter 16.01.
Note: The setting overrides the normal stop mode setting (parameter 21.03)
when the Run Enable signal is switched off.
WARNING! The drive will restart after the Run Enable signal restores
(if the start signal is on).
RAMP STOP The application program stops the drive along the deceleration ramp defined in 1
group 22 ACCEL/DECEL.
COAST STOP The application program stops the drive by cutting off the motor power supply 2
(the inverter IGBTs are blocked). The motor rotates freely to zero speed.
WARNING! If the brake control function is on, the application program
uses ramp stop in spite of the selection COAST STOP (see parameter
group 42 BRAKE CONTROL).
OFF2 STOP The application program stops the drive by cutting off the motor power supply 3
(the inverter IGBTs are blocked). The motor rotates freely to zero speed. The
drive will restart only when the Run Enable signal is on and the start signal is
switched on (the program receives the rising edge of the start signal).

129

OFF3 STOP The application program stops the drive along the ramp defined by parameter 4
22.07. The drive will restart only when the Run Enable is on and the start signal
is switched on (the program receives the rising edge of the start signal).
21.08 SCALAR FLY START Activates the flying start feature in the scalar control mode. See parameters
21.01 and 99.04.
NO Inactive 0
YES Active 65535
21.09 START INTRL FUNC Defines how the Start Interlock input on RMIO board affects the drive
operation.
OFF2 STOP Drive running: 1 = Normal operation. 0 = Stop by coasting. 1
Drive stopped: 1 = Start allowed. 0 = No start allowed.
Restart after OFF2 STOP: Input is back to 1 and the drive receives rising edge
of the Start signal.
OFF3 STOP Drive running: 1 = Normal operation. 0 = Stop by ramp. The ramp time is 2
defined by parameter 22.07 EM STOP RAMP.
Drive stopped: 1 = Normal start. 0 = No start allowed.
Restart after OFF3 STOP: Start Interlock input = 1 and the drive receives rising
edge of the Start signal.
21.10 ZERO SPEED DELAY Defines the delay for the zero speed delay function. The function is useful in
applications where a smooth and quick restarting is essential. During the delay
the drive knows accurately the rotor position.
No Zero Speed Delay With Zero Speed Delay

Speed Speed
Speed controller Speed controller remains live.
switched off: Motor Motor is decelerated to true 0
coasts to stop. speed.
Zero Speed Zero Speed
Time Delay Time

No Zero Speed Delay
The drive receives a stop command and decelerates along a ramp. When the
motor actual speed falls below an internal limit (called Zero Speed), the speed
controller is switched off. The inverter modulation is stopped and the motor
coasts to standstill.
With Zero Speed Delay
The drive receives a stop command and decelerates along a ramp. When the
actual motor speed falls below an internal limit (called Zero Speed), the zero
speed delay function activates. During the delay the functions keeps the speed
controller live: the inverter modulates, motor is magnetised and the drive is
ready for a quick restart.
0.0 … 60.0 s Delay time 10 = 1 s
22 ACCEL/DECEL Acceleration and deceleration times. See section Acceleration and
deceleration ramps on page 57.
22.01 ACC/DEC SEL Selects the active acceleration/deceleration time pair.
ACC/DEC 1 Acceleration time 1 and deceleration time 1 are used. See parameters 22.02 1
and 22.03.

130

ACC/DEC 2 Acceleration time 2 and deceleration time 2 are used. See parameters 22.04 2
and 22.05.
DI1 Acceleration/deceleration time pair selection through digital input DI1. 0 = 3
Acceleration time 1 and deceleration time 1 are in use. 1 = Acceleration time 2
and deceleration time 2 are in use.
PAR 22.08&09 Acceleration and deceleration times given by parameters 22.08 and 22.09 15
22.02 ACCEL TIME 1 Defines the acceleration time 1 i.e. the time required for the speed to change
from zero to the maximum speed.
- If the speed reference increases faster than the set acceleration rate, the
motor speed will follow the acceleration rate.
- If the speed reference increases slower than the set acceleration rate, the
motor speed will follow the reference signal.
- If the acceleration time is set too short, the drive will automatically prolong the
acceleration in order not to exceed the drive operating limits.
0.00 … 1800.00 s Acceleration time 0 … 18000
22.03 DECEL TIME 1 Defines the deceleration time 1 i.e. the time required for the speed to change
from the maximum (see parameter 20.02) to zero.
- If the speed reference decreases slower than the set deceleration rate, the
motor speed will follow the reference signal.
- If the reference changes faster than the set deceleration rate, the motor
speed will follow the deceleration rate.
- If the deceleration time is set too short, the drive will automatically prolong the
deceleration in order not to exceed drive operating limits. If there is any doubt
about the deceleration time being too short, ensure that the DC overvoltage
control is on (parameter 20.05).
Note: If a short deceleration time is needed for a high inertia application, the
drive should be equipped with an electric braking option e.g. with a brake
chopper and a brake resistor.
0.00 … 1800.00 s Deceleration time 0 … 18000
22.04 ACCEL TIME 2 See parameter 22.02.
0.00 … 1800.00 s See parameter 22.02. 0 … 18000
22.05 DECEL TIME 2 See parameter 22.03.
0.00 … 1800.00 s See parameter 22.03. 0 … 18000

131

22.06 ACC/DEC RAMP Selects the shape of the acceleration/deceleration ramp.
SHPE See also section Jogging on page 79.
0.00 … 1000.00 s 0.00 s: Linear ramp. Suitable for steady acceleration or deceleration and for 0 … 100000
slow ramps.
0.01 … 1000.00 s: S-curve ramp. S-curve ramps are ideal for conveyors
carrying fragile loads, or other applications where a smooth transition is
required when changing from one speed to another. The S curve consists of
symmetrical curves at both ends of the ramp and a linear part in between.
A rule of thumb Speed Linear ramp: Par. 22.06 = 0 s

A suitable relation between the Max
ramp shape time and the
acceleration ramp time is 1/5.
S-curve ramp:
Par. 22.06 > 0 s
time
Par. 22.02 Par. 22.06
22.07 EM STOP RAMP Defines the time inside which the drive is stopped if
TIME - the drive receives an emergency stop command or
- the Run Enable signal is switched off and the Run Enable function has value
OFF3 (see parameter 21.07).
The emergency stop command can be given through a fieldbus or an
Emergency Stop module (optional). Consult the local ABB representative for
more information on the optional module and the related settings of the
Standard Control Program.
0.00 … 2000.00 s Deceleration time 0 … 200000
22.08 ACC PTR Defines the source or constant for value PAR 22.08&09 of parameter 22.01.
-255.255.31 … Parameter index or a constant value. See parameter 10.04 for information on 100 = 1 s
32768 … C.32767
22.09 DEC PTR Defines the source or constant for value PAR 22.08&09 of parameter 22.01
-255.255.31 … Parameter index or a constant value. See parameter 10.04 for information on 100 = 1 s
32768 … C.32767

132

23 SPEED CTRL Speed controller variables. The parameters are not visible if parameter 99.04 =
SCALAR. See section Speed controller tuning on page 58.
23.01 GAIN Defines a relative gain for the speed controller. Great gain may cause speed
oscillation.
The figure below shows the speed controller output after an error step when
the error remains constant.
%
Gain = Kp = 1
TI = Integration time = 0
TD= Derivation time = 0
Error Value
Controller Output
Controller e = Error value
output = Kp · e
t
0.0 … 250.0 Gain 0 … 25000
23.02 INTEGRATION TIME Defines an integration time for the speed controller. The integration time
defines the rate at which the controller output changes when the error value is
constant. The shorter the integration time, the faster the continuous error value
is corrected. Too short an integration time makes the control unstable.
%
Controller Output
Gain = Kp = 1
TI = Integration time > 0
Kp · e TD= Derivation time = 0
Kp · e e = Error value
t
TI
0.01 … 999.97 s Integration time 10 …
999970

133

23.03 DERIVATION TIME Defines the derivation time for the speed controller. Derivative action boosts
the controller output if the error value changes. The longer the derivation time,
the more the speed controller output is boosted during the change. If the
derivation time is set to zero, the controller works as a PI controller, otherwise
as a PID controller.
The derivation makes the control more responsive for disturbances.
Note: Changing this parameter is recommended only if a pulse encoder is
used.
Gain = Kp = 1
TI = Integration time > 0
TD= Derivation time > 0
Ts= Sample time period = 1 ms
Δe = Error value change between
% two samples
Controller Output
De
Kp · TD ·
Ts Kp · e
Error Value
Kp · e e = Error value
t
TI
0.0 … 9999.8 ms Derivation time value. 1 = 1 ms
23.04 ACC Defines the derivation time for acceleration/(deceleration) compensation. In
COMPENSATION order to compensate inertia during acceleration a derivative of the reference is
added to the output of the speed controller. The principle of a derivative action
is described for parameter 23.03.
Note: As a general rule, set this parameter to the value between 50 and 100%
of the sum of the mechanical time constants of the motor and the driven
machine. (The speed controller Autotune Run does this automatically, see
parameter 23.06.)
The figure below shows the speed responses when a high inertia load is
accelerated along a ramp.
No Acceleration Compensation Acceleration Compensation
% % Speed reference
Actual speed
t t
0.00 … 999.98 s Derivation time 0 … 9999

134

23.05 SLIP GAIN Defines the slip gain for the motor slip compensation control. 100% means full
slip compensation; 0% means no slip compensation. The default value is
100%. Other values can be used if a static speed error is detected despite of
the full slip compensation.
Example: 1000 rpm constant speed reference is given to the drive. Despite of
the full slip compensation (SLIP GAIN = 100%), a manual tachometer
measurement from the motor axis gives a speed value of 998 rpm. The static
speed error is 1000 rpm - 998 rpm = 2 rpm. To compensate the error, the slip
gain should be increased. At the 106% gain value, no static speed error exists.
0.0 … 400.0% Slip gain value. 0 … 400
23.06 AUTOTUNE RUN Start automatic tuning of the speed controller. Instructions:
- Run the motor at a constant speed of 20 to 40% of the rated speed.
- Change the autotuning parameter 23.06 to YES.
Note: The motor load must be connected to the motor.
NO No autotuning. 0
YES Activates the speed controller autotuning. Automatically reverts to NO. 65535
23.07 SP ACT FILT TIME Defines the time constant of the actual speed filter, i.e. time within the actual
speed has reached 63% of the nominal speed.
0...1000000 ms Time constant 1 = 1 ms
24 TORQUE CTRL Torque control variables.
Visible only if parameter 99.02 = T CNTRL and parameter 99.04 = DTC.
24.01 TORQ RAMP UP Defines the torque reference ramp up time.
0.00 … 120.00 s Time for the reference to increase from zero to the nominal motor torque. 0 … 12000
24.02 TORQ RAMP DOWN Defines the torque reference ramp down time.
0.00 … 120.00 s Time for the reference to decrease from the nominal motor torque to zero. 0 … 12000
25 CRITICAL SPEEDS Speed bands within which the drive is not allowed to operate. See section
Critical speeds on page 57.
25.01 CRIT SPEED Activates/deactivates the critical speeds function.
SELECT Example: A fan has vibrations in the range of 540 to 690 rpm and 1380 to
1560 rpm. To make the drive to jump over the vibration speed ranges:
- activate the critical speeds function,
- set the critical speed ranges as in the figure below.
Motor speed
(rpm) 1 Par. 25.02 = 540 rpm
1560 2 Par. 25.03 = 690 rpm
3 Par. 25.04 = 1380 rpm
1380
4 Par. 25.05 = 1590 rpm
690
540 Drive speed reference
1 2 3 4 (rpm)
Note: If parameter 99.02 = PID CTRL, the critical speeds are not in use.
OFF Inactive 0
ON Active. 65535

135

25.02 CRIT SPEED 1 LOW Defines the minimum limit for critical speed range 1.
0 … 18000 rpm Minimum limit. The value cannot be above the maximum (parameter 25.03). 0 … 18000
Note: If parameter 99.04 = SCALAR, the unit is Hz.
25.03 CRIT SPEED 1 HIGH Defines the maximum limit for critical speed range 1.
0 … 18000 rpm Maximum limit. The value cannot be below the minimum (parameter 25.02). 0 … 18000
Note: If parameter 99.04 = SCALAR, the unit is Hz.
25.04 CRIT SPEED 2 LOW See parameter 25.02.
0 … 18000 rpm See parameter 25.02. 0 … 18000
25.05 CRIT SPEED 2 HIGH See parameter 25.03.
25.06 CRIT SPEED 3 LOW See parameter 25.02.
25.07 CRIT SPEED 3 HIGH See parameter 25.03.
26 MOTOR CONTROL
26.01 FLUX OPTIMIZATION Activates/deactivates the flux optimisation function. See section Flux
Optimisation on page 56.
Note: The function cannot be used if parameter 99.04 = SCALAR.
NO Inactive 0
YES Active 65535
26.02 FLUX BRAKING Activates/deactivates the flux braking function.
Note: The function cannot be used if parameter 99.04 = SCALAR.
See section Flux Braking on page 55.
NO Inactive 0
YES Active 65535
26.03 IR-COMPENSATION Defines the relative output voltage boost at zero speed (IR compensation). The
function is useful in applications with high break-away torque, but no DTC
motor control cannot be applied. The figure below illustrates the IR
compensation. See section IR compensation for a scalar controlled drive on
page 60.
Note: The function can be used only if parameter 99.04 is SCALAR.
U /UN
(%)
Relative output voltage. IR
compensation set to 15%.
100%
Relative output voltage. No IR

15%
compensation.
f (Hz)
Field weakening point
0 … 30% Voltage boost at zero speed in percent of the motor nominal voltage 0 … 3000

136

26.04 IR STEP-UP FREQ Defines the frequency at which the step-up IR compensation reaches the 100 = 1
IR compensation used in scalar control (26.03 IR COMPENSATION).
A voltage boost is used in step-up applications to achieve higher break-away
torque. Since voltage cannot be fed to the transformer at 0 Hz, special IR
compensation is used in step-up applications. Full IR compensation starts
around slip frequency. The figure below illustrates the step-up
IR compensation.
U / UN
(%)
100%
26.03 IR
COMPENSATION
f (Hz)
26.04 IR STEP-UP Field weakening

FREQ point (FWP)
For more information, see the Sine Filters User’s Manual for ACS800 Drives
0...50 Hz Frequency
26.05 HEX FIELD WEAKEN Selects whether motor flux is controlled along a circular or a hexagonal pattern
in the field weakening area of the frequency range (above 50/60 Hz). See
section Hexagonal motor flux on page 61.
OFF The rotating flux vector follows a circular pattern. Optimal selection in most 0
applications: Minimal losses at constant load. Maximal instantaneous torque is
not available in the field weakening range of the speed.
ON Motor flux follows a circular pattern below the field weakening point (typically 65535
50 or 60 Hz) and a hexagonal pattern in the field weakening range. Optimal
selection in the applications that require maximal instantaneous torque in the
field weakening range of the speed. The losses at constant operation are
higher than with the selection NO.
26.06 FLUX REF PTR Selects the source for the flux reference, or sets the flux reference value.
+255.255.31 / C.- the difference. The range of the flux is 25 … 140%. With constant value
32768 … C.32767 settings 100% = C.10000. Typically there is no need to change this value.
26.07 FLYSTART CUR REF Defines the current reference used with flying start (start to a rotating motor) 1 = 1%
[%] when no pulse encoder is used.
If flying start fails (i.e. drive is unable to detect motor speed 01.02 SPEED):
Monitor signals 01.02 SPEED and 01.04 CURRENT with DriveWindow PC tool
and increase the reference in steps of 5% until the flying start function is
successfully performed (i.e. drive is able to detect 01.02 SPEED).
See also parameter 26.08 FLYSTART INIT DLY.
0…100% Value in percent

137

26.08 FLYSTART INIT DLY Defines together with the motor characteristics the delay before the speed 1=1
value estimated at the beginning of flying start is connected to the speed
reference ramp output. Increase the delay, if the motor starts to rotate in the
wrong direction or if the motor starts to rotate with the wrong speed reference.
See also parameter 26.07 FLYSTART CUR REF [%].
0…60 Delay
26.09 FS METHOD Activates the flux correction at low frequencies, < 3 Hz, when the torque 1=1
exceeds 30%. Effective in the motoring and generating modes.
1 = ON Active
0 = OFF Inactive
26.10 RS20 [mOhm] Defines the stator resistance of the motor model at 20°C. 28676 =
By increasing the default value defined during ID run (does not include the 1 Ohm
temperature dependence of the resistance), the motor model can be fine tuned
especially in applications where the motor or ambient temperature is not
measured.
Note: If stator resistance value is too high, the desired starting torque cannot
be achieved.
0…x mOhm Resistance. The maximum value depends on the defined motor
parameters (99 START-UP DATA).
27 BRAKE CHOPPER Control of the brake chopper.
27.01 BRAKE CHOPPER Activates the brake chopper control.
CTL Note: If an external chopper (e.g. NBRA-xxx) is used, parameter must be
disabled.
OFF Inactive 0
ON Active. Note: Ensure the brake chopper and resistor are installed and the 65535
overvoltage control is switched off (parameter 20.05).
27.02 BR OVERLOAD Activates the overload protection of the brake resistor. The user-adjustable
FUNC variables are parameters 27.04 and 27.05.
NO Inactive 0
WARNING Active. If the drive detects an overload, it generates a warning. 1
FAULT Active. If the drive detects an overload, it trips on a fault. 2
27.03 BR RESISTANCE Defines the resistance value of the brake resistor. The value is used for brake
chopper protection.
0.00 … 100.00 ohm Resistance value 0 … 100
27.04 BR THERM TCONST Defines the thermal time constant of the brake resistor. The value is used in the
overload protection. See parameter 27.02.
With type SACE brake resistors, the parameter setting must be 200 s.
With type SAFUR brake resistors, the parameter setting must be 555 s.
0.000 … 10000.000 s Time constant 1=1
27.05 MAX CONT BR Defines the maximum continuous braking power which will raise the resistor
POWER temperature to the maximum allowed value. The value is used in the overload
protection. See parameter 27.02.
0.00 …10000 kW Power 1=1
27.06 BC CTRL MODE Selects the control mode of the braking chopper.

138

AS GENERATOR Chopper operation is allowed when the DC voltage exceeds the braking limit, 0
the inverter bridge modulates and the motor generates power to the drive.
The selection prevents the operation in case the intermediate circuit DC
voltage rises due to abnormally high supply voltage level. Long time supply
voltage rise would damage the chopper.
COMMON DC Chopper operation is allowed always when the DC voltage exceeds the 65535
braking limit. The selection is to be used in applications where several
inverters are connected to the same intermediate circuit (DC bus).
WARNING! Excessive supply voltage will raise the intermediate circuit
voltage above the operation limit of the chopper. If the voltage remains
abnormally high for a long period, the braking chopper will be
overloaded and damaged.
30 FAULT FUNCTIONS Programmable protection functions
30.01 AI<MIN FUNCTION Selects how the drive reacts when an analogue input signal falls below the set
minimum limit.
Note: The analogue input minimum setting must be set to 0.5 V (1 mA) or
above (see parameter group 13 ANALOGUE INPUTS).
FAULT The drive trips on a fault and the motor coasts to stop. 1
NO Inactive 2
CONST SP 15 The drive generates a warning AI < MIN FUNC (8110) and sets the speed to 3
the value defined by parameter 12.16.
WARNING! Make sure that it is safe to continue operation in case the
analogue input signal is lost.
LAST SPEED The drive generates a warning AI < MIN FUNC (8110) and freezes the speed 4
to the level the drive was operating at. The speed is determined by the average
speed over the previous 10 seconds.
WARNING! Make sure that it is safe to continue operation in case the
analogue input signal is lost.
30.02 PANEL LOSS Selects how the drive reacts to a control panel communication break.
FAULT Drive trips on a fault and the motor stops as defined by parameter 21.03. 1
CONST SP 15 The drive generates a warning and sets the speed to the speed defined by 2
parameter 12.16.
WARNING! Make sure that it is safe to continue operation in case of a
panel communication break.
LAST SPEED The drive generates a warning and freezes the speed to the level the drive was 3
operating at. The speed is determined by the average speed over the previous
10 seconds.
panel communication break.
30.03 EXTERNAL FAULT Selects an interface for an external fault signal. See section External Fault on
page 61.
NOT SEL Inactive 1
DI1 External fault indication is given through digital input DI1. 0: Fault trip. Motor 2
coasts to stop. 1: No external fault.

139

30.04 MOTOR THERM Selects how the drive reacts when the motor overtemperature is detected by
PROT the function defined by parameter 30.05. See section Motor Thermal
Protection on page 62.
FAULT The drive generates a warning when the temperature exceeds the warning 1
level (95% of the allowed maximum value). The drive trips on a fault when the
temperature exceeds the fault level (100% of the allowed maximum value).
WARNING The drive generates a warning when the temperature exceeds the warning 2
level (95% of the allowed maximum value).
NO Inactive 3
30.05 MOT THERM P Selects the thermal protection mode of the motor. When overtemperature is
MODE detected, the drive reacts as defined by parameter 30.04.
DTC The protection is based on the calculated motor thermal model. The following 1
assumptions are used in the calculation:
- The motor is at the estimated temperature (value of 01.37 MOTOR
TEMP EST saved at power switch off) when the power is switched on. With the
first power switch on, the motor is at the ambient temperature (30°C).
- The motor temperature increases if it operates in the region above the load
curve.
- The motor temperature decreases if it operates in the region below the curve.
This applies only if the motor is overheated.
- The motor thermal time constant is an approximate value for a standard self-
ventilated squirrel-cage motor.
It is possible to finetune the model by parameter 30.07.
Note: The model cannot be used with high power motors (parameter 99.06 is
higher than 800 A).
WARNING! The model does not protect the motor if it does not cool
properly due to dust and dirt.

140

USER MODE The protection is based on the user-defined motor thermal model and the 2
following basic assumptions:
- The motor is at the estimated temperature (value of 01.37 MOTOR
TEMP EST saved at power switch off) when the power is switched on. With the
first power switch on, the motor is at the ambient temperature (30°C).
- The motor temperature increases if it operates in the region above the motor
load curve.
- The motor temperature decreases if it operates in the region below the curve.
This applies only if the motor is overheated.
The user-defined thermal model uses the motor thermal time constant
(parameter 30.06) and the motor load curve (parameters 30.07, 30.08 and
30.09). User tuning is typically needed only if the ambient temperature differs
from the normal operating temperature specified for the motor.
WARNING! The model does not protect the motor if it does not cool
properly due to dust and dirt.

141

THERMISTOR Motor thermal protection is activated through digital input DI6. A motor 3
thermistor, or a break contact of a thermistor relay, must be connected to digital
input DI6. The drive reads the DI6 states as follows:
DI6 Status (Thermistor resistance) Temperature

1 (0 … 1.5 kohm) Normal
0 (4 kohm or higher) Overtemperature
WARNING! According to IEC 664, the connection of the motor

thermistor to the digital input requires double or reinforced insulation
between motor live parts and the thermistor. Reinforced insulation
entails a clearance and creeping distance of 8 mm (400 / 500 VAC equipment).
If the thermistor assembly does not fulfil the requirement, the other I/O
terminals of the drive must be protected against contact, or a thermistor relay
must be used to isolate the thermistor from the digital input.
WARNING! Digital input DI6 may be selected for another use. Change
these settings before selecting THERMISTOR. In other words, ensure
that digital input DI6 is not selected by any other parameter.
The figure below shows the alternative thermistor connections. At the motor
end the cable shield should be earthed through a 10 nF capacitor. If this is not
possible, the shield is to be left unconnected.
Alternative 1
Thermistor
relay
RMIO board, X22
6 DI6
7 +24 VDC
T
Motor
Alternative 2 RMIO board, X22
6 DI6
7 +24 VDC
T 10 nF
Motor

142

30.06 MOTOR THERM Defines the thermal time constant for the user-defined thermal model (see the
TIME selection USER MODE of parameter 30.05).
Motor
Load
100%
Temperature
t
100%
63%
t
Motor thermal time constant
256.0 … 9999.8 s Time constant 256 … 9999
30.07 MOTOR LOAD Defines the load curve together by parameters 30.08 and 30.09. The load
CURVE curve is used in the user-defined thermal model (see the selection USER
MODE of parameter 30.05).
I/IN I = Motor current

(%) IN = Nominal motor current
150
30.07
100
50
30.08
30.09 Drive output frequency
50.0 … 150.0% Allowed continuous motor load in percent of the nominal motor current. 50 … 150
30.08 ZERO SPEED LOAD Defines the load curve together with parameters 30.07 and 30.09.
25.0 … 150.0% Allowed continuous motor load at zero speed in percent of the nominal motor 25 … 150
current
30.09 BREAK POINT Defines the load curve together with parameters 30.07 and 30.08.
1.0 … 300.0 Hz Drive output frequency at 100% load 100 …
30000

143

30.10 STALL FUNCTION Selects how the drive reacts to a motor stall condition. The protection wakes up
if:
- the drive is at stall limit (defined by parameters 20.03, 20.13 and 20.14)
- the output frequency is below the level set by parameter 30.11 and
- the conditions above have been valid longer than the time set by parameter
30.12.
Note: Stall limit is restricted by internal current limit 03.04
TORQ_INV_CUR_LIM.
See section Stall Protection on page 63.
FAULT The drive trips on a fault. 1
WARNING The drive generates a warning. The indication disappears in half of the time set 2
by parameter 30.12.
NO Protection is inactive. 3
30.11 STALL FREQ HI Defines the frequency limit for the stall function. See parameter 30.10.
0.5 … 50.0 Hz Stall frequency 50 … 5000
30.12 STALL TIME Defines the time for the stall function. See parameter 30.10.
10.00 … 400.00 s Stall time 10 … 400
30.13 UNDERLOAD FUNC Selects how the drive reacts to underload. The protection wakes up if:
- the motor torque falls below the curve selected by parameter 30.15,
- output frequency is higher than 10% of the nominal motor frequency and
- the above conditions have been valid longer than the time set by parameter
30.14.
See section Underload Protection on page 63.
WARNING The drive generates a warning. 2
30.14 UNDERLOAD TIME Time limit for the underload function. See parameter 30.13.
0 … 600 s Underload time 0 … 600
30.15 UNDERLOAD Selects the load curve for the underload function. See parameter 30.13.
CURVE
TM/TN
TM = Motor torque
(%) TN= Nominal motor torque
100 ƒN = Nominal motor frequency
80 3
70%
60 2
50%
40 1 5
30%
20
4
0
ƒN 2.4 * ƒN
1…5 Number of the load curve 1…5

144

30.16 MOTOR PHASE Activates the motor phase loss supervision function.
LOSS See section Motor Phase Loss on page 63.
NO Inactive 0
FAULT Active. The drive trips on a fault. 65535
30.17 EARTH FAULT Selects how the drive reacts when an earth fault is detected in the motor or the
motor cable. See section Earth Fault Protection on page 64.
30.18 COMM FLT FUNC Selects how the drive reacts in a fieldbus communication break, i.e. when the
drive fails to receive the Main Reference Data Set or the Auxiliary Reference
Data Set. The time delays are given by parameters 30.19 and 30.21.
FAULT Protection is active. The drive trips on a fault and stops the motor as defined by 1
parameter 21.03.
CONST SP 15 Protection is active. The drive generates a warning and sets the speed to the 3
value defined by parameter 12.16.
communication break.
LAST SPEED Protection is active. The drive generates a warning and freezes the speed to 4
the level the drive was operating at. The speed is determined by the average
speed over the previous 10 seconds.
communication break.
30.19 MAIN REF DS T-OUT Defines the time delay for the Main Reference data set supervision. See
parameter 30.18.
0.1 … 60.0 s Time delay 10 … 6000
30.20 COMM FLT RO/AO Selects the operation of the fieldbus controlled relay output and analogue
output in a communication break. See groups 14 RELAY OUTPUTS and 15
ANALOGUE OUTPUTS and chapter Fieldbus control. The delay for the
supervision function is given by parameter 30.21.
ZERO Relay output is de-energised. Analogue output is set to zero. 0
LAST VALUE The relay output keeps the last state before the communication loss. The 65535
analogue output gives the last value before the communication loss.
WARNING! After the communication recovers, the update of the relay
and the analogue outputs starts immediately without fault message
resetting.
30.21 AUX DS T-OUT Defines the delay time for the Auxiliary Reference data set supervision. See
parameter 30.18. The drive automatically activates the supervision 60 seconds
after power switch-on if the value is other than zero.
Note: The delay also applies for the function defined by parameter 30.20.
0.0 … 60.0 s Time delay. 0.0 s = The function is inactive. 0 … 6000
30.22 IO CONFIG FUNC Selects how the drive reacts in case an optional input or output channel has
been selected as a signal interface, but the communication to the appropriate
analogue or digital I/O extension module has not been set up accordingly in
parameter group 98 OPTION MODULES.
Example: The supervision function wakes up if parameter 16.01 is set to DI7,
but 98.03 is set to NO.

145

NO Inactive. 1
WARNING Active. The drive generates a warning. 2
30.23 LIMIT WARNING Activates/deactivates limit alarms INV CUR LIM, DC BUS LIM, MOT CUR LIM,
MOT TORQ LIM and/or MOT POW LIM. For more information, see chapter
Fault tracing.
0...255 Value in decimal. As default none of the alarms are active, i.e. parameter value -
is 0.
bit 0 INV_CUR_LIM_IND
bit 1 DC_VOLT_LIM_IND
bit 2 MOT_CUR_LIM_IND
bit 3 MOT_TORQ_LIM_IND
bit 4 MOT_POW_LIM_IND
Example: When parameter value is set to 3 (bit 0 and 1 values are 1), alarms
INV CUR LIM and DC BUS LIM are active.
31 AUTOMATIC RESET Automatic fault reset.
Automatic resets are possible only for certain fault types and when the
automatic reset function is activated for that fault type.
The automatic reset function is not operational if the drive is in local control (L
visible on the first row of the panel display).
See section Automatic resets on page 67.
31.01 NUMBER OF TRIALS Defines the number of automatic fault resets the drive performs within the time
defined by parameter 31.02.
0…5 Number of the automatic resets 0
31.02 TRIAL TIME Defines the time for the automatic fault reset function. See parameter 31.01.
1.0 … 180.0 s Allowed resetting time 100 …
18000
31.03 DELAY TIME Defines the time that the drive will wait after a fault before attempting an
automatic reset. See parameter 31.01.
0.0 … 3.0 s Resetting delay 0 … 300
31.04 OVERCURRENT Activates/deactivates the automatic reset for the overcurrent fault.
NO Inactive 0
YES Active 65535
31.05 OVERVOLTAGE Activates/deactivates the automatic reset for the intermediate link overvoltage
fault.
NO Inactive 0
YES Active 65535
31.06 UNDERVOLTAGE Activates/deactivates the automatic reset for the intermediate link undervoltage
fault.
NO Inactive 0
YES Active 65535
31.07 AI SIGNAL<MIN Activates/deactivates the automatic reset for the fault AI SIGNAL<MIN
(analogue input signal under the allowed minimum level).
NO Inactive 0
YES Active. 65535
WARNING! The drive may restart even after a long stop if the
analogue input signal is restored. Ensure that the use of this feature
will not cause danger.

146

31.08 LINE CONV Activates/deactivates the automatic reset for the fault LINE CONV (FF51) (fault
on line side converter).
NO Inactive 0
YES Active 65535
32 SUPERVISION Supervision limits. A relay output can be used to indicate when the value is
above/below the limit. See section Supervisions on page 67.
32.01 SPEED1 FUNCTION Activates/deactivates the speed supervision function and selects the type of
the supervision limit.
NO Supervision is not used. 1
LOW LIMIT Supervision wakes up if the value is below the limit. 2
HIGH LIMIT Supervision wakes up if the value is above the limit. 3
ABS LOW LIMIT Supervision wakes up if the value is below the set limit. The limit is supervised 4
in both rotating directions. The figure below illustrates the principle.
speed/rpm
ABS LOW LIMIT
-ABS LOW LIMIT
32.02 SPEED1 LIMIT Defines the speed supervision limit. See parameter 32.01.
- 18000 … 18000 rpm Value of the limit - 18000 …
18000
32.03 SPEED2 FUNCTION See parameter 32.01.
LOW LIMIT See parameter 32.01. 2
HIGH LIMIT See parameter 32.01. 3
ABS LOW LIMIT See parameter 32.01. 4
32.04 SPEED2 LIMIT See parameter 32.01.
- 18000 … 18000 rpm See parameter 32.01. - 18000 …
18000
32.05 CURRENT Activates/deactivates the motor current supervision function and selects the
FUNCTION type of the supervision limit.
32.06 CURRENT LIMIT Defines the limit for the motor current supervision (see parameter 32.05).
0 … 1000 A Value of the limit 0 … 1000
32.07 TORQUE 1 Activates/deactivates the motor torque supervision function and selects the
32.08 TORQUE 1 LIMIT Defines the limit for the motor torque supervision (see parameter 32.07).
-600 … 600% Value of the limit in percent of the motor nominal torque -6000 …
6000

147

32.09 TORQUE 2 Activates/deactivates the motor torque supervision function and selects the
32.10 TORQUE 2 LIMIT Defines the limit for the motor torque supervision (see parameter 32.09).
-600 … 600% Value of the limit in percent of motor nominal torque -6000 …
6000
32.11 REF1 FUNCTION Activates/deactivates the external reference REF1 supervision function and
selects the type of the supervision limit.
32.12 REF1 LIMIT Defines the limit for REF1 supervision (see parameter 32.11).
0 … 18000 rpm Value of the limit 0 … 18000
32.13 REF2 FUNCTION Activates/deactivates external reference REF2 supervision function and
selects the type of the supervision limit.
32.14 REF2 LIMIT Defines the limit for REF2 supervision (see parameter 32.13).
0 … 600% Value of the limit 0 … 6000
32.15 ACT1 FUNCTION Activates/deactivates the supervision function for variable ACT1 of the process
PID controller and selects the type of the supervision limit.
32.16 ACT1 LIMIT Defines the limit for ACT1 supervision (see parameter 32.15).
32.17 ACT2 FUNCTION Activates/deactivates the supervision function for variable ACT2 of the process
PID controller and selects the type of the supervision limit.
32.18 ACT2 LIMIT Defines the limit for ACT2 supervision (see parameter 32.17).
33 INFORMATION Program versions, test date
33.01 SOFTWARE Displays the type and the version of the firmware package in the drive.
VERSION Note: Parameter setting cannot be changed by the user.

148

Decoding key:
ASxxxxyx
Product Series
A = ACS800
Product
S = ACS800 Standard
Firmware Version
7xyx = Version 7.xyx
33.02 APPL SW VERSION Displays the type and the version of the application program.
Note: Parameter setting cannot be changed by the user.
Decoding key:
ASAxxxyx
Product Series
A = ACS800
Product
S = ACS800 Standard
Firmware Type
A = Application Program
Firmware Version
7xyx = Version 7.xyx
33.03 TEST DATE Displays the test date.

Note: Parameter setting cannot be changed by the user.
Date value in format DDMMYY (day, month, year) -
33.04 BOARD TYPE Shows the control board type. Note: RMIO-1x boards have different type of
FLASH memory chips than RMIO-0x. Only software version ASXR7300 or
later will operate with the RMIO-1x boards.
34 PROCESS VARIABLE - user variable and unit
- filtering for the actual signals speed and torque
- reset of the run time counter
34.01 SCALE Scales the selected drive variable into a desired user-defined variable, which is
stored as an actual signal 01.01. The block diagram below illustrates the use of
the parameters that define actual signal 01.01.
PARAMETER
TABLE
Select
00.00
•••
99.99
34.03 Mul.
34.01 01.01
Select
NO
Unit for actual
FPM signal 01.01
34.02
0.00…100000.00% Scaling factor 0…100000

149

34.02 P VAR UNIT Selects the unit for the process variable. See parameter 34.01.
NO No unit is selected. 1
rpm revolutions per minute 2
% percent 3
m/s metres per second 4
A ampere 5
V volt 6
Hz hertz 7
s second 8
h hour 9
kh kilohour 10
C celsius 11
lft pounds per foot 12
mA milliampere 13
mV millivolt 14
kW kilowatt 15
W watt 16
kWh kilowatt hour 17
F fahrenheit 18
hp horsepower 19
MWh megawatt hour 20
m3h cubic metres per hour 21
l/s litres per second 22
bar bar 23
kPa kilopascal 24
GPM gallons per minute 25
PSI pounds per square inch 26
CFM cubic feet per minute 27
ft foot 28
MGD millions of gallons per day 29
iHg inches of mercury 30
FPM feet per minute 31
lbs pound 32
34.03 SELECT P VAR Selects the drive variable scaled into a desired process variable. See
parameter 34.01.
0 … 9999 Parameter index 0 … 9999
34.04 MOTOR SP FILT TIM Defines a filter time constant for actual signal 01.02 SPEED. The time constant
has an effect on all functions in which signal SPEED is used.
The actual speed value is used e.g. in speed supervision (parameter group 32
SUPERVISION) as an analogue output value (group 15 ANALOGUE
OUTPUTS) or as an actual signal shown on the control panel display or PC
screen.

150

0 … 20000 ms Filter time constant 0 … 20000
%
100
Filtered Signal
t = time
t
T
34.05 TORQ ACT FILT TIM Defines a filter time for the actual signal torque (actual signal 01.05). Affects
also on the torque supervision (parameters 32.07 and 32.09) and the torque
read through an analogue output.
0 … 20000 ms Filter time constant 0 … 20000
%
100
Filtered Signal
t = time
t
T
34.06 RESET RUN TIME Resets the motor running time counter (actual signal 01.43).
NO No reset. 0
YES Reset. The counter restarts from zero. 65535
35 MOT TEMP MEAS Motor temperature measurement. For the function description see sections
Motor temperature measurement through the standard I/O on page 71 and
Motor temperature measurement through an analogue I/O extension on page
73.
35.01 MOT 1 TEMP AI1 SEL Activates the motor 1 temperature measurement function and selects the
sensor type.
Note: If an optional analogue I/O extension module RAIO is used for the
temperature measurement and 35.01 MOT 1 TEMP AI1 SEL and/or 35.04
MOT 2 TEMP AI2 SEL are set to 1xPT100, analogue extension module input
signal range must be set to 0...2 V (instead of 0...10 V) with DIP switches.
NOT IN USE The function is inactive. 1
1xPT100 The function is active. The temperature is measured with one Pt 100 sensor. 2
Analogue output AO1 feeds constant current through the sensor. The sensor
resistance increases as the motor temperature rises, as does the voltage over
the sensor. The temperature measurement function reads the voltage through
analogue input AI1 and converts it to degrees centigrade.
2XPT100 The function is active. Temperature is measured using two Pt 100 sensors. 3
See selection 1xPT100.
3XPT100 The function is active. Temperature is measured using three Pt 100 sensors. 4
See selection 1xPT100.

151

1...3 PTC The function is active. The temperature is supervised using one to three PTC 5
sensors or one to three KTY84-1xx silicon temperature sensors. Analogue
output AO1 feeds constant current through the sensor(s). The resistance of the
sensor increases sharply as the motor temperature rises over the sensor
reference temperature (Tref), as does the voltage over the resistor. The
temperature measurement function reads the voltage through analogue input
AI1 and converts it into ohms. The figure below shows typical PTC sensor
resistance values as a function of the motor operating temperature.
Ohm
4000
Temperature Resistance
Normal 0 … 1.5 kohm 1330
Excessive > 4 kohm
550
100
T
35.02 MOT 1 TEMP ALM L Defines the alarm limit for motor 1 temperature measurement. The alarm
indication is given when the limit is exceeded.
-10 … 5000 ohm/°C Limit in °C or ohms. °C: parameter 35.01 is 1xPT100, 2XPT100, 3XPT100. -10 … 5000
(PTC/Pt100) Ohm: parameter 35.01 is 1...3 PTC.
35.03 MOT 1 TEMP FLT L Defines the fault trip limit for motor 1 temperature measurement. The fault
indication is given when the limit is exceeded.
-10 … 5000 ohm/°C Limit in °C or ohms. °C: parameter 35.01 is 1xPT100, 2XPT100, 3XPT100. -10 … 5000
(PTC/Pt100) Ohm: parameter 35.01 is 1...3 PTC.
35.04 MOT 2 TEMP AI2 SEL Activates the motor 2 temperature measurement function and selects the
sensor type. Two motors can be protected only by using an optional analogue
extension module. Parameter 98.12 needs to be activated.
Note: If 98.12 is activated, the analogue I/O extension is also used for motor 1
temperature measurement (the standard I/O terminals are not in use).
Note: If an optional analogue I/O extension module RAIO is used for the
temperature measurement and 35.01 MOT 1 TEMP AI1 SEL and/or 35.04
MOT 2 TEMP AI2 SEL are set to 1xPT100, analogue extension module input
signal range must be set to 0...2 V (instead of 0...10 V) with DIP switches.
NOT IN USE See 35.01. 1
1xPT100 See 35.01. 2
2XPT100 See 35.01. 3
3XPT100 See 35.01. 4
1...3 PTC See 35.01. 5
35.05 MOT 2 TEMP ALM L Defines the alarm limit for the motor 2 temperature measurement function. The
alarm indication is given when the limit is exceeded.
-10 … 5000 ohm/°C See 35.02. -10 … 5000
(PTC/Pt100)

152

35.06 MOT 2 TEMP FLT L Defines the fault trip limit for the motor 2 temperature measurement function.
The fault indication is given when the limit is exceeded.
-10 … 5000 ohm/°C See 35.03. -10 … 5000
(PTC/Pt100)
35.07 MOT MOD Selects whether measured motor 1 temperature is used in the motor model
COMPENSAT compensation.
NO The function is inactive. 1
YES The temperature is used in the motor model compensation. 2
Note: Selection is possible only when Pt 100 sensor(s) are used.
40 PID CONTROL - process PID control (99.02 = PID CTRL)
- speed or torque reference trimming (99.02 is not PID CTRL)
- sleep function for the process PID control (99.02 = PID CTRL)
For more information, see section Process PID control on page 68.
40.01 PID GAIN Defines the gain of the process PID controller.
0.1 … 100.0 Gain value. The table below lists a few examples of the gain settings and the 10 … 10000
resulting speed changes when
- a 10% or 50% error value is connected to the controller
(error = process reference - process actual value).
- motor maximum speed is 1500 rpm (parameter 20.02)
PID Gain Speed Change: Speed Change:

10% Error 50% Error
0.5 75 rpm 375 rpm
1.0 150 rpm 750 rpm
3.0 450 rpm 1500 rpm (limited)
40.02 PID INTEG TIME Defines the integration time for the process PID controller.
Error/Controller output
O I = controller input (error)
I
O = controller output
G·I G = gain
t = time
G·I Ti = integration time
time
Ti
0.02 … 320.00 s Integration time 2 … 32000
40.03 PID DERIV TIME Defines the derivation time of the process PID controller. The derivative
component at the controller output is calculated on basis of two consecutive
error values (EK-1 and EK) according to the following formula:
PID DERIV TIME · (EK - EK-1)/TS, in which
TS = 12 ms sample time.
E = Error = Process reference - process actual value
0.00 … 10.00 s Derivation time. 0 … 1000

153

40.04 PID DERIV FILTER Defines the time constant of the 1-pole filter used to smooth the derivative
component of the process PID controller.
0.04 … 10.00 s Filter time constant. 4 … 1000
%
100
Filtered Signal
t = time
t
T
40.05 ERROR VALUE INV Inverts the error at the process PID controller input (error = process reference -
process actual value).
NO No inversion 0
YES Inversion. 65535
With sleep function, the drive operation is as follows:
The drive enters the sleep mode when the motor speed is below the sleep
level (02.02 < 40.21) and when the process PID control actual value is smaller
than the wake-up level (01.34 < 40.23).
The drive wakes up when the process PID actual value is greater than the
wake-up level (01.34 > 40.23).
See also section Sleep function for the process PID control on page 69.
40.06 ACTUAL VALUE SEL Selects the process actual value for the process PID controller: The sources
for the variable ACT1 and ACT2 are further defined by parameters 40.07 and
40.08.
ACT1 ACT1 1
ACT1-ACT2 Subtraction of ACT1 and ACT 2. 2
ACT1+ACT2 Addition of ACT1 and ACT2 3
ACT1*ACT2 Multiplication of ACT1 and ACT2 4
ACT1/ACT2 Division of ACT1 and ACT2 5
MIN(A1,A2) Selects the smaller of ACT1 and ACT2 6
MAX(A1,A2) Selects the higher of ACT1 and ACT2 7
sqrt(A1-A2) Square root of the subtraction of ACT1 and ACT2 8
sqA1+sqA2 Addition of the square root of ACT1 and the square root of ACT2 9
40.07 ACTUAL1 INPUT SEL Selects the source for the variable ACT1. See parameter 40.06.
40.08 ACTUAL2 INPUT SEL Selects the source for the variable ACT2. See parameter 40.06.

154

40.09 ACT1 MINIMUM Defines the minimum value for the variable ACT1 if an analogue input is
selected as a source for ACT1. See parameter 40.07. The minimum and
maximum (40.10) settings of ACT1 define how the voltage/current signal
received from the measuring device is converted to a percentage value used
by the process PID controller.
-1000 … 1000% Minimum value in percent of the set analogue input range. The equation below -10000 …
instructs how to calculate the value when analogue input AI1 is used as a 10000
variable ACT1.
AI1min - 13.01
ACT1 MINIMUM = · 100%
13.02 - 13.01
AI1min The voltage value received from the measuring device when
the measured process actual value is at the desired minimum
level.
13.01 AI1 minimum (parameter setting)
13.02 AI1 maximum (parameter setting)
40.10 ACT1 MAXIMUM Defines the maximum value for the variable ACT1 if an analogue input is
selected as a source for ACT1. See parameter 40.07. The minimum (40.09)
and maximum settings of ACT1 define how the voltage/current signal received
from the measuring device is converted to a percentage value used by the
process PID controller.
-1000 … 1000% Maximum value in percent of the set analogue input signal range. The -10000 …
equation below instructs how to calculate the value when analogue input AI1 is 10000
used as a variable ACT1.
AI1max - 13.01
ACT1 MAXIMUM = · 100%
13.02 - 13.01
AI1max The voltage value received from the measuring device when
the measured process actual value is at the desired maximum
level.
13.01 AI1 minimum (parameter setting)
13.02 AI1 maximum (parameter setting)
40.11 ACT2 MINIMUM See parameter 40.09.

-1000 … 1000% See parameter 40.09. -10000 …
10000
40.12 ACT2 MAXIMUM See parameter 40.10.
-1000 … 1000% See parameter 40.10. -10000 …

10000
40.13 PID INTEGRATION Activates the integration of the process PID controller.
OFF Inactive 1
ON Active 2

155

40.14 TRIM MODE Activates the trim function and selects between the direct and proportional
trimming. Using the trim it is possible to combine a corrective factor to the drive
reference. See section Reference trimming on page 47.
Example: A speed-controlled conveyor line where the line tension also needs
to be considered: The speed reference is slightly adjusted (trimmed)
depending on the value of the measured line tension.
Not visible when parameter 99.02 = PID CTRL.
OFF The trim function is deactivated. 1
PROPORTIONAL The trim function is active. The trimming factor is relative to the external 2
%-reference (REF2). See parameter 11.06.
DIRECT The trim function is active. The trimming factor is relative to a fixed maximum 3
limit used in the reference control loop (maximum speed, frequency or torque).
40.15 TRIM REF SEL Selects the signal source for the trim reference. Not visible when parameter
99.02 = PID CTRL.
Example: AI5 as a trim reference

sclAI5
minAI5 = parameter 13.16
maxAI5 = parameter 13.17
sclAI5 = parameter 13.18
Trim reference
AI5 be used only with an optional

I/O extension module.
-sclAI5

PAR 40.16 Value of parameter 40.16 is used as the trim reference. 6
PAR 40.28 Value of parameter 40.28 is used as the trim reference. 7
40.16 TRIM REFERENCE Defines the trim reference value when parameter 40.15 has the value PAR
40.16 selected. Not visible when parameter 99.02 = PID CTRL.
-100.0 … 100.0% Trim reference - 10000 …
10000
40.17 TRIM RANGE Defines the multiplier for the PID controller output used as the trimming factor.
ADJUST Not visible when parameter 99.02 = PID CTRL.
-100.0 … 100.0% Multiplying factor - 10000 …
10000
40.18 TRIM SELECTION Selects whether the trimming is used for correcting the speed or torque
reference.
Not visible when parameter 99.02 = PID CTRL.
SPEED TRIM Speed reference trimming 1

156

TORQUE TRIM Torque reference trimming 2
DIRECT SPD T Speed reference trimming. Trim reference is added to the speed reference 3
after ramp calculations. Trimming is not effective during ramp stop, emergency
stop or at speed defined by parameter 30.18 in a fieldbus communication
break.
40.19 ACTUAL FILT TIME Defines the time constant for the filter through which the actual signals are
connected to the process PID controller.
0.04 … 10.00 s Filter time constant. 4 … 1000
%
100 I = filter input (step)
Filtered Signal t = time
t
T
40.20 SLEEP SELECTION Activates the sleep function and selects the source for the activation input.
Visible only when parameter 99.02 = PID CTRL.
See section Sleep function for the process PID control on page 69.
OFF Inactive 1
INTERNAL Activated and deactivated automatically as defined by parameters 40.21 and 2
40.23.
DI1 The function is activated/deactivated through digital input DI1. 3
Activation: Digital input DI1 = 1. Deactivation: DI1 = 0.
The internal sleep criteria set by parameters 40.21 and 40.23 are not effective.
The sleep start and stop delays are effective (parameter 40.22 and 40.24).
40.21 SLEEP LEVEL Defines the start limit for the sleep function. If the motor speed is below a set
level (40.21) longer than the sleep delay (40.22), the drive shifts to the sleeping
mode: the motor is stopped and the control panel shows the warning message
“SLEEP MODE”.
0.0 … 7200.0 rpm Sleep start level 0 … 7200
40.22 SLEEP DELAY Defines the delay for the sleep start function. See parameter 40.21. When the
motor speed falls below the sleep level, the counter starts. When the motor
speed exceeds the sleep level, the counter resets.

157

0.0 … 3600.0 s Sleep start delay 0 … 36000
40.23 WAKE UP LEVEL Defines the wake-up limit for the sleep function. The drive wakes up if the
process actual value is below a set level (40.23) longer than the wake-up delay
(40.24).
0.0 … 100.0% The wake-up level in percent of the actual process value. 0 … 10000
40.24 WAKE UP DELAY Defines the wake-up delay for the sleep function. See parameter 40.23. When
the process actual value falls below the wake-up level, the wake-up counter
starts. When the process actual value exceeds the wake-up level, the counter
resets.
0.0 … 3600.0 s Wake-up delay 0 …36000
40.25 ACTUAL1 PTR Defines the source or constant for value PAR 40.25 of parameter 40.07.
32768 … C.32767
40.26 PID MINIMUM Defines the minimum limit for the PID controller output. Using the minimum and
maximum limits, it is possible to restrict the operation to a certain speed range.
Example: The process PID control is restricted to the forward rotation direction
of the motor by setting the PID minimum limit to 0% and the maximum to
100%.
-100 … 100% Limit in percent of the Absolute Maximum Speed of the motor 100 = 1%
40.27 PID MAXIMUM Defines the maximum limit for the PID controller output. Using the minimum
and maximum limits, it is possible to restrict the operation to a certain speed
range. See parameter 40.26.
-100 … 100% Limit in percent of the Absolute Maximum Speed of the motor 100 = 1%
40.28 TRIM REF PTR Defines the trim reference value when parameter 40.15 has been set to value
PAR 40.28.
-255.255.31 … Parameter index or a constant value: 100 = 1%
42 BRAKE CONTROL Control of a mechanical brake. The function operates on a 100 ms time level.
For the function description, see section Control of a mechanical brake on
page 75.
42.01 BRAKE CTRL Activates the brake control function.
OFF Inactive 1
ON Active 2
42.02 BRAKE Activates the external brake on/off supervision and selects the source for the
ACKNOWLEDGE signal. The use of the external on/off supervision signal is optional.
OFF Inactive 1
DI5 Active. Digital input DI5 is the signal source. DI5 = 1: The brake is open. 2
DI5 = 0: the brake is closed.

158

42.03 BRAKE OPEN DELAY Defines the brake open delay (= the delay between the internal open brake
command and the release of the motor speed control). The delay counter
starts when the drive has magnetised the motor and risen the motor torque to
the level required at the brake release (parameters 42.07 and 42.08).
Simultaneously with the counter start, the brake function energises the relay
output controlling the brake and the brake starts opening.
0.0 … 5.0 s Delay time. Set the delay the same as the mechanical opening delay of the 0 … 500
brake specified the brake manufacturer.
42.04 BRAKE CLOSE Defines the brake close delay. The delay counter starts when the motor actual
DELAY speed has fallen below the set level (parameter 42.05) after the drive has
received the stop command. Simultaneously with the counter start, the brake
control function de-energises the relay output controlling the brake and the
brake starts closing. During the delay, the brake function keeps the motor live
preventing the motor speed from falling below zero.
0.0 … 60.0 s Delay time. Set the delay time to the same value as the mechanical make-up 0 … 6000
time of the brake (= operating delay when closing) specified by the brake
manufacturer.
42.05 ABS BRAKE CLS Defines the brake close speed. See parameter 42.04.
SPD
0 … 1000 rpm Speed (an absolute value) 0 …100000
42.06 BRAKE FAULT FUNC Defines how the drive reacts in case the status of the optional external brake
acknowledgement signal does not meet the status presumed by the brake
control function.
FAULT The drive trips on a fault: fault indication and drive stops the motor. 1
42.07 START TORQ REF Selects the source for the motor starting torque reference applied at the brake
SEL release. The value is read in percent of the motor nominal torque.
NO No source selected. This is the default value. 1
PAR 42.08 Defined by parameter 42.08. 7
MEMORY The motor torque stored at the previous brake close command. 8
42.08 START TORQ REF Defines the motor starting torque at brake release if parameter 42.07 has value
PAR 40.28.
-300 … 300% Torque value in percent of the motor nominal torque -30000 …
30000

159

42.09 EXTEND RUN T Defines an extended run time for the brake control function at stop. During the
delay, the motor is kept magnetised and ready for an immediate restart.
0.0 … 60.0 s 0.0 s = Normal stop routine of the brake control function: The motor 100 = 1 s
magnetisation is switched off after the brake close delay has passed.
0.1 … 60.0 s = Extended stop routine of the brake control function: The motor
magnetisation is switched off after the brake close delay and the extended run
time have passed. During the extended run time, a zero torque reference is
applied, and the motor is ready for a immediate restart.
Start/Stop
Motor magnetised
Actual speed
1 = brake close speed
2 = brake close delay
3 = extended run time
1
t
2 3
42.10 LOW REF BRK HOLD Activates a brake hold function and defines the hold delay for it. The function
stabilises the operation of the brake control application when the motor
operates near zero speed and there is no measured speed feedback available
(pulse encoder).
0.0 … 60.0 s 0.0 s = inactive. 100 = 1 s
0.1 s … 60.0 s = active. When the absolute value of the motor speed reference
falls below the brake close speed:
- The brake hold delay counter starts.
- The brake is closed according to normal stop routine of the brake control
function.
During the delay, the function keeps the brake closed despite of the speed
reference value and the value of start command. When the set delay has
passed, the normal operation resumes.
50 ENCODER MODULE Encoder connection. Visible only when a pulse encoder module (optional) is
installed and activated by parameter 98.01.
The settings will remain the same even though the application macro is
changed.
50.01 PULSE NR States the number of encoder pulses per one revolution.
0 … 29999 ppr Pulse number in pulses per round (ppr) 0 … 29999
50.02 SPEED MEAS MODE Defines how the encoder pulses are calculated.
A -- B DIR Channel A: positive edges calculated for speed. Channel B: direction. 0
A --- Channel A: positive and negative edges calculated for speed. Channel B: not 1
used.
A --- B DIR Channel A: positive and negative edges are calculated for speed. Channel B: 2
direction.
A --- B --- All edges of the signals are calculated. 3

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50.03 ENCODER FAULT Defines the operation of the drive if a failure is detected in communication
between the pulse encoder and the pulse encoder interface module, or
between the module and the drive. Encoder supervision function activates if
either of the following conditions is valid:
-The difference between estimated and measured speed is greater than 20%
of the motor nominal speed.
- No pulses are received from the encoder within the defined time (see
parameter 50.04) and the motor torque is at the allowed maximum value.
WARNING The drive generates a warning indication. 0
FAULT The drive trips on a fault, gives a fault indication and stops the motor. 65535
50.04 ENCODER DELAY Defines the time delay for the encoder supervision function (See parameter
50.03).
0 … 50000 ms Time delay 0 … 50000
50.05 ENCODER DDCS CH Defines the fibre optic channel of the control board from which the drive
program reads the signals coming from the pulse encoder interface module.
The setting is valid only if the module is connected to the drive via the DDCS
link (i.e. not to the option slot of the drive).
CH 1 Signals via channel 1 (CH1). The pulse encoder interface module must be 1
connected to CH1 instead of CH2 in applications where CH2 is reserved by a
Master station (e.g. a Master/Follower application). See also parameter 70.03.
CH 2 Signals via channel 2 (CH2). Can be used in most cases. 2
50.06 SPEED FB SEL Defines the speed feedback value used in control.
INTERNAL Calculated speed estimate 65535
ENCODER Actual speed measured with an encoder 0
50.07 ENC CABLE CHECK Selects the drive operation when encoder signal is missing.
Note: Monitoring is only for RTAC-03. For more information, see RTAC-03
Pulse Encoder Interface Module User’s Manual [3AFE68650500 (English)].
NO No action 0
WARNING Drive generates warning ENC CABLE. 1
FAULT Drive trips on fault ENC CABLE. 2
51 COMM MODULE The parameters are visible and need to be adjusted, only when a fieldbus
DATA adapter module (optional) is installed and activated by parameter 98.02. For
details on the parameters, refer to the manual of the fieldbus module and
chapter Fieldbus control.
These parameter settings will remain the same even though the macro is
changed.
52 STANDARD The settings for the Standard Modbus Link. See chapter Fieldbus control.
MODBUS
52.01 STATION NUMBER Defines the address of the device. Two units with the same address are not
allowed on-line.
1 … 247 Address 1=1
52.02 BAUDRATE Defines the transfer rate of the link.
600 600 bit/s 1
1200 1200 bit/s 2
2400 2400 bit/s 3
4800 4800 bit/s 4

161

9600 9600 bit/s 5
19200 19200 bit/s 6
52.03 PARITY Defines the use of parity and stop bit(s). The same setting must be used in all
on-line stations.
NONE1STOPBIT No parity bit, one stop bit 1
NONE2STOPBIT No parity bit, two stop bits 2
ODD Odd parity indication bit, one stop bit 3
EVEN Even parity indication bit, one stop bit 4
60 MASTER/ Master/Follower application. For more information, see section Master/
FOLLOWER Follower use of several drives on page 78 and a separate Master/Follower
Application Guide [3AFE64590430 (English)].
60.01 MASTER LINK MODE Defines the role of the drive on the Master/Follower link.
Note: Two Master stations are not allowed on-line. If a Follower drive is
changed to be a Master drive (or vice versa) by this parameter, the RMIO
board must be powered up again for the M/F link to work properly.
NOT IN USE The Master/Follower link is not active. 1
MASTER Master drive 2
FOLLOWER Follower drive 3
STANDBY Follower drive which reads the control signals through a fieldbus interface, not 4
from the Master/Follower link as usual.
60.02 TORQUE SELECTOR Selects the reference used in motor torque control. Typically, the value needs
to be changed only in the Follower station(s).
The parameter is visible only when parameter 99.02 = T CTRL.
External control location 2 (EXT2) must be active to enable torque selector.
ZERO This selection forces the output of the torque selector to zero. 1
SPEED The follower speed controller output is used as a reference for motor torque 2
control. The drive is speed-controlled. SPEED can be used both in the
Follower and in the Master if
- the motor shafts of the Master and Follower are connected flexibly. (A slight
speed difference between the Master and the Follower is possible/allowed.)
- drooping is used (see parameter 60.06).
TORQUE The drive is torque-controlled. The selection is used in the Follower(s) when 3
the motor shafts of the Master and Follower are coupled solidly to each other
by gearing, a chain or other means of mechanical power transmission and no
speed difference between the drives is allowed or possible.
Note: If TORQUE is selected, the drive does not restrict the speed variation as
long as the speed is within the limits defined by parameters 20.01 and 20.02.
More definite speed supervision is often needed. In those cases, the selection
ADD should be used instead of TORQUE.
MINIMUM The torque selector compares the direct torque reference and the speed 4
controller output, and the smaller of them is used as the reference for the
motor torque control. MINIMUM is selected in special cases only.
MAXIMUM The torque selector compares the direct torque reference and the speed 5
controller output and the greater of them is used as the reference for the motor
torque control. MAXIMUM is selected in special cases only.

162

ADD The torque selector adds the speed controller output to the direct torque 6
reference. The drive is torque-controlled in the normal operating range. The
selection ADD, together with the window control, forms a speed supervision
function for a torque-controlled Follower drive. See parameter 60.03.
60.03 WINDOW SEL ON Activates the Window control function. The Window control, together with
selection ADD at parameter 60.02, forms a speed supervision function for a
torque-controlled drive. The parameter is visible only when parameter 99.02 is
T CTRL. External control location 2 (EXT2) must be active to enable window
control.
NO Inactive 0
YES Window control is active. Selection YES is used only when parameter 60.02 65535
has value ADD. Window control supervises the speed error value (Speed
Reference - Actual Speed). In the normal operating range, window control
keeps the speed controller input at zero. The speed controller is evoked only if:
- the speed error exceeds the value of parameter 60.04 or
- the absolute value of the negative speed error exceeds the value of
parameter 60.05.
When the speed error moves outside the window, the exceeding part of the
error value is connected to the speed controller. The speed controller produces
a reference term relative to the input and gain of the speed controller
(parameter 23.01) which the torque selector adds to the torque reference. The
result is used as the internal torque reference for the drive.
Example: In a load loss condition, the internal torque reference of the drive is
decreased to prevent an excessive rise of the motor speed. If window control
were inactivated, the motor speed would rise until a speed limit of the drive
were reached.
60.04 WINDOW WIDTH Defines the supervision window width above the speed reference. See
POS parameter 60.03. The parameter is visible only when parameter 99.02 is T
CTRL.
0 … 1500 rpm Positive window width 0… 20000
60.05 WINDOW WIDTH Defines the supervision window width below the speed reference. See
NEG parameter 60.03. The parameter is visible only when parameter 99.02 is T
CTRL.
0 … 1500 rpm Negative window width 0… 20000

163

60.06 DROOP RATE Defines the droop rate. The parameter value needs to be changed only if both
the Master and the Follower are speed-controlled:
- External control location 1 (EXT1) is selected (see parameter 11.02 or
- External control location 2 (EXT2) is selected (see parameter 11.02) and
parameter 60.02 is set to SPEED.
The droop rate needs to be set both for the Master and the Follower. The
correct droop rate for a process must be found out case by case in practice.
The drooping prevents a conflict between the Master and the Follower by
allowing a slight speed difference between them. The drooping slightly
decreases the drive speed as the drive load increases. The actual speed
decrease at a certain operating point depends on the droop rate setting and
the drive load ( = torque reference / speed controller output). At 100% speed
controller output, drooping is at its nominal level, i.e. equal to the value of the
DROOP RATE. The drooping effect decreases linearly to zero along with the
decreasing load.
Speed Decrease =
Motor
Speed Controller Output · Drooping · Max. Speed
Speed Example: Speed Controller output is 50%, DROOP RATE is
% of
1%, maximum speed of the drive is 1500 rpm.
nominal Speed decrease = 0.50 · 0.01 · 1500 rpm = 7.5 rpm
No Drooping
100% } Par. 60.06 DROOP RATE
Drooping
Speed Controller Drive load

100% Output / %
0 … 100% Droop rate in percent of the motor nominal speed 0 … 1000

60.07 MASTER SIGNAL 2 Selects the signal that is sent by the Master to the Follower(s) as Reference 1
(speed reference).
0000 … 9999 Parameter index 0000 …
9999
60.08 MASTER SIGNAL 3 Selects the signal that is sent by the Master to the Follower(s) as Reference 2
(torque reference).
0000 … 9999 Parameter index 0000 …
9999
70 DDCS CONTROL Settings for the fibre optic channels 0, 1 and 3.
70.01 CHANNEL 0 ADDR Defines the node address for channel 0. No two nodes on-line may have the
same address. The setting needs to be changed when a master station is
connected to channel 0 and it does not automatically change the address of
the slave. Examples of such masters are an ABB Advant Controller or another
drive.
1 … 125 Address. 1 … 125
70.02 CHANNEL 3 ADDR Node address for channel 3. No two nodes on-line may have the same
address. Typically the setting needs to be changed when the drive is
connected in a ring which consists of several drives and a PC with the
DriveWindow program running.
1 … 254 Address. 1 … 254

164

70.03 CH1 BAUD RATE The communication speed of channel 1. Typically the setting needs to be
changed only if the pulse encoder interface module is connected to channel 1
instead of channel 2. Then the speed must be changed to 4 Mbit/s. See also
parameter 50.05.
8 Mbit/s 8 megabits per second 0
70.04 CH0 DDCS HW Selects the topology of the channel 0 link.
CONN
RING Devices are connected in ring topology. 0
STAR Devices are connected in a star topology. 65535
70.05 CH2 HW Selects the topology of the DDCS channel CH2 link. 1=1
CONNECTION
0 = RING Devices are connected in a ring. Forwarding of messages is enabled.
1 = STAR Devices are connected in a star. Forwarding of messages is disabled. This
selection is used with NDBU branching units.
72 USER LOAD CURVE See section User load curve on page 81.
72.01 OVERLOAD FUNC Activates the user load curve and selects how the drive reacts when the user
load curve has been exceeded.
NO User load curve is inactive. 0
WARNING The drive generates a warning USER L CURVE. Drive output current is not 1
limited.
FAULT The drive trips on a fault USER L CURVE. 2
LIMIT Drive output current is limited to Iuser curve. 3
LIMIT / WARN Drive output current is limited to Iuser curve and the drive generates a warning 4
USER L CURVE.
72.02 LOAD CURRENT 1 Defines the first current point of the load curve at the frequency defined by par.
72.10 LOAD FREQ 1.
0...800% Value in percent of the nominal motor current 1=1
72.03 LOAD CURRENT 2 Defines the second current point of the load curve at the frequency defined by
par. 72.11 LOAD FREQ 2.
72.04 LOAD CURRENT 3 Defines the third current point of the load curve at the frequency defined by par.
72.12 LOAD FREQ 3.
72.05 LOAD CURRENT 4 Defines the fourth current point of the load curve at the frequency defined by
72.06 LOAD CURRENT 5 Defines the fifth current point of the load curve at the frequency defined by par.
72.14 LOAD FREQ 5.
72.07 LOAD CURRENT 6 Defines the sixth current point of the load curve at the frequency defined by

165

72.08 LOAD CURRENT 7 Defines the seventh current point of the load curve at the frequency defined by
72.09 LOAD CURRENT 8 Defines the eighth current point of the load curve at the frequency defined by
72.10 LOAD FREQ 1 Defines the first frequency point of the load curve.
0... par. 72.11 % Value in percent of the nominal motor frequency 1=1
72.11 LOAD FREQ 2 Defines the second frequency point of the load curve.
par. 72.10... Value in percent of the nominal motor frequency 1=1
par. 72.12 %
72.12 LOAD FREQ 3 Defines the third frequency point of the load curve.
par. 72.13 %
72.13 LOAD FREQ 4 Defines the fourth frequency point of the load curve.
par. 72.14 %
72.14 LOAD FREQ 5 Defines the fifth frequency point of the load curve.
par. 72.15 %
72.15 LOAD FREQ 6 Defines the sixth frequency point of the load curve.
par. 72.16 %
72.16 LOAD FREQ 7 Defines the seventh frequency point of the load curve.
par. 72.17 %
72.17 LOAD FREQ 8 Defines the eight frequency point of the load curve.
par. 72.16...600% Value in percent of the nominal motor frequency 1=1
72.18 LOAD CURRENT Defines the overload current. Value is used by the overload integrator (∫I2dt).
LIMIT If the continuous motor load capacity (i.e. the defined user load curve) is not
100% at the nominal frequency, calculate the overload current using the
following equation:
2 2 2
72.18 LOAD CURRENT LIMIT = I overload – I user curve + 100
where Ioverload is the motor overload and Iuser curve is the current defined by the
user load curve at the nominal frequency. User load curve is defined by
parameters 72.02...72.17.
Example: Motor overload capacity is 150% of the nominal current for
10 s / 10 min and the continuous load capacity is 80% at the nominal
frequency:
2 2 2
72.18 LOAD CURRENT LIMIT = 150 – 80 + 100 = 162%
72.19 LOAD THERMAL TIME = 10 s
72.20 LOAD COOLING TIME = 590 s
100...800% Value in percent of the nominal motor current (99.06 MOTOR NOM 10 = 1%
CURRENT)

166

72.19 LOAD THERMAL Defines the overload time. Value is used by the overload integrator (∫I2dt). See 10 = 1 s
TIME the example given for par. 72.18 LOAD CURRENT LIMIT.
0.0...9999.9 s Time. If the value is set to zero, the drive output current is limited to the user
load curve defined by parameters 72.02...72.17.
72.20 LOAD COOLING Defines the cooling time. The output of the overload integrator is set to zero if
TIME the current stays continuously below the user load curve for the defined cooling
time. See the example given for par. 72.18 LOAD CURRENT LIMIT.
0...9999 s Time 1=1s
83 ADAPT PROG CTRL Control of the Adaptive Program execution. For more information, see the
Adaptive Program Application Guide [3AFE64527274 (English)].
83.01 ADAPT PROG CMD Selects the operation mode for the Adaptive Program.
STOP Stop. The program cannot be edited. 1
RUN Run. The program cannot be edited. 2
EDIT Stop to edit mode. Program can be edited. 3
83.02 EDIT COMMAND Selects the command for the block placed in the location defined by parameter
83.03. The program must be in editing mode (see parameter 83.01).
NO Home value. The value automatically restores to NO after an editing command 1
has been executed.
PUSH Shifts the block in location defined by parameter 83.03 and the following blocks 2
one location up. A new block can be placed in the emptied location by
programming the Block Parameter Set as usual.
Example: A new block needs to be placed in between the current block
number four (parameters 84.20 … 84.25) and five (parameters 84.25 …
84.29).
In order to do this:
- Shift the program to the editing mode by parameter 83.01.
- Select location number five as the desired location for the new block by
parameter 83.03.
- Shift the block in location number 5 and the following blocks one location
forward by parameter 83.02. (selection PUSH)
- Program the emptied location number 5 by parameters 84.25 to 84.29 as
usual.
DELETE Deletes the block in location defined by parameter 83.03 and shifts the 3
following blocks one step down.
PROTECT Activation of the Adaptive Program protection. Activate as follows: 4
- Ensure the Adaptive Program operation mode is START or STOP (parameter
83.01).
- Set the passcode (parameter 83.05).
- Change parameter 83.02 to PROTECT.
When activated:
- All parameters in group 84 excluding the block output parameters are hidden
(read protected).
- It is not possible to switch the program to the editing mode (parameter 83.01).
- Parameter 83.05 is set to 0.

167

UNPROTECT Inactivation of the Adaptive Program protection. Inactivate as follows: 5
- Ensure the Adaptive Program operation mode is START or STOP (parameter
83.01).
- Set the passcode (parameter 83.05).
- Change parameter 83.02 to UNPROTECT.
Note: If the passcode is lost, it is possible to reset the protection also by
changing the application macro setting (parameter 99.02).
83.03 EDIT BLOCK Defines the block location number for the command selected by parameter
83.02.
1 … 15 Block location number 1=1
83.04 TIMELEVEL SEL Selects the execution cycle time for the Adaptive Program. The setting is valid
for all blocks.
12 ms 12 milliseconds 1
83.05 PASSCODE Sets the passcode for the Adaptive Program protection. The passcode is
needed at activation and inactivation of the protection. See parameter 83.02.
0… Passcode. The setting restores to 0 after the protection is activated/inactivated.
Note: When activating, write down the passcode and store it in a safe place.
84 ADAPTIVE - selections of the function blocks and their input connections.
PROGRAM - diagnostics
For more information, see the Adaptive Program Application Guide
84.01 STATUS Shows the value of the Adaptive Program status word. The table below shows
the alternative bit states and the corresponding values on the panel display.
Bit Display Meaning
0 1 Stopped
1 2 Running
2 4 Faulted
3 8 Editing
4 10 Checking
5 20 Pushing
6 40 Popping
8 100 Initialising
84.02 FAULTED PAR Points out the faulted parameter in the Adaptive Program. -
84.05 BLOCK1 Selects the function block for Block Parameter Set 1. See the Adaptive
Program Application Guide [3AFE64527274 (English)].
ABS 11
ADD 10
AND 2
BITWISE 26
COMPARE 16
COUNT 21
DPOT 23
EVENT 20

168

FILTER 13
MASK-SET 24
MAX 17
MIN 18
MULDIV 12
NO 1
OR 3
PI 14
PI-BAL 15
PI BIPOLAR 25
RAMP 22
SR 5
SWITCH-B 7
SWITCH-I 19
TOFF 9
TON 8
TRIGG 6
XOR 4
84.06 INPUT1 Selects the source for input I1 of Block Parameter Set 1.
-255.255.31 … Parameter index or a constant value: -
Example: The state of digital input DI2 is connected to Input 1 as follows:
- Set the source selection parameter (84.06) to +.01.17.01. (The application
program stores the state of digital input DI2 to bit 1 of actual signal 01.17.)
- If you need an inverted value, switch the sign of the pointer value
(-01.17.01.).
84.07 INPUT2 See parameter 84.06.
-255.255.31 … See parameter 84.06. -
+255.255.31 / C.-
32768 … C.32767
84.08 INPUT3 See parameter 84.06.
-255.255.31 … See parameter 84.06. -
+255.255.31 / C.-
32768 … C.32767
84.09 OUTPUT Stores and displays the output of Block Parameter Set 1.
… …
84.79 OUTPUT Stores the output of Block Parameter Set 15. -
85 USER CONSTANTS Storage of the Adaptive Program constants and messages. For more
information, see the Adaptive Program Application Guide [3AFE64527274
(English)].
85.01 CONSTANT1 Sets a constant for the Adaptive Program.
-8388608 to 8388607 Integer value 1=1

169

-8388608 to 8388607 Integer value 1=1
-8388608 to 8388607 Integer value 1=1
-8388608 to 8388607 Integer value 1=1
-8388608 to 8388607 Integer value 1=1
-8388608 to 8388607 Integer value 1=1
-8388608 to 8388607 Integer value 1=1
-8388608 to 8388607 Integer value 1=1
-8388608 to 8388607 Integer value 1=1
-8388608 to 8388607 Integer value 1=1
85.11 STRING1 Stores a message to be used in the Adaptive Program (EVENT block).
MESSAGE1 Message -
MESSAGE2 Message -
MESSAGE3 Message -
MESSAGE4 Message -
MESSAGE5 Message -
90 D SET REC ADDR - Addresses into which the received fieldbus data sets are written.
- Numbers of the main and auxiliary data sets.
The parameters are visible only when a fieldbus communication is activated by
parameter 98.02. For more information, see chapter Fieldbus control.
90.01 AUX DS REF3 Selects the address into which the value of fieldbus reference REF3 is written.
0 … 8999 Parameter index
90.04 MAIN DS SOURCE Defines the data set from which the drive reads the Control Word, Reference
REF1 and Reference REF2.
1 … 255 Data set number
90.05 AUX DS SOURCE Defines the data set from which the drive reads References REF3, REF4 and
REF5.

170

1 … 255 Data set number
92 D SET TR ADDR Main and Auxiliary Data Sets which the drive sends to the fieldbus master
station.
The parameters are visible only when a fieldbus communication is activated by
parameter 98.02. For more information, see chapter Fieldbus control.
92.01 MAIN DS STATUS Stores the address from which the Main Status Word is read from. Fixed value,
WORD not visible.
302 (fixed) Parameter index
92.02 MAIN DS ACT1 Selects the address from which the Actual Signal 1 is read to the Main Data
Set.
92.03 MAIN DS ACT2 Selects the address from which the Actual Signal 2 is read to the Main Data
Set.
92.04 AUX DS ACT3 Selects the address from which the Actual Signal 3 is read to the Auxiliary Data
Set.
Set.
Set.
92.07 MSW B10 PTR Selects the address from which the 03.02 Main Status Word bit 10 is read from.
-255.255.31 … Parameter index or a constant value:
95 HARDWARE SPECIF Fan speed control, sine filter application etc.
95.01 FAN SPD CTRL Selects the speed control of the optional inverter cooling fan.
MODE
CONST 50 Hz Fan is running at constant frequency of 50 Hz when powered. 0

171

RUN/STOP Drive stopped: Fan is running at constant frequency of 10 Hz. 1
Drive running: Fan is running at constant frequency of 50 Hz.
CONTROLLED The speed of the fan is determined from IGBT temperature vs. fan speed 2
curve.
95.02 FUSE SWITCH CTRL Activates the inverter DC switch (switch fuse) monitoring function. The
monitoring must be active when the Switch Fuse Control Board (ASFC) is in
use and connected to the inverter AINT board, i.e. in all frame R8i inverters
equipped with the DC switch. The function must be inactive in units that do not
use the ASFC board with the DC switch, i.e. for frame R2i…R7i inverters and
all single drive units where no DC switch exists. The default setting (ON or
OFF) for each unit is set accordingly at the factory as default.
ACS800 IGBT pulses are always blocked when the program detects that the
DC switch is opened or inverter charging is ongoing (at power switch on). The
application program generates alarm INV DISABLED if the DC switch is
opened when the inverter is stopped. The inverter trips to fault INV DISABLED
if the DC switch is opened when the inverter is running.
OFF Inactive 0
ON Active 1
95.03 INT CONFIG USER Number of parallel connected inverter modules. Activates the Reduced Run
function. See section Reduced Run function on page 80.
1...12 Number of parallel connected inverter modules
95.04 EX/SIN REQUEST Activates the sine filter or Ex-motor application.
NO Inactive 1
EX Ex-motor application. Used with motors which comply with the ATEX directive. 2
SIN Sine filter application. See the Sine Filters User’s Manual for ACS800 Drives 3
EX&SIN EX-motor and sine filter applications. See the Sine Filters User’s Manual for 4
ACS800 Drives [3AFE68389178 (English)].
95.05 ENA INC SW FREQ Activates the minimum switching frequency limitation for Ex-motor
applications. Parameter is visible if parameter 95.04 EX/SIN REQUEST is set
to EX.
NO Inactive 0
YES Active. Minimum switching frequency limit is set to 2 kHz. Used with motors 1
with an ATEX certification based on 2 kHz minimum switching frequency.

172

95.06 LCU Q PW REF Defines the reference value for the line-side converter reactive power
generation. Line-side converter can generate reactive power to the supply
network. This reference is written into line-side converter unit parameter 24.02
Q POWER REF2. For more information, see IGBT Supply Control Program 7.x
Firmware manual [3AFE68315735 (English)].
Example 1: When parameter 24.03 Q POWER REF2 SEL is set to PERCENT,
value 10000 of parameter 24.02 Q POWER REF2 equals to value 100% of
parameter 24.01 Q POWER REF (i.e. 100% of the converter nominal power
given in signal 04.06 CONV NOM POWER).
Example 2: When parameter 24.03 Q POWER REF2 SEL is set to kVAr, value
1000 of parameter 24.02 Q POWER REF2 equals to parameter 24.01 Q
POWER REF value calculated with the following equation: 100 · (1000 kVAr
divided by converter nominal power in kVAr)%.
Example 3: When parameter 24.03 Q POWER REF2 SEL is set to PHI, value
3000 of parameter 24.02 POWER REF2 equals approximately to parameter
24.01 Q POWER REF value calculated with the following equation:
S
P P Q
cos ( 30 ) = ---- = ------------------------
S 2 2 30°
P +Q
P
Positive reference 30° denotes capacitive load.
Negative reference 30° denotes inductive load.
P = signal 01.09 POWER value
Parameter 24.03 values are converter to degrees by the line-side converter
application program: -3000...30000 = -30°...30°. Value -10000/10000 equals to
-30°/30°, since the range is limited to -3000/3000.
-10000...10000 Reference value. See par.
description.
95.07 LCU DC REF Defines the intermediate circuit DC voltage reference for the line-side
converter. This reference is written into line-side converter parameter 23.01 DC
VOLT REF. For more information, see IGBT Supply Control Program 7.x
Firmware manual [3AFE68315735 (English)].
0...1100 V Voltage 1=1V
95.08 LCU PAR1 SEL Selects the line-side converter address from which the actual signal 09.12 LCU
ACT SIGNAL1 is read from.
0…9999 Line-side converter parameter index. Default value 106 = line-side converter 0…9999
parameter 01.06 LINE CURRENT. For more information, see IGBT Supply
Control Program 7.x Firmware manual [3AFE68315735 (English)].
95.09 LCU PAR2 SEL Selects the line-side converter address from which the actual signal 09.13 LCU
ACT SIGNAL2 is read from.
0…9999 Line-side converter parameter index. Default value 110 = line side converter 0…9999
parameter 01.10 DC VOLTAGE. For more information, see IGBT Supply
Control Program 7.x Firmware manual [3AFE68315735 (English)].
95.10 TEMP INV AMBIENT Defines the ambient temperature for the Enhanced drive temperature
monitoring function. See Enhanced drive temperature monitoring for ACS800-
U2, -U4 and -U7, frame sizes R7 and R8 on page 65.
Note: If ambient temperature exceeds 40°C, the drive load capacity
decreases. See the derating instructions in the appropriate hardware manual.
20...50°C Temperature 10 = 1°C

173

96 EXTERNAL AO Output signal selection and processing for the analogue extension module
(optional).
The parameters are visible only when the module is installed and activated by
parameter 98.06.
96.01 EXT AO1 Selects the signal connected to analogue output AO1 of the analogue I/O
extension module.
COM.REF4 See parameter 15.01. 15
96.02 INVERT EXT AO1 Activates the inversion of analogue output AO1 of the analogue I/O extension
module.
NO Inactive 0
YES Active. The analogue signal is at a minimum level when the drive signal 65535
indicated is at its maximum and vice versa.

174

96.03 MINIMUM EXT AO1 Defines the minimum value for the analogue output AO1 of the analogue I/O
extension module.
Note: Actually, the setting 10 mA or 12 mA does not set the AO1 minimum but
fixes 10/12 mA to actual signal value zero.
Example: Motor speed is read through the analogue output.
- The motor nominal speed is 1000 rpm (parameter 99.08).
- 96.02 is NO.
- 96.05 is 100%.
The analogue output value as a function of the speed is shown below.
Analogue output
mA
20
Analogue output
signal minimum
12 1 0 mA
10 2 4 mA
3 10 mA
4 2 2 4 12 mA
4
3 1 1
-1000 -500 0 500 1000

Speed/rpm
0 mA 0 mA 1
4 mA 4 mA 2
10 mA 10 mA 3
12 mA 12 mA 4
96.04 FILTER EXT AO1 Defines the filtering time constant for analogue output AO1 of the analogue I/O
extension module. See parameter 15.04.
0.00 … 10.00 s Filtering time constant 0 … 1000
96.05 SCALE EXT AO1 Defines the scaling factor for analogue output AO1 of the analogue I/O
10 … 1000% Scaling factor 100 …
10000
96.06 EXT AO2 Selects the signal connected to analogue output AO2 of the analogue I/O
extension module.

175

COM.REF5 See parameter 15.06. 15
96.07 INVERT EXT AO2 Activates the inversion of analogue output AO2 of the analogue I/O extension
module. The analogue signal is at its minimum level when the drive signal
indicated is at its maximum and vice versa.
NO Inactive 0
YES Active 65535
96.08 MINIMUM EXT AO2 Defines the minimum value for analogue output AO2 of the analogue I/O
0 mA 0 mA 1
4 mA 4 mA 2
10 mA 10 mA 3
12 mA 12 mA 4
96.09 FILTER EXT AO2 Defines the filtering time constant for analogue output AO2 of the analogue I/O
0.00 … 10.00 s Filtering time constant 0 … 1000
96.10 SCALE EXT AO2 Defines the scaling factor for analogue output AO2 of the analogue I/O
10 … 1000% Scaling factor 100 …
10000
96.11 EXT AO1 PTR Defines the source or constant for value PAR 96.11 of parameter 96.01. 1000 =
1 mA
32768 … C.32767
96.12 EXT AO2 PTR Defines the source or constant for value PAR 96.12 of parameter 96.06. 1000 =
1 mA
32768 … C.32767
98 OPTION MODULES Activation of the option modules.
The parameter settings will remain the same even though the application
macro is changed (parameter 99.02).
98.01 ENCODER MODULE Activates the communication to the optional pulse encoder module. See also
parameter group 50 ENCODER MODULE.
NTAC Communication active. Module type: NTAC module. Connection interface: 0
Fibre optic DDCS link.
Note: Module node number must be set to 16. For directions, see the
NTAC-0x/NDIO-0x/NAIO-0x Module Installation and Start-up Guide
[3AFY58919730 (English)].
NO Inactive 1
RTAC-SLOT1 Communication active. Module type: RTAC. Connection interface: Option 2
slot 1 of the drive.

176

RTAC-SLOT2 Communication active. Module type: RTAC. Connection interface: Option 3
RTAC-DDCS Communication active. Module type: RTAC. Connection interface: Optional I/O 4
module adapter (AIMA) that communicates with the drive through a fibre optic
DDCS link.
Note: Module node number must be set to 16. For directions, see the RTAC-01
Pulse Encoder Interface User's Manual [3AFE64486853 (English)].
RRIA-SLOT1 Communication active. Module type: RRIA. Connection interface: option slot 1 5
of the drive.
RRIA-SLOT2 Communication active. Module type: RRIA. Connection interface: option slot 2 6
of the drive.
RRIA-DDCS Communication active. Module type: RRIA. Connection interface: Optional I/O 7
DDCS link.
Note: Module node number must be set to 16. For directions, see RRIA-01
Resolver Interface Module User's Manual [3AFE68570760 (English)].
RTAC03-SLOT1 Communication active. Module type: RTAC-03. Connection interface: Option
RTAC03-SLOT2 Communication active. Module type: RTAC-03. Connection interface: Option
RTAC03-DDCS Communication active. Module type: RTAC-03. Connection interface: Optional
I/O module adapter (AIMA) that communicates with the drive through a fibre
optic DDCS link.
Note: Module node number must be set to 16. For directions, see the RTAC-03
Pulse Encoder Interface User's Manual [3AFE68650500 (English)].
98.02 COMM. MODULE Activates the external serial communication and selects the interface. See
LINK chapter Fieldbus control.
NO No communication 1
FIELDBUS The drive communicates through an Rxxx type fieldbus adapter connected to 2
slot 1 or through an Nxxx type fieldbus adapter connected to RMIO board
channel CH0. See also parameter group 51 COMM MODULE DATA.
ADVANT The drive communicates with an ABB Advant OCS system via CH0 on the 3
RDCO board (optional). See also parameter group 70 DDCS CONTROL.
STD MODBUS The drive communicates with a Modbus controller via the Modbus Adapter 4
Module (RMBA) in option slot 1 of the drive. See also parameter 52
STANDARD MODBUS.
CUSTOMISED The drive communicates via a customer specified link. The control sources are 5
defined by parameters 90.04 and 90.05.
98.03 DI/O EXT MODULE 1 Activates the communication to the digital I/O extension module 1 (optional)
and defines the type and connection interface of the module.
Module inputs: See parameter 98.09 for the use of the inputs in the drive
application program.
Module outputs: See parameters 14.10 and 14.11 for selecting the drive states
that are indicated through the relay outputs.
NDIO Communication active. Module type: NDIO module. Connection interface: 1
Note: Module node number must be set to 2. For directions, see the NTAC-0x/
NDIO-0x/NAIO-0x Module Installation and Start-up Guide [3AFY58919730
(English)].

177

NO Inactive 2
RDIO-SLOT1 Communication active. Module type: RDIO. Connection interface: Option slot 1 3
of the drive.
of the drive.
RDIO-DDCS Communication active. Module type: RDIO. Connection interface: Optional I/O 5
DDCS link.
Note: Module node number must be set to 2. For directions, see the RDIO
Module User’s Manual [3AFE64485733 (English)].
(English)].
NO Inactive 2
of the drive.
of the drive.
DDCS link.
(English)].
NO Inactive 2
of the drive.
of the drive.

178

DDCS link.
98.06 AI/O EXT MODULE Activates the communication to the analogue I/O extension module (optional),
Module inputs:
- Values AI5 and AI6 in the drive application program are connected to module
inputs 1 and 2.
- See parameters 98.13 and 98.14 for the signal type definitions.
Module outputs:
- See parameters 96.01 and 96.06 for selecting the drive signals that are
indicated through module outputs 1 and 2.
NAIO Communication active. Module type: NAIO. Connection interface: Fibre optic 1
DDCS link.
(English)].
NO Communication inactive 2
RAIO-SLOT1 Communication active. Module type: RAIO. Connection interface: Option slot 1 3
of the drive.
of the drive.
RAIO-DDCS Communication active. Module type: RAIO. Connection interface: Optional I/O 5
DDCS link.
Note: Module node number must be set to 5. For directions, see the RAIO
98.07 COMM PROFILE Defines the profile on which the communication with the fieldbus or another
drive is based. Visible only when fieldbus communication is activated by
parameter 98.02.
ABB DRIVES ABB Drives profile 1
GENERIC Generic drive profile. Typically used with the fieldbus modules that have the 2
type designation of form Rxxx (installed in the option slot of the drive).
CSA 2.8/3.0 Communication profile used by application program versions 2.8 and 3.0. 3
98.09 DI/O EXT1 DI FUNC Defines the naming of the inputs of digital I/O extension module 1 in the drive
application program. See parameter 98.03.
DI7,8 DI1 and DI2 of the module extend the number of input channels. The module 1
inputs are named DI7 and DI8.
REPL DI1,2 DI1 and DI2 of the module replace the standard input channels DI1 and DI2. 2
The inputs are named DI1 and DI2.
DI7,8,9 DI1, DI2 and DI3 of the module extend the number of input channels. The 3
module inputs are named DI7, DI8 and DI9.
REPL DI1,2,3 DI1, DI2 and DI3 of the module replace the standard input channels DI1, DI2 4
and DI3. The inputs are named DI1, DI2 and DI3.

179

DI10,11,12 DI1, DI2 and DI3 of the module extend the number of input channels. The 3
module inputs are named DI10, DI11 and DI12.
REPL DI4,5,6 DI1, DI2 and DI3 of the module replace the standard input channels DI1, DI2 4
and DI3. The inputs are named DI4, DI5 and DI6.
98.12 AI/O MOTOR TEMP Activates the communication to the analogue I/O extension module and
reserves the module for the use of the motor temperature measurement
function. The parameter also defines the type and connection interface of the
module.
For more information on the temperature measurement function, see
parameter group 35 MOT TEMP MEAS and section Motor temperature
measurement through an analogue I/O extension on page 73.
The use of the analogue inputs (AI) and outputs (AO) of the module is shown in
the table below.
Motor 1 temperature measurement

AO1 Feeds a constant current to motor 1 temperature sensor. The current
value depends on the setting of parameter 35.01:
- AO1 is 9.1 mA with selection 1xPT100
- AO1 is 1.6 mA with selection 1...3 PTC
AI1 Measures voltage over motor 1 temperature sensor.
Motor 2 temperature measurement
AO2 Feeds a constant current to motor 2 temperature sensor. The current
value depends on the setting of parameter 35.04:
- AO2 is 9.1 mA with selection 1xPT100,
- AO2 is 1.6 mA with selection 1...3 PTC
AI2 Measures voltage over motor 2 temperature sensor.
Before setting the drive parameters, ensure the module hardware settings are
appropriate for the motor temperature measurement:
1. The module node number is 9.
2. The input signal type selections are the following:
- for one Pt 100 sensor measurement, set the range to 0 … 2 V.
- for two to three Pt 100 sensors or one to three PTC sensors, set the range to
0 … 10 V.
3. The operation mode selection is unipolar.

180

NAIO Communication active. Module type: NAIO. Connection interface: Fibre optic 1
DDCS link.
Note: Make the module hardware settings as described above. For
instructions, see the NTAC-0x/NDIO-0x/NAIO-0x Module Installation and Start-
up Guide [3AFY58919730 (English)].
NO Inactive 2
of the drive.
Note: Make the module hardware settings as described above. The node
number is not required. For directions, see the RAIO Module User’s Manual
of the drive.
Note: Make the module hardware settings as described above. The node
number is not required. For directions, see the RAIO Module User’s Manual
RAIO-DDCS Communication active. Module type: RAIO. Connection interface: Optional I/O 5
DDCS link.
Note: Set the module node number to 9. For directions, see the RAIO Module
User’s Manual [3AFE64484567 (English)].
98.13 AI/O EXT AI1 FUNC Defines the signal type for input 1 of the analogue I/O extension module (AI5 in
the drive application program). The setting must match the signal connected to
the module.
Note: The communication must be activated by parameter 98.06.
UNIPOLAR AI5 Unipolar 1
BIPOLAR AI5 Bipolar 2
98.14 AI/O EXT AI2 FUNC Defines the signal type for input 2 of the analogue I/O extension module (AI6 in
the drive application program). The setting must match the signal connected to
the module.
Note: The communication must be activated by parameter 98.06.
UNIPOLAR AI6 Unipolar 1
BIPOLAR AI6 Bipolar 2
98.16 SIN FILT SUPERV Activates the communication to the digital I/O extension module and reserves
the module for the use of the sine-filter temperature measurement.
Parameter is visible if parameter 95.04 is set to SIN or EX&SIN. Parameter
value is automatically set to NO, when parameter 95.04 value is changed.
Note: This parameter is used only in special applications.
NDIO Module type: NDIO module. Connection interface: Fibre optic DDCS link. 1
Note: Module node number must be set to 8. For directions see the NTAC-0x/
(English)].
NO Supervision disabled. 2
RDIO-SLOT1 Module type: RDIO. Connection interface: Option slot 1 of the drive. 3
RDIO-SLOT2 Module type: RDIO. Connection interface: Option slot 2 of the drive. 4

181

RDIO-DDCS Module type: RDIO. Connection interface: Optional I/O module adapter (AIMA) 5
that communicates with the drive through a fibre optic DDCS link.
Module User's Manual [3AFE64485733 (English)].
99 START-UP DATA Language selection. Definition of motor set-up data.
99.01 LANGUAGE Selects the display language.
ENGLISH British English 0
ENGLISH AM American English. If selected, the unit of power used is HP instead of kW. 1
DEUTSCH German 2
ITALIANO Italian 3
ESPANOL Spanish 4
PORTUGUES Portuguese 5
NEDERLANDS Dutch 6
FRANCAIS French 7
DANSK Danish 8
SUOMI Finnish 9
SVENSKA Swedish 10
CESKY Czech 11
POLSKI/LOC1 Polish 12
PO-RUS/LOC2 Russian 13
99.02 APPLICATION Selects the application macro. See chapter Application macros for more
MACRO information.
Note: When you change the default parameter values of a macro, the new
settings become valid immediately and stay valid even if the power of the drive
is switched off and on. However, backup of the default parameter settings
(factory settings) of each standard macro is still available. See parameter
99.03.
FACTORY Factory for basic applications 1
HAND/AUTO Two control devices are connected to the drive: 2
- device 1 communicates through the interface defined by external control
location EXT1.
- device 2 communicates through the interface defined by external control
location EXT2.
- EXT1 or EXT2 is active at a time. Switching through a digital input.
PID-CTRL PID control. For application in which the drive controls a process value. E.g. 3
pressure control by the drive running the pressure boost pump. Measured
pressure and the pressure reference are connected to the drive.
See sections Process PID control on page 68 and Sleep function for the
process PID control on page 69.
T-CTRL Torque Control macro 4
SEQ CTRL Sequential Control macro. For applications that are frequently run through a 5
pre-defined speed pattern (constant speeds and acceleration and deceleration
ramps).
USER 1 LOAD User 1 macro loaded into use. Before loading, check that the saved parameter 6
settings and the motor model are suitable for the application.

182

USER 1 SAVE Save User 1 macro. Stores the current parameter settings and the motor 7
model.
Note: There are parameters that are not included in the macros. See
parameter 99.03.
USER 2 LOAD User 2 macro loaded into use. Before loading, check that the saved parameter 8
settings and the motor model are suitable for the application.
USER 2 SAVE Save User 2 macro. Stores the current parameter settings and the motor 9
model.
Note: There are parameters that are not included in the macros. See
parameter 99.03.
99.03 APPLIC RESTORE Restores the original settings of the active application macro (99.02).
- If a standard macro (Factory, ... , Sequential Control) is active, the parameter
values are restored to the default settings (factory settings). Exceptions:
parameter settings in parameter group 99 remain unchanged. The motor
model remains unchanged.
- If User Macro 1 or 2 is active, the parameter values are restored to the last
saved values. In addition, the last saved motor model are restored. Exceptions:
Settings of parameters 16.05 and 99.02 remain unchanged.
Note: The parameter settings and the motor model are restored according to
the same principles when a macro is changed to another.
NO No action 0
YES Restoring 65535
99.04 MOTOR CTRL MODE Selects the motor control mode.
DTC Direct Torque Control mode is suitable for most applications. 0
SCALAR Scalar control is suitable in special cases where the DTC cannot be applied. 65535
The scalar control mode is recommended:
- for multimotor drives with variable number of motors
- when the nominal current of the motor is less than 1/6 of the nominal output
current of the drive (inverter)
- the drive is used for test purposes with no motor connected.
Note: The outstanding motor control accuracy of the DTC cannot be achieved
in scalar control. The differences between the scalar and DTC control modes
are pointed out in this manual in relevant parameter lists. There are some
standard features that are disabled in the scalar control mode: Motor
Identification Run (group 99 START-UP DATA), Speed Limits (group 20
LIMITS), Torque Limit (group 20 LIMITS), DC Hold (group 21 START/STOP),
DC Magnetizing (group 21 START/STOP), Speed Controller Tuning (group 23
SPEED CTRL), Torque Control (group 24 TORQUE CTRL), Flux Optimization
(group 26 MOTOR CONTROL), Flux Braking (group 26 MOTOR CONTROL),
Underload Function (group 30 FAULT FUNCTIONS), Motor Phase Loss
Protection (group 30 FAULT FUNCTIONS), Motor Stall Protection (group 30
FAULT FUNCTIONS).
For more information, see section Scalar control on page 60.
99.05 MOTOR NOM Defines the nominal motor voltage. Must be equal to the value on the motor
VOLTAGE rating plate.
1/2 … 2 · UN Voltage. Allowed range is 1/2 … 2 · UN of the drive. 1=1V
Note: The stress on the motor insulations is always dependent on the drive
supply voltage. This also applies to the case where the motor voltage rating is
lower than the rating of the drive and the supply of the drive.

183

99.06 MOTOR NOM Defines the nominal motor current. Must be equal to the value on the motor
CURRENT rating plate.
Note: Correct motor run requires that the magnetizing current of the motor
does not exceed 90 percent of the nominal current of the inverter.
0 … 2 · I2hd Allowed range: approx. 1/6 … 2 · I2hd of ACS800 (parameter 99.04 = DTC). 1 = 0.1 A
Allowed range: approx. 0 … 2 · I2hd of ACS800 (parameter 99.04 = SCALAR).
99.07 MOTOR NOM FREQ Defines the nominal motor frequency.
8 … 300 Hz Nominal frequency (50 or 60 Hz typically) 800 …
30000
99.08 MOTOR NOM SPEED Defines the nominal motor speed. Must be equal to the value on the motor
rating plate. The motor synchronous speed or another approximate value must
not be given instead!
Note: If the value of parameter 99.08 is changed, the speed limits in parameter
group 20 LIMITS change automatically as well.
1 … 18000 rpm Nominal motor speed 1 … 18000
99.09 MOTOR NOM Defines the nominal motor power. Set exactly as on the motor rating plate.
POWER
0 … 9000 kW Nominal motor power 0 … 90000
99.10 MOTOR ID RUN Selects the type of the motor identification. During the identification, the drive
MODE will identify the characteristics of the motor for optimum motor control. The ID
Run Procedure is described in chapter Start-up and control through the I/O.
Note: The ID Run (STANDARD or REDUCED) should be selected if:
- The operation point is near zero speed, and/or
- Operation at torque range above the motor nominal torque within a wide
speed range and without any measured speed feedback is required.
Note: The ID Run (STANDARD or REDUCED) cannot be performed if
See section Motor identification on page 53.
ID MAGN No ID Run. The motor model is calculated at first start by magnetising the 1
motor for 20 to 60 s at zero speed. This can be selected in most applications.
STANDARD Standard ID Run. Guarantees the best possible control accuracy. The ID Run 2
takes about one minute.
Note: The motor must be de-coupled from the driven equipment.
Note: Check the direction of rotation of the motor before starting the ID Run.
During the run, the motor will rotate in the forward direction.
WARNING! The motor will run at up to approximately 50 … 80% of the
nominal speed during the ID Run. ENSURE THAT IT IS SAFE TO
RUN THE MOTOR BEFORE PERFORMING THE ID RUN!
REDUCED Reduced ID Run. Should be selected instead of the Standard ID Run: 3
- if mechanical losses are higher than 20% (i.e. the motor cannot be de-
coupled from the driven equipment)
- if flux reduction is not allowed while the motor is running (i.e. in case of a
motor with an integrated brake supplied from the motor terminals).
Note: Check the direction of rotation of the motor before starting the ID Run.
During the run, the motor will rotate in the forward direction.
WARNING! The motor will run at up to approximately 50 … 80% of the
nominal speed during the ID Run. ENSURE THAT IT IS SAFE TO
RUN THE MOTOR BEFORE PERFORMING THE ID RUN!

184

99.11 DEVICE NAME Defines the name for the drive or application. The name is visible on the
control panel display in the Drive Selection Mode. Note: The name can be
typed only by using a drive PC tool.

185
Fieldbus control
Chapter overview
The chapter describes how the drive can be controlled by external devices over
a communication network.
System overview
The drive can be connected to an external control system – usually a fieldbus
controller – via an adapter module. The drive can be set to receive all of its control
information through the external control interface, or the control can be distributed
between the external control interface and other available sources, for example
digital and analogue inputs. The following diagram shows the control interfaces and
I/O connections of the drive.
Fieldbus
controller
Fieldbus
(* (*
ACS800 Other
devices
Advant
Fieldbus adapter Controller controller
Rxxx (e.g. AC 800M,
Modbus AC 80)
Slot 1
RMIO board
(*
RMBA-01 adapter
std. Modbus link
Slot 1 or 2 I/O adapter
RTAC/RDIO/RAIO
CH1
RDCO comm. AIMA-01 I/O
module (DDCS) adapter module
CH0 Fieldbus adapter

(DDCS) Nxxx
or
Data Flow
Control Word (CW)
References
Process I/O (cyclic)
Status Word (SW)
Actual values
Parameter R/W requests/responses Service messages (acyclic)
(* Either an Rxxx or Nxxx, and an RMBA-01 adapter can be connected to the drive simultaneously.
Fieldbus control
186
Redundant fieldbus control

It is possible to connect two fieldbuses to the drive with the following adapter
configuration:
• Type Rxxx fieldbus adapter module (not RMBA-01) is installed in drive slot 1.
• RMBA-01 Modbus Adapter module is installed in drive slot 2.
E.g. PROFIBUS Modbus
ACS800
RMIO board
RPBA-01 adapter
PROFIBUS-DP link
Slot 1
RMBA-01 adapter
std. Modbus link
Slot 2
The control (i.e. the Main Reference data set, see section The fieldbus control
interface on page 196) is activated by setting parameter 98.02 to FIELDBUS or
STD MODBUS.
In case there is a communication problem with one fieldbus, the control can be
switched to the other fieldbus. Switching between the buses can be controlled
e.g. with adaptive programming. Parameters and signals can be read by both
fieldbuses, but simultaneous cyclical writing to the same parameter is forbidden.
Fieldbus control
187
Setting up communication through a fieldbus adapter module

Fieldbus adapters for several communication protocols are available (e.g.
PROFIBUS and Modbus). Rxxx type fieldbus adapter modules are mounted in
expansion slot 1 of the drive. Nxxx type fieldbus adapter modules are connected to
channel CH0 of the RDCO module.
Note: For instructions on setting up an RMBA-01 module, see section Setting up
communication through the Standard Modbus Link on page 189.
Before configuring the drive for fieldbus control, the adapter module must be
mechanically and electrically installed according to the instructions given in the
hardware manual of the drive, and the module manual.
The following table lists the parameters which need to be defined when setting up
communication through a fieldbus adapter.
Parameter Alternative Setting for Function/Information
settings fieldbus control
COMMUNICATION INITIALISATION
98.02 NO FIELDBUS Initialises communication between drive and

FIELDBUS fieldbus adapter module. Activates module set-up
ADVANT parameters (Group 51).
STD MODBUS
CUSTOMISED
98.07 ABB DRIVES ABB DRIVES Selects the communication profile used by the
GENERIC GENERIC or drive. See section Communication profiles on page
CSA 2.8/3.0 CSA 2.8/3.0 204.
ADAPTER MODULE CONFIGURATION
51.01 MODULE – – Displays the type of the fieldbus adapter module.

TYPE
51.02 (FIELDBUS These parameters are adapter module-specific. For more information, see the module manual.
PARAMETER 2) Note that not all of these parameters are necessarily visible.
•••
51.26 (FIELDBUS
PARAMETER 26)
51.27 FBA PAR (0) DONE – Validates any changed adapter module
REFRESH* (1) REFRESH configuration parameter settings. After refreshing,
the value reverts automatically to DONE.
51.28 FILE CPI xyz (binary coded – Displays the required CPI firmware revision of the
FW REV* decimal fieldbus adapter as defined in the configuration file
stored in the memory of the drive. The CPI firmware
version of the fieldbus adapter (refer to par. 51.32)
must contain the same or a later CPI version to be
compatible. x = major revision number; y = minor
revision number; z = correction number. Example:
107 = revision 1.07.
Fieldbus control
188
Parameter Alternative Setting for Function/Information

settings fieldbus control
51.29 FILE xyz (binary coded – Displays the fieldbus adapter module configuration
CONFIG ID* decimal) file identification stored in the memory of the drive.
This information is drive application program-
dependent.
51.30 FILE xyz (binary coded – Displays the fieldbus adapter module configuration
CONFIG REV* decimal) file revision stored in the memory of the drive.
x = major revision number; y = minor revision
number; z = correction number. Example: 1 =
revision 0.01.
51.31 FBA (0) IDLE – Displays the status of the adapter module.
STATUS* (1) EXEC. INIT IDLE = Adapter not configured.
(2) TIME OUT
EXEC. INIT = Adapter initialising.
(3) CONFIG
ERROR TIME OUT = A timeout has occurred in the
(4) OFF-LINE communication between the adapter and the drive.
(5) ON-LINE CONFIG ERROR = Adapter configuration error.
(6) RESET The major or minor revision code of the CPI
program revision in the drive is not the revision
required by the module (refer to par. 51.32) or
configuration file upload has failed more than five
times.
OFF-LINE = Adapter is off-line.
ON-LINE = Adapter is on-line.
RESET = Adapter performing a hardware reset.
51.32 FBA CPI FW – – Displays the CPI program revision of the module
REV* inserted in slot 1. x = major revision number;
y = minor revision number; z = correction number.
Example: 107 = revision 1.07.
51.33 FBA APPL – – Displays the application program revision of the

FW REV* module inserted in slot 1. x = major revision
number; y = minor revision number; z = correction
number. Example: 107 = revision 1.07.
*Parameters 51.27 to 51.33 are only visible when type Rxxx fieldbus adapter is installed.
After the module configuration parameters in group 51 have been set, the drive
control parameters (section Drive control parameters on page 193) must be checked
and adjusted where necessary.
The new settings will take effect when the drive is next powered up, or when
parameter 51.27 is activated.
Fieldbus control
189
Setting up communication through the Standard Modbus Link

An RMBA-01 Modbus Adapter installed in slot 1 or 2 of the drive forms an interface
called the Standard Modbus Link. The Standard Modbus Link can be used for
external control of the drive by a Modbus controller (RTU protocol only).
Before configuring the drive for Modbus control, the adapter module must be
mechanically and electrically installed according to the instructions given in the
hardware manual of the drive, and the module manual.
The following table lists the parameters, which need to be defined when setting up
communication through the standard Modbus link.
Parameter Alternative settings Setting for control Function/Information
through Standard
Modbus Link
98.02 NO STD MODBUS Initialises communication between drive

FIELDBUS (Standard Modbus Link) and Modbus-protocol
ADVANT controller. Activates communication parameters
STD MODBUS in group 52.
CUSTOMISED
98.07 ABB DRIVES ABB DRIVES Selects the communication profile used by the
GENERIC drive. See section Communication profiles on
CSA 2.8/3.0 page 204.
COMMUNICATION PARAMETERS
52.01 1 to 247 – Specifies the station number of the drive on the

Standard Modbus Link.
52.02 600 – Defines the communication speed for the

1200 Standard Modbus Link.
2400
4800
9600
19200
52.03 ODD – Selects the parity setting for the Standard

EVEN Modbus Link.
NONE1STOPBIT
NONE2STOPBIT
After the communication parameters in group 52 have been set, the drive control
parameters (section Drive control parameters on page 193) must be checked and
adjusted where necessary.
Fieldbus control
190
Modbus addressing
In the Modbus controller memory, the Control Word, the Status Word, the
references, and the actual values are mapped as follows:
Data from fieldbus controller to drive Data from drive to fieldbus controller
Address Contents Address Contents
40001 Control Word 40004 Status Word
40002 Reference 1 40005 Actual 1
More information on Modbus communication is available from the Modicon

website http://www.modicon.com.
Fieldbus control
191
Setting up communication through Advant controller

The Advant controller is connected via DDCS link to channel CH0 of the RDCO
module.
• AC 800M Advant Controller
DriveBus connection: CI858 DriveBus Communication Interface required. See CI858
DriveBus Communication Interface User’s Manual, [3AFE 68237432 (English)].
Optical ModuleBus connection: TB811 (5 MBd) or TB810 (10 MBd) Optical
ModuleBus Port Interface required. See section Optical ModuleBus connection
below.
For more information, see AC 800M Controller Hardware Manual [3BSE027941
(English)], AC 800M/C Communication, Protocols and Design Manual [3BSE028811
(English),] ABB Industrial Systems, Västerås, Sweden.
• AC 80 Advant Controller
Optical ModuleBus connection: TB811 (5 MBd) or TB810 (10 MBd) Optical
ModuleBus Port Interface required. See section Optical ModuleBus connection
below.
• CI810A Fieldbus Communication Interface (FCI)
Optical ModuleBus connection
TB811 (5 MBd) or TB810 (10 MBd) Optical ModuleBus Port Interface required.
The TB811 Optical ModuleBus Port Interface is equipped with 5 MBd optical
components and the TB810 is equipped with 10 MBd components. All optical
components on a fibre optic link must be of the same type since 5 MBd components
do not match with 10 MBd components. The choice between TB810 and TB811
depends on the equipment it is connected to. With RDCO Communication Option
Module, the Interface is selected as follows:
Optional ModuleBus Port DDCS Communication Option Module
Interface
RDCO-01 RDCO-02 RDCO-03
TB811 × ×
TB810 ×
If branching unit NDBU-85/95 is used with CI810A, TB810 Optical ModuleBus Port
Interface must be used.
Fieldbus control
192
The following table lists the parameters which need to be defined when setting up
communication between the drive and Advant controller.
Parameter Alternative settings Setting for control through Function/Information
CH0
98.02 NO ADVANT Initialises communication between drive

FIELDBUS (fibre optic channel CH0) and Advant
ADVANT controller. The transmission speed is
STD MODBUS 4 Mbit/s.
CUSTOMISED
98.07 ABB DRIVES ABB DRIVES Selects the communication profile used by
GENERIC the drive. See section Communication
CSA 2.8/3.0 profiles on page 204.
70.01 0-254 AC 800M ModuleBus 1...125 Defines the node address for DDCS
AC 80 ModuleBus 17-125 channel CH0.
FCI (CI810A) 17-125
70.04 RING Selects the topology of the channel CH0

STAR link.
After the communication initialisation parameters have been set, the drive control
parameters (section Drive control parameters on page 193) must be checked and
adjusted where necessary.
In an Optical ModuleBus connection, channel 0 address (parameter 70.01) is
calculated from the value of the POSITION terminal in the appropriate database
element (for the AC 80, DRISTD) as follows:
1. Multiply the hundreds of the value of POSITION by 16.
2. Add the tens and ones of the value of POSITION to the result.
For example, if the POSITION terminal of the DRISTD database element has the
value of 110 (the tenth drive on the Optical ModuleBus ring), parameter 70.01 must
be set to 16 × 1 + 10 = 26.
Fieldbus control
193
Drive control parameters

After the fieldbus communication has been set up, the drive control parameters
listed in the table below must be checked and adjusted where necessary.
The Setting for fieldbus control column gives the value to use when the fieldbus
interface is the desired source or destination for that particular signal. The
Function/Information column gives a description of the parameter.
The fieldbus signal routes and message composition are explained later in section
The fieldbus control interface on page 196.
Parameter Setting for Function/Information
fieldbus control
CONTROL COMMAND SOURCE SELECTION
10.01 COMM.CW Enables the fieldbus Control Word (except 03.01 Main Control Word bit 11)
when EXT1 is selected as the active control location. See also par. 10.07.
10.02 COMM.CW Enables the fieldbus Control Word (except 03.01 Main Control Word bit 11)
when EXT2 is selected as the active control location.
10.03 FORWARD Enables rotation direction control as defined by parameters 10.01 and
REVERSE or 10.02. The direction control is explained in section Reference handling on
REQUEST page 198.
10.07 0 or 1 Setting the value to 1 overrides the setting of par. 10.01 so that the fieldbus
Control Word (except 03.01 Main Control Word bit 11) is enabled when
EXT1 is selected as the active control location.
Note 1: Only visible with the Generic Drive communication profile selected
(see par. 98.07).
Note 2: Setting not saved into permanent memory.
10.08 0 or 1 Setting the value to 1 overrides the setting of par. 11.03 so that Fieldbus
reference REF1 is used when EXT1 is selected as the active control
location.
Note 1: Only visible with the Generic Drive communication profile selected
(see par. 98.07).
Note 2: Setting not saved into permanent memory.
11.02 COMM.CW Enables EXT1/EXT2 selection by fieldbus Control Word bit 11 EXT CTRL
LOC.
11.03 COMM.REF1 Fieldbus reference REF1 is used when EXT1 is selected as the active
FAST COMM control location. See section References on page 197 for information on
COM.REF1+AI1 the alternative settings.
COM.REF1+AI5
COM.REF1*AI1 or
COM.REF1*AI5
11.06 COMM.REF2 Fieldbus reference REF2 is used when EXT2 is selected as the active
FAST COMM control location. See section References on page 197 for information on
COM.REF2+AI1 the alternative settings.
COM.REF2+AI5
COM.REF2*AI1 or
COM.REF2*AI5
Fieldbus control
194

fieldbus control
OUTPUT SIGNAL SOURCE SELECTION
14.01 COM.REF3 Enables relay output RO1 control by fieldbus reference REF3 bit 13.
15.01 COMM.REF4 Directs the contents of fieldbus reference REF4 to analogue output AO1.
Scaling: 20000 = 20 mA
15.06 COMM.REF5 Directs the contents of fieldbus reference REF5 to analogue output AO2.
Scaling: 20000 = 20 mA.
SYSTEM CONTROL INPUTS
16.01 COMM.CW Enables the control of the Run Enable signal through fieldbus 03.01 Main
Control Word bit 3.
Note: Must be set to YES when the Generic Drive communication profile is
selected (see par. 98.07).
16.04 COMM.CW Enables fault reset through fieldbus 03.01 Main Control Word bit 7.
Note: Reset through fieldbus Control Word (03.01 bit 7) is enabled
automatically and it is independent of parameter 16.04 setting if parameter
10.01 or 10.02 is set to COMM.CW.
16.07 DONE; SAVE Saves parameter value changes (including those made through fieldbus
control) to permanent memory.
COMMUNICATION FAULT FUNCTIONS
30.18 FAULT Determines drive action in case fieldbus communication is lost.

NO CONST SP15 Note: The communication loss detection is based on monitoring of
LAST SPEED received Main and Auxiliary data sets (whose sources are selected with
parameters 90.04 and 90.05 respectively).
30.19 0.1 … 60.0 s Defines the time between Main Reference data set loss detection and the
action selected with parameter 30.18.
30.20 ZERO Determines the state in which relay outputs RO1 to RO3 and analogue
LAST VALUE outputs AO1 and AO2 are left upon loss of the Auxiliary Reference data set.
30.21 0.0 … 60.0 s Defines the time between Auxiliary Reference data set loss detection and
the action selected with parameter 30.18.
Note: This supervision function is disabled if this parameter, or parameters
90.01, 90.02 and 90.03 are set to 0.
FIELDBUS REFERENCE TARGET SELECTION
90.01 0 … 8999 Defines the drive parameter into which the value of fieldbus reference
REF3 is written.
Format: xxyy, where xx = parameter group (10 to 89), yy = parameter
Index. E.g. 3001 = parameter 30.01.
Fieldbus control
195

fieldbus control
REF4 is written.
Format: see parameter 90.01.
REF5 is written.
90.04 1 (Fieldbus Control) or If 98.02 is set to CUSTOMISED, this parameter selects the source from
81 (Standard Modbus which the drive reads the Main Reference data set (comprising the fieldbus
Control) Control Word, fieldbus reference REF1, and fieldbus reference REF2).
90.05 3 (Fieldbus Control) or If 98.02 is set to CUSTOMISED, this parameter selects the source from
83 (Standard Modbus which the drive reads the Auxiliary Reference data set (comprising fieldbus
Control) references REF3, REF4 and REF5).
ACTUAL SIGNAL SELECTION FOR FIELDBUS
92.01 302 (Fixed) The Status Word is transmitted to as the first word of the Main Actual Signal
data set.
92.02 0 … 9999 Selects the Actual signal or parameter value to be transmitted as the
second word (ACT1) of the Main Actual Signal data set.
Format: (x)xyy, where (x)x = actual signal group or parameter group, yy =
actual signal or parameter index. E.g. 103 = actual signal 1.03
FREQUENCY; 2202 = parameter 22.02 ACCEL TIME 1.
Note: With the Generic Drive communication profile active (par. 98.07 =
GENERIC), this parameter is fixed to 102 (actual signal 1.02 SPEED – in
DTC motor control mode) or 103 (1.03 FREQUENCY – in Scalar mode).
92.03 0 … 9999 Selects the actual signal or parameter value to be transmitted as the third
word (ACT2) of the Main Actual Signal data set.
92.04 0 … 9999 Selects the actual signal or parameter value to be transmitted as the first
word (ACT3) of the Auxiliary Actual Signal data set.
92.05 0 … 9999 Selects the actual signal or parameter value to be transmitted as the
second word (ACT4) of the Auxiliary Actual Signal data set.
92.06 0 … 9999 Selects the actual signal or parameter value to be transmitted as the third
word (ACT5) of the Auxiliary Actual Signal data set.
92.07 -255.255.31…+255.255.31 Selects the address from which the 03.02 Main Status Word bit 10 is read
/ C.-32768 … C.32767 from.
/ C.-32768 … C.32767 from.
/ C.-32768 … C.32767 from.
Fieldbus control
196
The fieldbus control interface

The communication between a fieldbus system and the drive employs data sets.
One data set (abbreviated DS) consists of three 16-bit words called data words
(DW). The Standard Control Program supports the use of four data sets, two in each
direction.
The two data sets for controlling the drive are referred to as the Main Reference data
set and the Auxiliary Reference data set. The sources from which the drive reads the
Main and Auxiliary Reference data sets are defined by parameters 90.04 and 90.05
respectively. The contents of the Main Reference data set are fixed. The contents of
the Auxiliary Reference data set can be selected using parameters 90.01, 90.02 and
90.03.
The two data sets containing actual information on the drive are referred to as the
Main Actual Signal data set and the Auxiliary Actual Signal data set. The contents of
both data sets are partly selectable with the parameters at group 92.
Data from fieldbus controller to drive Data from drive to fieldbus controller
Word Contents Selector Word Contents Selector
*Index Main Reference data set DS1 *Index Main Actual Signal data set DS2
1 1st word Control Word (Fixed) 4 1st word Status Word (Fixed)
2 2nd word Reference 1 (Fixed) 5 2nd word Actual 1 **Par. 92.02
3 3rd word Reference 2 (Fixed) 6 3rd word Actual 2 Par. 92.03
*Index Auxiliary Reference data set DS3 *Index Aux. Actual Signal data set DS4
7 1st word Reference 3 Par. 90.01 10 1st word Actual 3 Par. 92.04
8 2nd word Reference 4 Par. 90.02 11 2nd word Actual 4 Par. 92.05
9 3rd word Reference 5 Par. 90.03 12 3rd word Actual 5 Par. 92.06
*The index number is required when data word allocation to process data is defined
via the fieldbus parameters at group 51. This function is dependent on the type of the
fieldbus adapter.
**With the Generic Drive communication profile active, Actual 1 is fixed to actual
signal 01.02 SPEED (in DTC motor control mode) or 01.03 FREQUENCY (in Scalar
mode).
The update time for the Main Reference and Main Actual Signal data sets is 6
milliseconds; for the Auxiliary Reference and Auxiliary Actual Signal data sets, it is
100 milliseconds.
Fieldbus control
197

The Control Word (CW) is the principal means of controlling the drive from a fieldbus
system. It is effective when the active control location (EXT1 or EXT2, see
parameters 10.01 and 10.02) is set to COMM.CW, or if par. 10.07 is set to 1 (with
Generic Drive communication profile only).
The Control Word is sent by the fieldbus controller to the drive. The drive switches
between its states according to the bit-coded instructions of the Control Word.
The Status Word (SW) is a word containing status information, sent by the drive to
the fieldbus controller.
See section Communication profiles on page 204 for information on the composition
of the Control Word and the Status Word.
References
References (REF) are 16-bit signed integers. A negative reference (indicating
reversed direction of rotation) is formed by calculating the two’s complement from
the corresponding positive reference value.
Fieldbus reference selection and correction
Fieldbus reference (called COM.REF in signal selection contexts) is selected by
setting a Reference selection parameter – 11.03 or 11.06 – to COMM.REFx, FAST
COMM, COM.REFx+AI1, COM.REFx+AI5, COM.REFx*AI1 or COM.REFx*AI5.
(With Generic Drive communication profile, fieldbus reference is also selected when
par. 10.08 is set to 1.) The latter four selections enable correction of the fieldbus
reference using analogue inputs as shown below. (An optional RAIO-01 Analogue
I/O Extension Module is required for use of Analogue input AI5).
COMM.REF1 (in 11.03) or COMM.REF2 (in 11.06)
The fieldbus reference is forwarded as such without correction.
FAST COMM
The fieldbus reference is forwarded as such without correction. The reference is
read every 2 milliseconds if either of the following conditions is met:
• Control location is EXT1, par. 99.04 MOTOR CTRL MODE is DTC, and par. 40.14
TRIM MODE is OFF
• Control location is EXT2, par. 99.04 MOTOR CTRL MODE is DTC, par. 40.14
TRIM MODE is OFF, and a torque reference is used.
In any other event, the fieldbus reference is read every 6 milliseconds.
Note: The FAST COMM selection disables the critical speed function.
Fieldbus control
198
COM.REF1+AI1; COM.REF1+AI5; COM.REF1*AI1; COM.REF1*AI5 (in 11.03)

COM.REF2+AI1; COM.REF2+AI5; COM.REF2*AI1; COM.REF2*AI5 (in 11.06)
These selections enable the correction of the fieldbus reference as follows:
Parameter Setting Effect of AI1/AI5 Input Voltage on Fieldbus Reference
COM.REFx+AI1
Fieldbus Reference
COM.REFx+AI5
Correction Coefficient
(100 + 0.5 × [par. 13.03])%
100%
(100 – 0.5 × [par. 13.03])%

0 5V 10 V AI1/AI5 Input
Voltage
COM.REFx*AI1
COM.REFx*AI5 Fieldbus Reference
Correction Coefficient
100%
50%
0%
0 5V 10 V AI1/AI5 Input
Voltage
Reference handling
The control of rotation direction is configured for each control location (EXT1 and
EXT2) using the parameters in group 10. Fieldbus references are bipolar, i.e. they
can be negative or positive. The following diagrams illustrate how group 10
parameters and the sign of the fieldbus reference interact to produce the reference
REF1/REF2.
Notes:
• With the ABB Drives communication profile, 100% reference is defined by
parameters 11.05 (REF1) and 11.08 (REF2).
• With the Generic Drive communication profile, 100% reference is defined by
parameter 99.08 in DTC motor control mode (REF1), or 99.07 in scalar control
mode (REF1), and by parameter 11.08 (REF2).
• External reference scaling parameters 11.04 and 11.07 are also in effect.
For information on the scaling of the fieldbus reference, see section Fieldbus
reference scaling on page 208 (for ABB Drives profile) or Fieldbus reference scaling
on page 211 (for Generic Drive profile).
Fieldbus control
199
*Direction determined by the sign of Direction determined by digital command,

COM.REF e.g. digital input, control panel
par. 10.03 Resultant Resultant

DIRECTION = REF1/2 REF1/2
FORWARD
Max.Ref. Max.Ref.
Fieldbus Fieldbus
Ref. 1/2 Ref. 1/2
-100% 100% -100% 100%
-163% 163% -163% 163%
–[Max.Ref.] –[Max.Ref.]

DIRECTION = REF1/2 REF1/2
REVERSE
Max.Ref. Max.Ref.
-163% 163% -163% 163%

Fieldbus -100% 100% Fieldbus -100% 100%
Ref. 1/2 Ref. 1/2

DIRECTION = REF1/2 REF1/2 Direction Command:
REQUEST FORWARD
Max.Ref. Max.Ref.
-163%
Fieldbus -100% Fieldbus
Ref. 1/2 Ref. 1/2
100% -100% 100%
163% -163% 163%
Direction Command:
REVERSE
*Direction is determined by the sign of COM.REF when

par. 10.01/10.02 EXTx STRT/STP/DIR is set to COMM.CW
OR
par. 11.03/11.06 EXT REFx SELECT is set to FAST COMM.
Actual Values
Actual Values (ACT) are 16-bit words containing information on selected operations
of the drive. The functions to be monitored are selected with the parameters in group
92. The scaling of the integers sent to the master as Actual Values depends on the
selected function; please refer to chapter Actual signals and parameters.
Fieldbus control
Block diagram: Control data input from fieldbus when a type Rxxx
200
fieldbus adapter is used DI1 11.02
•
•
COMM.CW •
10.01 03.01
DI1 MAIN CW
Fieldbus control
30.18 COMM FAULT FUNC
DATA •
Fieldbus Words 1 … n ** 30.19 MAIN REF DS T-OUT •
SET COMM.CW •
Adapter TABLE
Slot1 10.02
Word 1 NO MAIN
1 AI1
(Control word) DS 1 FIELD- REFERENCE
2 •
Word 2 BUS DATA SET • 01.11
3 COMM.REF •
(Speed/freq ref.*) 4 ADVANT EXT REF1
DS CW
Word 3 5 DS 2 STD 11.03
PAR 6 MODBUS REF1
3 AI1
… 7 CUSTOM- REF2 •
8 DS 3 ISED • 01.12
DS COMM.REF •
Word n 9 EXT REF2
PAR 10 98.02 11.06
n
11 DS 4
12
13
14 DS 5 PARAMETER
15 Bits
13…15 90.01 TABLE
••• Relay Outputs

(see 14.01…14.03) 10.01
NO
Fieldbus specific selectors 97
FIELD-
in Group 51** 98 DS 33 BUS
Addresses for words 3 … n in 99 AUXILIARY 10.02
ADVANT
format xxyy REFERENCE
••• STD DATA SET
xx Address MODBUS
00 yy = word no. in data set 90.02 •••
CUSTOM- REF3
table ISED Analogue Output
01 … xx = par. group REF4 AO1 (see 15.01)
89.99
99 yy = par. index 98.02 REF5
in parameter table
•••
90.03 •••
30.20 COMM FLT RO/AO Analogue Output
30.21 AUX REF DS T-OUT AO2 (see 15.06)
•••
* Depends on the selected motor control mode (parameter 99.04).

** See the fieldbus adapter user’s manual for more information.
Block diagram: Actual value selection for fieldbus when a type Rxxx
fieldbus adapter is used
DATA SET
TABLE
ACTUAL SIGNAL/ 1 Words 1 … n *** Fieldbus

PARAMETER 92.01 * DS 1 2 Adapter
TABLE 3 (Slot 1)
4 Word 1
MAIN DS 2 5 (STATUS WORD)
1.01 ACTUAL SIGNAL 6 Word 2
DATA SET 7 (ACT1**)
DS
92.02 ** STATUS WORD* DS 3 8 Word 3
1.02 9 PAR
ACT1** 3
10 …
ACT2 DS 4 11
••• DS
12 Word n
PAR n
92.03 •••
3.99
97
DS 33 98
••• 99
•••
10.01 92.04 Fieldbus specific selectors
in Group 51 ***
••• AUXILIARY Addresses for words 3 … n in
ACTUAL SIGNAL format xxyy
DATA SET xx Address
••• 92.05 00 yy = word no. in data set
ACT3
table
ACT4
01 … xx = par. group
ACT5
••• 99 yy = par. index
in parameter table
99.99 92.06
* Fixed to 03.02 MAIN STATUS WORD (bits 10, 13 and 14 are programmable).
** Fixed to 01.02 SPEED (DTC control) or 01.03 FREQUENCY (Scalar control) when Generic communication profile is used.
*** See the fieldbus adapter user’s manual for more information.
201
Fieldbus control
Block diagram: Control data input from fieldbus when a type Nxxx
202
DI1 11.02
•
DATA 30.18 COMM FAULT FUNC •
COMM.CW •
Fieldbus control
SET 30.19 MAIN REF DS T-OUT
TABLE 10.01 03.01
NO DI1 MAIN CW
3 words FIELD- MAIN •
DS 1 •
Fieldbus (6 bytes) BUS REFERENCE COMM.CW •
Adapter ADVANT DATA SET
10.02
(CH0) DS 2 STD
MODBUS
CW AI1
1 REF1 •
• CUSTOM- • 01.11
3 words DS 3 • ISED COMM.REF •
• REF2 EXT REF1
(6 bytes)
255 11.03
90.04 98.02
DS 4 AI1
•
• 01.12
COMM.REF •
Modbus EXT REF2
•••
Controller 11.06
40001 3 words
40002 DS 81
(6 bytes)
40003 Standard NO
Modbus FIELD-
DS 82 Bits PARAMETER
Link BUS
13…15 90.01 TABLE
(RMBA) ADVANT
40007 (Slot 1/2) AUXILIARY Relay Outputs
3 words STD
40008 DS 83 REFERENCE (see 14.01…14.03) 10.01
(6 bytes) MODBUS
40009 DATA SET
1 CUSTOM-
•
DS 84 • ISED REF3
• 10.02
255
98.02 REF4
90.05
••• REF5
90.02 •••
Analogue Output
AO1 (see 15.01)
30.18 COMM FAULT FUNC 89.99
30.20 COMM FLT RO/AO
30.21 AUX REF DS T-OUT
•••
90.03
Analogue Output
AO2 (see 15.06)
Block Diagram: Actual value selection for fieldbus when a type Nxxx
DATA SET
TABLE
ACTUAL SIGNAL/
PARAMETER 92.01* DS 1
TABLE
MAIN 3 words
DS 2
1.01 (6 bytes) Fieldbus
ACTUAL SIGNAL
DATA SET Adapter
92.02 STATUS WORD* DS 3 (CH0)
1.02
ACT1**
ACT2 3 words
DS 4
••• (6 bytes)
92.03 •••
3.99
Modbus
DS 81 Controller
•••
40004
3 words
DS 82 40005
10.01 (6 bytes) Standard
92.04 40006
Modbus
DS 83 Link
••• AUXILIARY
ACTUAL SIGNAL 40010
DATA SET 3 words
DS 84 40011
99.99 (6 bytes)
92.05 40012
ACT3
ACT4
•••
ACT5
92.06
* Fixed to 03.02 MAIN STATUS WORD (bits 10, 13 and 14 are programmable).
** Fixed to 01.02 SPEED (DTC motor control) or 0103 FREQUENCY (Scalar control) when Generic communication profile is used.
203
Fieldbus control
204
Communication profiles
The ACS800 supports three communication profiles:
• ABB Drives communication profile
• Generic Drive communication profile.
• CSA 2.8/3.0 communication profile.
The ABB Drives communication profile should be selected with type Nxxx fieldbus
adapter modules, and when the manufacturer-specific mode is selected (via the
PLC) with type Rxxx fieldbus adapter modules.
The Generic Drive profile is supported by type Rxxx fieldbus adapter modules only.
The CSA 2.8/3.0 communication profile can be selected for backward compatibility
with Application Program versions 2.8 and 3.0. This eliminates the need for
reprogramming the PLC when drives with the above-mentioned program versions
are replaced.
ABB Drives communication profile

The ABB Drives communication profile is active when parameter 98.07 is set to
ABB DRIVES. The Control Word, Status Word, and reference scaling for the profile
are described below.
The ABB Drives communication profile can be used through both EXT1 and EXT2.
The Control Word commands are in effect when par. 10.01 or 10.02 (whichever
control location is active) is set to COMM.CW.
Fieldbus control
205
03.01 MAIN CONTROL WORD

The upper case boldface text refers to the states shown in Figure 1.
Bit Name Value Enter STATE/Description
0 OFF1 CONTROL 1 Enter READY TO OPERATE.
0 Stop along currently active deceleration ramp (22.03/22.05). Enter OFF1 ACTIVE;
proceed to READY TO SWITCH ON unless other interlocks (OFF2, OFF3) are active.
1 OFF2 CONTROL 1 Continue operation (OFF2 inactive).
Enter OFF2 ACTIVE; proceed to SWITCH-ON INHIBITED.
2 OFF3 CONTROL 1 Continue operation (OFF3 inactive).
0 Emergency stop, stop within time defined by par. 22.07. Enter OFF3 ACTIVE; proceed
to SWITCH-ON INHIBITED.
Warning: Ensure motor and driven machine can be stopped using this stop mode.
3 INHIBIT_ 1 Enter OPERATION ENABLED. (Note: The Run Enable signal must be active; see
OPERATION parameter 16.01. If par. 16.01 is set to COMM.CW, this bit also activates the Run
Enable signal.)
0 Inhibit operation. Enter OPERATION INHIBITED.
ZERO Enter RAMP FUNCTION GENERATOR: OUTPUT ENABLED.
0 Force Ramp Function Generator output to zero.
Drive ramps to stop (current and DC voltage limits in force).
5 RAMP_HOLD 1 Enable ramp function.
Enter RAMP FUNCTION GENERATOR: ACCELERATOR ENABLED.
0 Halt ramping (Ramp Function Generator output held).
6 RAMP_IN_ 1 Normal operation. Enter OPERATING.
ZERO 0 Force Ramp Function Generator input to zero.
7 RESET 0⇒1 Fault reset if an active fault exists. Enter SWITCH-ON INHIBITED.
0 Continue normal operation.
8 INCHING_1 1 Not in use.
1⇒0 Not in use.
9 INCHING_2 1 Not in use.
1⇒0 Not in use.
10 REMOTE_CMD 1 Fieldbus control enabled.
0 Control Word <> 0 or Reference <> 0: Retain last Control Word and Reference.
Control Word = 0 and Reference = 0: Fieldbus control enabled.
Reference and deceleration/acceleration ramp are locked.
11 EXT CTRL LOC 1 Select External Control Location EXT2. Effective if par. 11.02 is set to COMM.CW.
0 Select External Control Location EXT1. Effective if par. 11.02 is set to COMM.CW.
12 … Reserved
15
Fieldbus control
206
03.02 MAIN STATUS WORD

The upper case boldface text refers to the states shown in Figure 1.
0 RDY_ON 1 READY TO SWITCH ON.
0 NOT READY TO SWITCH ON.
1 RDY_RUN 1 READY TO OPERATE.
0 OFF1 ACTIVE.
2 RDY_REF 1 OPERATION ENABLED.
0 OPERATION INHIBITED.
3 TRIPPED 1 FAULT.
0 No fault.
4 OFF_2_STA 1 OFF2 inactive.
0 OFF2 ACTIVE.
5 OFF_3_STA 1 OFF3 inactive.
0 OFF3 ACTIVE.
6 SWC_ON_INHIB 1 SWITCH-ON INHIBITED.
0
7 ALARM 1 Warning/Alarm.
0 No Warning/Alarm.
8 AT_SETPOINT 1 OPERATING. Actual value equals reference value (= is within tolerance limits
i.e in speed control the speed error is less than or equal to 10% of the nominal
motor speed).
0 Actual value differs from reference value (= is outside tolerance limits).
9 REMOTE 1 Drive control location: REMOTE (EXT1 or EXT2).
0 Drive control location: LOCAL.
10 ABOVE_LIMIT 1 Bit is read from the address defined by parameter 92.07 MSW B10 PTR.
The default value is signal 03.14 bit 9 ABOVE_LIMIT: Actual frequency or
speed value equals or exceeds the supervision limit (par. 32.02).
0 Actual frequency or speed value is within supervision limit.
11 EXT CTRL LOC 1 External Control Location EXT2 selected.
0 External Control Location EXT1 selected.
12 EXT RUN ENABLE 1 External Run Enable signal received.
0 No External Run Enable received.
13 Bit is read from the address defined by parameter 92.08 MSW B13 PTR.
By default no address has been selected.
14 Bit is read from the address defined by parameter 92.09 MSW B14 PTR.
By default no address has been selected.
15 1 Communication error detected by fieldbus adapter module (on fibre optic
channel CH0).
0 Fieldbus adapter (CH0) communication OK.
Fieldbus control
207
SWITCH-ON
MAINS OFF INHIBITED (SW Bit6=1)
ABB Drives
Power ON (CW Bit0=0)
Communication
NOT READY Profile
TO SWITCH ON (SW Bit0=0)
A B C D
CW = Control Word
SW = Status Word
(CW=xxxx x1xx xxxx x110)
n = Speed
I = Input Current
(CW Bit3=0)
RFG = Ramp Function Generator
READY TO f = Frequency
OPERATION SWITCH ON (SW Bit0=1)
INHIBITED (SW Bit2=0)
from any state
operation
(CW=xxxx x1xx xxxx x111)
inhibited
Fault
READY TO
FAULT
from any state

(CW Bit7=1)
(CW=xxxx x1xx xxxx 1111
OFF1 (CW Bit0=0) and SW Bit12=1)

ACTIVE (SW Bit1=0) Emergency Stop Emergency OFF
OFF3 (CW Bit2=0) OFF2 (CW Bit1=0)
(CW Bit3=1
n(f)=0 / I=0 and
OFF3 OFF2
SW Bit12=1)
B C D ACTIVE (SW Bit5=0) ACTIVE (SW Bit4=0)
n(f)=0 / I=0
(CW Bit4=0)
OPERATION
C D
ENABLED (SW Bit2=1)
A
(CW Bit5=0) (CW=xxxx x1xx xxx1 1111)
D RFG: OUTPUT
ENABLED
B
(CW Bit6=0) (CW=xxxx x1xx xx11 1111)
RFG: ACCELERATOR
ENABLED
C
(CW=xxxx x1xx x111 1111)
OPERATING
(SW Bit8=1)
D
Figure 1 State Machine for the ABB Drives communication profile.
Fieldbus control
208
Fieldbus reference scaling

With the ABB Drives communication profile active, fieldbus references REF1 and
REF2 are scaled as shown in the table below.
Note: Any correction of the reference is applied before scaling. See section
References on page 197.
Ref. Application Range Reference type Scaling Notes
No. Macro used
(par. 99.02)
REF1 (any) -32768 ... Speed or Frequency -20000 = -[par. 11.05] Final reference limited by
32767 (not with -1 = -[par. 11.04] 20.01/20.02 [speed] or
FAST COMM) 20.07/20.08 [frequency].
0 = [par. 11.04]
20000 = [par. 11.05]
Speed or Frequency -20000 = -[par. 11.05] Final reference limited by

with FAST COMM 0=0 20.01/20.02 [speed] or
20.07/20.08 [frequency].
20000 = [par. 11.05]
REF2 FACTORY, -32768 ... Speed or Freq. (not -20000 = -[par. 11.08] Final reference limited by
HAND/AUTO, 32767 with FAST COMM) -1 = -[par. 11.07] 20.01/20.02 [speed] or
or SEQ CTRL 0 = [par. 11.07] 20.07/20.08 [frequency].
20000 = [par. 11.08]
Speed or Freq. with -20000 = -[par. 11.08] Final reference limited by

FAST COMM 0=0 20.01/20.02 [speed] or
20000 = [par. 11.08] 20.07/20.08 [frequency].
T CTRL or -32768 ... Torque (not with -10000 = -[par. 11.08] Final reference limited by
M/F (optional) 32767 FAST COMM) -1 = -[par. 11.07] par. 20.04.
0 = [par. 11.07]
10000 = [par. 11.08]
Torque with -10000 = -[par. 11.08] Final reference limited by

FAST COMM 0=0 par. 20.04.
10000 = [par. 11.08]
PID CTRL -32768 ... PID Reference -10000 = -[par. 11.08]

32767 (not with -1 = -[par. 11.07]
FAST COMM) 0 = [par. 11.07]
10000 = [par. 11.08]
PID Reference with -10000 = -[par. 11.08]

FAST COMM 0=0
10000 = [par. 11.08]
Fieldbus control
209
Generic Drive communication profile

The Generic Drive communication profile is active when parameter 98.07 is set to
GENERIC. The Generic Drive profile realises the device profile for drives – speed
control only – as defined by specific fieldbus standards such as PROFIDRIVE for
PROFIBUS, AC/DC Drive for DeviceNet, Drives and Motion Control for CANopen,
etc. Each device profile specifies its Control and Status Words, Reference and
Actual value scaling. The profiles also define Mandatory services which are
transferred to the application interface of the drive in a standardised way.
The Generic Drive communication profile can be used through both EXT1 and
EXT2*. The proper functioning of the Generic Drive profile requires that Control
Word commands are enabled by setting parameter 10.01 or 10.02 (whichever
control location is active) to COMM.CW (or par. 10.07 to 1) and by setting parameter
16.01 to YES.
*For vendor specific support of EXT2 reference, see appropriate fieldbus manual.
Note: The Generic Drive profile is only available with type Rxxx fieldbus adapter
modules.
Fieldbus control
210
Drive commands supported by the Generic Drive communication profile

Name Description
STOP The drive decelerates the motor to zero speed according to the active deceleration ramp
(parameter 22.03 or 22.05).
START The drive accelerates to the set reference value according to the active acceleration ramp (par.
22.02 or 22.04). The direction of rotation is determined by the sign of the reference value and the
setting of par. 10.03.
COAST STOP The drive coasts to stop, i.e. the drive stops modulating. However, this command can be
overridden by the Brake Control function, which forces the drive to decelerate to zero speed by the
active deceleration ramp. When the Brake Control function is active, Coast stop and Emergency
coast stop (OFF2) commands given after the Emergency ramp stop (OFF3) coast the drive to
a stop.
QUICK STOP The drive decelerates the motor to zero speed within the emergency stop deceleration time
defined by par. 22.07.
CURRENT LIMIT The drive decelerates the motor to zero speed according to the set current limit (par. 20.03) or
STOP (CLS) torque limit (20.04), whichever is first reached. The same procedure is valid in case of a Voltage
Limit Stop (VLS).
INCHING1 With this command active, the drive accelerates the motor to Constant Speed 12 (defined by par.
12.13). After the command is removed, the drive decelerates the motor to zero speed.
Note: The speed reference ramps are not effective. The speed change rate is only limited by the
current (or torque) limit of the drive.
Note: Inching 1 takes priority over Inching 2.
Note: Not effective in Scalar control mode.
INCHING2 With this command active, the drive accelerates the motor to Constant Speed 13 (defined by par.
12.14). After the command is removed, the drive decelerates the motor to zero speed.
Note: The speed reference ramps are not effective. The speed change rate is only limited by the
current (or torque) limit of the drive.
Note: Inching 1 takes priority over Inching 2.
Note: Not effective in Scalar control mode.
RAMP OUT ZERO When active, forces the output of the reference function generator to zero.
RAMP HOLD When active, freezes the reference function generator output.
FORCED TRIP Trips the drive. The drive will indicate fault FORCED TRIP.
RESET Resets an active fault.
Fieldbus control
211
Fieldbus reference scaling

With the Generic Drive communication profile active, the speed reference value
received from the fieldbus and the actual speed value received from the drive are
scaled as shown in the table below.
Note: Any correction of the reference (see section References on page 197) is
applied before scaling.
Ref. Application Range Reference Speed reference Actual speed Notes
No. Macro used type scaling scaling*
(par. 99.02)
REF1 (any) -32768... Speed or 0=0 0=0

32767 Frequency 20000 = 20000 = [par.
[par. 99.08 (DTC) / 99.08 (DTC) /
99.07 (scalar)]** 99.07 (scalar)]**
REF2 FACTORY, -32768... Speed or Freq. -20000 = -[par. 11.08] 0=0 Final reference
HAND/AUT 32767 (not with -1 = -[par. 11.07] 20000 = [par. limited by
or SEQ FAST COMM) 0 = [par. 11.07] 99.08 (DTC) / 20.01/20.02
CTRL 20000 = [par. 11.08] 99.07 (scalar)]** [speed] or
20.07/20.08
[frequency]
Speed or Freq. -20000 = -[par. 11.08] 0=0 Final reference

with 0=0 20000 = [par. limited by
FAST COMM 20000 = [par. 11.08] 99.08 (DTC) / 20.01/20.02
99.07 (scalar)]** [speed] or
20.07/20.08
[frequency]
T CTRL or -32768... Torque -10000 = -[par. 11.08] 0=0 Final reference

M/F 32767 (not with -1 = -[par. 11.07] 20000 = [par. limited by par.
(optional) FAST COMM) 0 = [par. 11.07] 99.08 (DTC) / 20.04
10000 = [par. 11.08] 99.07 (scalar)]**
Torque with -10000 = -[par. 11.08] 0=0 Final reference

FAST COMM 0=0 20000 = [par. limited by par.
10000 = [par. 11.08] 99.08 (DTC) / 20.04
99.07 (scalar)]**
PID CTRL -32768... PID Reference -10000 = -[par. 11.08] 0=0

32767 (not with -1 = -[par. 11.07] 20000 = [par.
FAST COMM) 0 = [par. 11.07] 99.08 (DTC) /
10000 = [par. 11.08] 99.07 (scalar)]**
PID Reference -10000 = -[par. 11.08] 0=0

with 0=0 20000 = [par.
FAST COMM 10000 = [par. 11.08] 99.08 (DTC) /
99.07 (scalar)]**
* With DTC the filter time of the actual speed value can be adjusted using parameter 34.04.
** Note: The maximum reference value is 163% (i.e. 163% = 1.63 · value of parameter 99.08/99.07 value).
Fieldbus control
212
CSA 2.8/3.0 communication profile

The CSA 2.8/3.0 communication profile is active when parameter 98.07 is set to
CSA 2.8/3.0. The Control Word and Status Word for the profile are described below.
CONTROL WORD for the CSA 2.8/3.0 communication profile
Bit Name Value Description
0 Reserved
1 ENABLE 1 Enabled.
0 Coast to stop.
2 Reserved
3 START/STOP 0 ⇒ 1 Start.
0 Stop according to parameter 21.03 STOP FUNCTION.
4 Reserved
5 CNTRL_MODE 1 Select control mode 2.
0 Select control mode 1.
6 Reserved
7 Reserved
8 RESET_FAULT 0 ⇒ 1 Reset drive fault.
9 … 15 Reserved
STATUS WORD for the CSA 2.8/3.0 communication profile

Bit Name Value Description
0 READY 1 Ready to start.
0 Initialising, or initialising error.
1 ENABLE 1 Enabled.
0 Coast to stop.
2 Reserved
3 RUNNING 1 Running with selected reference.
0 Stopped.
4 Reserved
5 REMOTE 1 Drive in Remote mode
0 Drive in Local mode
6 Reserved
7 AT_SETPOINT 1 Drive at reference
0 Drive not at reference
8 FAULTED 1 A fault is active.
0 No active faults
9 WARNING 1 A warning is active.
0 No active warnings
10 LIMIT 1 Drive at a limit
0 Drive at no limit
11 … 15 Reserved
The reference and actual scaling is equal to that of the ABB Drives profile.
Fieldbus control
213
Diverse status, fault, alarm and limit words

03.03 AUXILIARY STATUS WORD
Bit Name Description
0 Reserved
1 OUT OF WINDOW Speed difference is out of the window (in speed control)*.
2 Reserved
3 MAGNETIZED Flux has been formed in the motor.
4 Reserved
5 SYNC RDY Position counter synchronised.
6 1 START NOT Drive has not been started after changing the motor
DONE parameters in group 99.
7 IDENTIF RUN Motor ID Run successfully completed.

DONE
8 START INHIBITION Prevention of unexpected start-up active.
9 LIMITING Control at a limit. See actual signal 3.04 LIMIT WORD 1 below.
10 TORQ CONTROL Torque reference is followed*.
11 ZERO SPEED Absolute value of motor actual speed is below zero speed limit
(4% of synchronous speed).
12 INTERNAL SPEED Internal speed feedback followed.

FB
13 M/F COMM ERR Master/Follower link (on CH2) communication error*.
14 … 15 Reserved
*See the Master/Follower Application Guide [3AFY58962180 (English)].
Fieldbus control
214
03.04 LIMIT WORD 1

Bit Name Active Limit
0 TORQ MOTOR LIM Pull-out limit
1 SPD_TOR_MIN_LIM Speed control torque min. limit
2 SPD_TOR_MAX_LIM Speed control torque max. limit
3 TORQ_USER_CUR_LIM User-defined current limit
4 TORQ_INV_CUR_LIM Internal current limit
5 TORQ_MIN_LIM Any torque min. limit
6 TORQ_MAX_LIM Any torque max. limit
7 TREF_TORQ_MIN_LIM Torque reference min. limit
8 TREF_TORQ_MAX_LIM Torque reference max. limit
9 FLUX_MIN_LIM Flux reference min. limit
10 FREQ_MIN_LIMIT Speed/Frequency min. limit
11 FREQ_MAX_LIMIT Speed/Frequency max. limit
12 DC_UNDERVOLT DC undervoltage limit
13 DC_OVERVOLT DC overvoltage limit
14 TORQUE LIMIT Any torque limit
15 FREQ_LIMIT Any speed/frequency limit
03.05 FAULT WORD 1

0 SHORT CIRC For the possible causes and remedies, see chapter Fault
tracing.
1 OVERCURRENT
2 DC OVERVOLT
3 ACS800 TEMP
4 EARTH FAULT
5 THERMISTOR
6 MOTOR TEMP
7 SYSTEM_FAULT A fault is indicated by the System Fault Word (Actual

Signal 3.07).
8 UNDERLOAD For the possible causes and remedies, see chapter Fault
tracing.
9 OVERFREQ
10 … 15 Reserved
Fieldbus control
215
03.06 FAULT WORD 2

0 SUPPLY PHASE For the possible causes and remedies, see chapter Fault
tracing.
1 NO MOT DATA
2 DC UNDERVOLT
3 Reserved
4 RUN DISABLED For the possible causes and remedies, see chapter Fault
tracing.
5 ENCODER ERR
6 I/O COMM
7 CTRL B TEMP
8 EXTERNAL FLT
9 OVER SWFREQ
10 AI < MIN FUNC
11 PPCC LINK
12 COMM MODULE
13 PANEL LOSS
14 MOTOR STALL
15 MOTOR PHASE
Fieldbus control
216
03.07 SYSTEM FAULT WORD

0 FLT (F1_7) Factory default parameter file error
1 USER MACRO User Macro file error
2 FLT (F1_4) FPROM operating error
3 FLT (F1_5) FPROM data error
4 FLT (F2_12) Internal time level 2 overflow
8 FLT (F2_16) State machine overflow
9 FLT (F2_17) Application program execution error
10 FLT (F2_18) Application program execution error
11 FLT (F2_19) Illegal instruction
12 FLT (F2_3) Register stack overflow
13 FLT (F2_1) System stack overflow
14 FLT (F2_0) System stack underflow
15 Reserved
03.08 ALARM WORD 1

0 START INHIBIT For the possible causes and remedies, see chapter Fault
tracing.
1 Reserved
2 THERMISTOR For the possible causes and remedies, see chapter Fault
tracing.
3 MOTOR TEMP
4 ACS800 TEMP
5 ENCODER ERR
6 T MEAS ALM
7 … 11 Reserved
12 COMM MODULE For the possible causes and remedies, see chapter Fault
tracing.
13 Reserved
14 EARTH FAULT For the possible causes and remedies, see chapter Fault
tracing.
15 Reserved
Fieldbus control
217
03.09 ALARM WORD 2

0 Reserved
1 UNDERLOAD For the possible causes and remedies, see chapter Fault
tracing.
2, 3 Reserved
4 ENCODER For the possible causes and remedies, see chapter Fault
tracing.
5, 6 Reserved
7 POWFAIL FILE (FFA0) Error in restoring POWERFAIL.DDF
8 ALM (OS_17) Error in restoring POWERDOWN.DDF
9 MOTOR STALL For the possible causes and remedies, see chapter Fault
tracing.
10 AI < MIN FUNC
11, 12 Reserved
13 PANEL LOSS For the possible causes and remedies, see chapter Fault
tracing.
14, 15 Reserved
03.13 AUXILIARY STATUS WORD 3

0 REVERSED Motor rotates in reverse direction.
1 EXT CTRL External control is selected.
2 REF 2 SEL Reference 2 is selected.
3 CONST SPEED A Constant Speed (1…15) is selected.
4 STARTED The drive has received a Start command.
5 USER 2 SEL User Macro 2 has been loaded.
6 OPEN BRAKE The Open Brake command is ON. See group 42 BRAKE
CONTROL.
7 LOSS OF REF The reference has been lost.
8 STOP DI STATUS The state of the interlock input on the RMIO board.
9 READY Ready to function: Run enable signal on, no fault
10 DATASET STATUS Data set has not been updated.
11 MACRO CHG Macro is changing or is being saved.
12…15 Reserved
Fieldbus control
218
03.14 AUXILIARY STATUS WORD 4

0 SPEED 1 LIM Output speed has exceeded or fallen below supervision

limit 1. See group 32 SUPERVISION.
1 SPEED 2 LIM Output speed has exceeded or fallen below supervision

limit 2. See group 32 SUPERVISION.
2 CURRENT LIM Motor current has exceeded or fallen below the set
supervision limit. See group 32 SUPERVISION.
3 REF 1 LIM Reference 1 has exceeded or fallen below the set

4 REF 2 LIM Reference 2 has exceeded or fallen below the set

5 TORQUE 1 LIM The motor torque has exceeded or fallen below the
TORQUE1 supervision limit. See group 32
SUPERVISION.
6 TORQUE 2 LIM The motor torque has exceeded or fallen below the
TORQUE2 supervision limit. See group 32
SUPERVISION.
7 ACT 1 LIM PID controller actual value 1 has exceeded or fallen below
the set supervision limit. See group 32 SUPERVISION.
8 ACT 2 LIM PID controller actual value 2 has exceeded or fallen below
the set supervision limit. See group 32 SUPERVISION.
9 ABOVE_LIMIT 1 = Actual frequency or speed value equals or exceeds the

supervision limit (par. 32.02).
0 = Actual frequency or speed value is within supervision
limit.
10 … Reserved
15
03.15 FAULT WORD 4

0 CHOKE OTEMP Step-up module fault
1 MOTOR 1 TEMP For the possible causes and remedies, see chapter Fault
tracing.
2 MOTOR 2 TEMP
3 BRAKE ACKN
4 … 15 Reserved
Fieldbus control
219
03.16 ALARM WORD 4

0 FAN OTEMP Step-up module fan overtemperature alarm
1 MOTOR 1 TEMP For the possible causes and remedies, see chapter Fault
tracing.
2 MOTOR 2 TEMP
3 BRAKE ACKN
4 SLEEP MODE
5 MACRO CHANGING User or Application macro is being saved or loaded
6 … 15 Reserved
03.17 FAULT WORD 5

0 BR BROKEN For the possible causes and remedies, see chapter Fault
tracing.
1 BR WIRING
2 BC SHORT CIR
3 BR OVERHEAT
4 BC OVERHEAT
5 IN CHOKE TEMP
6 PP OVERLOAD
7 INV DISABLED
8 TEMP DIF
9 POWERF INV xx/

POWERFAIL
10 INT CONFIG
11 USER L CURVE
12 Reserved
13 INV OVERTEMP For the possible causes and remedies, see chapter Fault
tracing.
14...15 Reserved
Fieldbus control
220
03.18 ALARM WORD 5

0 REPLACE FAN For the possible causes and remedies, see chapter Fault
tracing.
1 SYNCRO SPEED
2 BR OVERHEAT
3 BC OVERHEAT
4 IN CHOKE TEMP
5 PP OVERLOAD
6 INV DISABLED
7 CUR UNBAL
8 INV CUR LIM
9 DC BUS LIM
10 MOT CUR LIM
11 MOT TORQ LIM
12 MOT POW LIM
13 USER L CURVE
14 Reserved
15 BATT FAILURE For the possible causes and remedies, see chapter Fault
tracing.
03.19 INT INIT FAULT

0 AINT FAULT Wrong EPLD version
1 AINT FAULT Wrong AINT board revision
2 AINT FAULT Du/dt limitation hardware failure
3 AINT FAULT Current measurement scaling error
4 AINT FAULT Voltage measurement scaling error
5 … 15 Reserved
This signal is active with AINT board.
Fieldbus control
221
03.30 LIMIT WORD INV

The LIMIT WORD INV Word includes faults and warnings, which occur when the
output current limit of the drive is exceeded. The current limit protects the drive in
various cases, e.g. integrator overload, high IGBT temperature etc.
0 INTEGRAT 200 Current limit at 200% integrator overload. Temperature

model is not active.*
1 INTEGRAT 150 Current limit at 150% integrator overload. Temperature

model is not active.*
2 INT LOW FREQ Current limit at high IGBT temperature with low output
frequency (<10 Hz). Temperature model is not active.*
3 INTG PP TEMP Current limit at high IGBT temperature. Temperature model

is not active.*
4 PP OVER TEMP Current limit at high IGBT temperature. Temperature model

is active.
5 PP OVERLOAD Current limit at high IGBT junction to case temperature.

Temperature model is active.
If the IGBT junction to case temperature continues to rise in

spite of the current limitation, PP OVERLOAD alarm or fault
occurs. See chapter Fault tracing
6 INV POW LIM Current limit at inverter output power limit
7 INV TRIP CUR Current limit at inverter overcurrent trip limit
8 OVERLOAD CUR Maximum inverter overload current limit. See par. 20.03.
9 CONT DC CUR Continuous dc-current limit
10 CONT OUT CUR Continuous output current limit (Icont.max)
11...15 Reserved
*Not active with ACS800 Factory macro default settings.
03.31 ALARM WORD 6

0 INV OVERTEMP For the possible causes and remedies, see chapter Fault
tracing.
1...2 Reserved
3 ENC CABLE For the possible causes and remedies, see chapter Fault
tracing.
4…15 Reserved
Fieldbus control
222
03.32 EXT IO STATUS

0 EMSTOP MODULE Emergency stop module is not communicating with the

ERROR drive software.
1 EMSTOP OFF2 CMD DI1 of emergency stop module. See 03.01 MAIN
CONTROL WORD bit1 OFF2 CONTROL.
2 EMSTOP OFF3 CMD DI2 of emergency stop module. See 03.01 MAIN
CONTROL WORD bit2 OFF3 CONTROL.
3 FREE DI3 of emergency stop module.
4 EMSTOP OFF3 STATUS RO1 of emergency stop module. See 03.02 MAIN STATUS
WORD bit5 OFF_3_STA. Bit inverted.
5 EMSTOP TRIP STATUS RO2 of emergency stop module. See 03.02 MAIN STATUS
WORD bit3 TRIPPED.
6 STEPUP MODULE Step up module is not communicating with the drive

ERROR software.
7 STEPUP CHOKE FLT DI1 of Step-Up module. For the possible causes and
CMD remedies, see chapter Fault tracing: CHOKE OTEMP
(FF82).
8 STEPUP FAN ALM CMD DI2 of Step-Up module. For possible causes and remedies,
see chapter Fault tracing: FAN OTEMP (FF83).
9 FREE DI3 of Step-Up module.
10 STEPUP MODULATING RO1 of Step-Up module. Drive is modulating.

STATUS
11 STEPUP TRIP STATUS RO2 of Step-Up module. See 03.02 MAIN STATUS WORD
bit3 TRIPPED.
12-15 Reserved
Fieldbus control
223
04.01 FAULTED INT INFO

The FAULTED INT INFO Word includes information on the location of faults PPCC
LINK, OVERCURRENT, EARTH FAULT, SHORT CIRCUIT, ACS800 TEMP,
TEMP DIF and POWERF INV (see 03.05 FAULT WORD 1, 03.06 FAULT WORD 2,
03.17 FAULT WORD 5 and chapter Fault tracing).
0 INT 1 FLT INT 1 board fault
12...14 Reserved
15 PBU FLT PBU board fault
Used only with parallel connected inverters.
Fieldbus control
224
Inverter Block Diagram
RMIO Motor Control and I/O Board

Upper-leg IGBTs INT Main Circuit Interface Board
RMIO INT PBU PPCS Link Branching Unit
Lower-leg IGBTs
U V W
Inverter Unit Block Diagram (2 to 12 parallel inverters)
RMIO PBU INT3

INT1 INT2
1 2 3
INT INT INT
U V W U V W U V W ...
04.02 INT SC INFO

The INT SC INFO Word includes information on the location of the SHORT CIRCUIT
fault (see 03.05 FAULT WORD 1 and chapter Fault tracing).
0 U-PH SC U Phase U upper-leg IGBT(s) short circuit
1 U-PH SC L Phase U lower-leg IGBT(s) short circuit
2 V-PH SC U Phase V upper-leg IGBT(s) short circuit
3 V-PH SC L Phase V lower-leg IGBT(s) short circuit
4 W-PH SC U Phase W upper-leg IGBT(s) short circuit
5 W-PH SC L Phase W lower-leg IGBT(s) short circuit
6...15 Reserved
Fieldbus control
225
Fault tracing
Chapter overview
The chapter lists all warning and fault messages including the possible cause and
corrective actions.
Safety
WARNING! Only qualified electricians are allowed to maintain the drive. The Safety
Instructions on the first pages of the appropriate hardware manual must be read
before you start working with the drive.
Warning and fault indications

A warning or fault message on the panel display indicates abnormal drive status.
Most warning and fault causes can be identified and corrected using this information.
If not, an ABB representative should be contacted.
If the drive is operated with the control panel detached, the red LED in the panel
mounting platform indicates the fault condition. (Note: Some drive types are not fitted
with the LEDs as standard).
The four digit code number in brackets after the message is for the fieldbus
communication. (See chapter Fieldbus control.)
How to reset
The drive can be reset either by pressing the keypad RESET key, by digital input or
fieldbus, or switching the supply voltage off for a while. When the fault has been
removed, the motor can be restarted.
Fault history
When a fault is detected, it is stored in the Fault History. The latest faults and
warnings are stored together with the time stamp at which the event was detected.
The fault logger collects 64 of the latest faults. When the drive power is switched off,
16 of the latest faults are stored.
See chapter Control panel for more information.
Fault tracing
226
Warning messages generated by the drive

WARNING CAUSE WHAT TO DO
3.08 AW 1 bit 4 Check heatsink fins for dust pick-up.
AI < MIN FUNC Analogue control signal is below minimum Check for proper analogue control signal
(8110) allowed value due to incorrect signal level or levels.
3.09 AW 2 bit 10 failure in control wiring. Check control wiring.
(programmable Check Fault Function parameters.
Fault Function
30.01)
BACKUP USED PC stored backup of drive parameters is Wait until download is completed.
(FFA3) downloaded into use.
BATT FAILURE APBU branching unit memory backup battery With parallel connected inverters, enable
(5581) error caused by backup battery by setting actuator 6 of switch
- incorrect APBU switch S3 setting S3 to ON.
3.18 AW 5 bit 15
- too low battery voltage. Replace backup battery.
BC OVERHEAT Brake chopper overload Stop drive. Let chopper cool down.
(7114) Check parameter settings of resistor overload
3.18 AW 5 bit 3 protection function (see parameter group 27
BRAKE CHOPPER).
Check that braking cycle meets allowed limits.
Check that drive supply AC voltage is not
excessive.
BRAKE ACKN Unexpected state of brake acknowledge signal See parameter group 42 BRAKE CONTROL.
(FF74) Check connection of brake acknowledgement
3.16 AW 4 bit 3 signal.
BR OVERHEAT Brake resistor overload Stop drive. Let resistor cool down.
3.18 AW 5 bit 2 protection function (see parameter group 27
BRAKE CHOPPER).
CALIBRA DONE Calibration of output current transformers is Continue normal operation.

(FF37) completed.
CALIBRA REQ Calibration of output current transformers is Calibration starts automatically. Wait for a
(FF36) required. Displayed at start if drive is in scalar while.
control (parameter 99.04) and scalar fly start
feature is on (parameter 21.08).
Fault tracing
227
(7510) master is lost. chapter Fieldbus control, or appropriate
3.08 AW 1 bit 12 fieldbus adapter manual.
(programmable Check parameter settings:
Fault Function - group 51 COMM MODULE DATA (for fieldbus
30.18, 30.19) adapter)
3.08 AW1 bit 14 and connected inverter modules. This can be Check that there is no earth fault in motor or
4.01 caused by external fault (earth fault, motor, motor cables:
(programmable motor cabling, etc.) or internal fault (damaged
- measure insulation resistances of motor and
Fault Function inverter component). xx (2...12) refers to
motor cable.
30.17) inverter module number.
If no earth fault can be detected, contact your
DC BUS LIM Drive limits torque due to too high or too low Informative alarm
(3211) intermediate circuit DC voltage. Check Fault Function parameters.
3.18 AW5 bit 9
(programmable
Fault Function
30.23)
EARTH FAULT Drive has detected load unbalance typically Check there are no power factor correction
(2330) due to earth fault in motor or motor cable. capacitors or surge absorbers in motor cable.
3.08 AW 1 bit 14 Check that there is no earth fault in motor or
(programmable motor cables:
Fault Function - measure insulation resistances of motor and
30.17) motor cable.
ENC CABLE Pulse encoder phase signal is missing. Check pulse encoder and its wiring.
(7310) Check pulse encoder interface module and its
3.31 AW 6 bit 3 wiring.
3.09 AW 2 bit 4 versa.
(7301) and pulse encoder interface module and encoder interface module and its wiring,
3.08 AW 1 bit 5 between module and drive parameter group 50 ENCODER MODULE
settings.
Fault tracing
228
FAN OTEMP Excessive temperature of drive output filter fan. Stop drive. Let it cool down.
(FF83) Supervision is in use in step-up drives. Check ambient temperature.
3.16 AW 4 bit 0 Check fan rotates in correct direction and air
flows freely.
HW RECONF RQ Inverter type (e.g. sr0025_3) has been Wait until alarm POWEROFF! activates and
(FF38) changed. Inverter type is usually changed at switch control board power off to validate
factory or during drive implementation. inverter type change.
ID DONE Drive has performed motor identification Continue drive operation.

(FF32) magnetisation and is ready for operation. This
warning belongs to normal start-up procedure.
ID MAGN Motor identification magnetisation is on. This Wait until drive indicates that motor
(FF31) warning belongs to normal start-up procedure. identification is completed.
ID MAGN REQ Motor identification is required. This warning Start Identification Magnetisation by pressing
(FF30) belongs to normal start-up procedure. Drive Start key, or select ID Run and start (see
expects user to select how motor identification parameter 99.10).
should be performed: By Identification
Magnetisation or by ID Run.
ID N CHANGED Drive ID number has been changed from 1. Change ID number back to 1. See chapter
(FF68) Control panel.
ID RUN Motor identification Run is on. Wait until drive indicates that motor
(FF35) identification Run is completed.
ID RUN SEL Motor Identification Run is selected, and drive Press Start key to start Identification Run.
(FF33) is ready to start ID Run. This warning belongs
to ID Run procedure.
3.18 AW 5 bit 4 Check that fan rotates in correct direction and
air flows freely.
INV CUR LIM Internal inverter current or power limit has Reduce load or increase ramp time.
(2212) been exceeded. Limit inverter actual power or decrease line-
3.18 AW 5 bit 8 side converter reactive power generation
(programmable reference value (parameter 95.06 LCU Q PW
Fault Function REF).
30.23) Check Fault Function parameters.
INV DISABLED Optional DC switch has opened while unit was Close DC switch.
(3200) stopped. Check AFSC-0x Fuse Switch Controller unit.
3.18 AW 5 bit 6
Fault tracing
229
INV OVERTEMP Converter module temperature is excessive. Check ambient temperature. If it exceeds
(4290) 40°C, ensure that load current does not
exceed derated load capacity of drive. See
3.31 AW 6 bit 0
appropriate hardware manual.
Check that ambient temperature setting is
correct (parameter 95.10).
Check converter module cooling air flow and
fan operation.
Cabinet installation: Check cabinet air inlet
filters. Change when necessary. See
Modules installed in cabinet by user: Check
that cooling air circulation in cabinet has been
prevented with air baffles. See module
installation instructions.
Check inside of cabinet and heatsink of
converter module for dust pick-up. Clean when
necessary.
IO CONFIG Input or output of optional I/O extension or Check Fault Function parameters.
(FF8B) fieldbus module has been selected as signal Check parameter group 98 OPTION
(programmable interface in application program but MODULES.
Fault Function communication to appropriate I/O extension
30.22) module has not been set accordingly.
MACRO CHANGE Macro is restoring or User macro is being Wait until drive has finished task.
(FF69) saved.
MOD BOARD T Overtemperature in AINT board of inverter Check inverter fan.

(FF88) module. Check ambient temperature.
09.11 AW 3 bit 14
MOD CHOKE T Overtemperature in choke of liquid cooled R8i Check inverter fan.
(FF89) inverter module. Check ambient temperature.
09.11 AW 3 bit 13 Check liquid cooling system.
MOT CUR LIM Drive limits motor current according to current Reduce load or increase ramp time.
(2300) limit defined by parameter 20.03 MAXIMUM Increase parameter 20.03 MAXIMUM
CURRENT. CURRENT value.
3.18 AW 5 bit 10
Fault Function
30.23)
3.09 AW 2 bit 9
(programmable
Fault Function
30.10)
MOTOR STARTS Motor Identification Run starts. This warning Wait until drive indicates that motor
(FF34) belongs to ID Run procedure. identification is completed.
Fault tracing
230
MOTOR TEMP Motor temperature is too high (or appears to be Check motor ratings, load and cooling.
(4310) too high) due to excessive load, insufficient Check start-up data.
3.08 AW 1 bit 3 motor power, inadequate cooling or incorrect
(programmable start-up data.
Fault Function
30.04…30.09)
MOTOR 1 TEMP Measured motor temperature has exceeded Check value of alarm limit.
(4312) alarm limit set by parameter 35.02. Check that actual number of sensors
3.16 AW 4 bit 1 corresponds to value set by parameter.
Let motor cool down. Ensure proper motor
cooling: Check cooling fan, clean cooling
surfaces, etc.
MOTOR 2 TEMP Measured motor temperature has exceeded Check value of alarm limit.
(4313) alarm limit set by parameter 35.05. Check that actual number of sensors
3.16 AW 4 bit 2 corresponds to value set by parameter.
Let motor cool down. Ensure proper motor
cooling: Check cooling fan, clean cooling
surfaces, etc.
MOT POW LIM Drive limits motor power according to limits Informative alarm
(FF86) defined by parameters 20.11 and 20.12. Check parameter 20.11 P MOTORING LIM
3.18 AW 5 bit 12 and 20.12 P GENERATING LIM settings.
Fault Function
30.23)
MOT TORQ LIM Drive limits motor torque according to Informative alarm
(FF85) calculated motor pull-out torque limit and Check parameter 20.13 MIN TORQ SEL and
minimum and maximum torque limits defined 20.14 MAX TORQ SEL settings.
3.18 AW 5 bit 11
by parameters 20.13 and 20.14.
Fault Function If LIMIT WORD 1 bit 0 TORQ MOTOR LIM
30.23) is 1,
- check motor parameter settings (parameter
group 99 START-UP DATA)
- ensure that ID run has been completed
successfully.
PANEL LOSS Control panel selected as active control Check panel connection (see appropriate
(5300) location for drive has ceased communicating. hardware manual).
3.09 AW 2 bit 13 Check control panel connector.
(programmable Replace control panel in mounting platform.
Fault Function Check Fault Function parameters.
30.02)
POINTER ERROR Source selection (pointer) parameter points to Check source selection (pointer) parameter
(FFD0) non existing parameter index. settings.
->POWEROFF! Inverter type (e.g. sr0025_3) has been Switch control board power off to validate
(FF39) changed. Inverter type is usually changed at inverter type change.
factory or during drive implementation.
Fault tracing
231
PP OVERLOAD Excessive IGBT junction to case temperature. Increase ramp time.

(5482) This can be caused by excessive load at low Reduce load.
frequencies (e.g. fast direction change with
3.18 AW 5 bit 5
excessive load and inertia).
REPLACE FAN Running time of inverter cooling fan has Replace fan.
(4280) exceeded its estimated life time. Reset fan run time counter 01.44.
3.18 AW 5 bit 0
SLEEP MODE Sleep function has entered sleeping mode. See parameter group 40 PID CONTROL.
(FF8C)
3.16 AW 4 bit 4
START INHIBI Optional start inhibit hardware logic is Check start inhibit circuit (AGPS board).
(FF7A) activated.
AW 1 bit 0
START INTERL No Start Interlock signal received. Check circuit connected to Start Interlock input
(FF8D) on RMIO board.
SYNCRO SPEED Value of motor nominal speed set to parameter Check nominal speed from motor rating plate
(FF87) 99.08 is not correct: Value is too near and set parameter 99.08 exactly accordingly.
synchronous speed of motor. Tolerance is
3.18 AW 5 bit 1
0.1%. This warning is active only in DTC mode.
TEMP DIF xx y Excessive temperature difference between Check cooling fan.

(4380) several parallel connected inverter modules. Replace fan.
xx (1...12) refers to inverter module number
4.01 FAULTED INT Check air filters.
INFO
and y refers to phase (U, V, W).
Alarm is indicated when temperature difference

is 15°C. Fault is indicated when temperature
difference is 20°C.
Excessive temperature can be caused e.g. by

unequal current sharing between parallel
connected inverters.
THERMISTOR Motor temperature is excessive. Motor thermal Check motor ratings and load.
(4311) protection mode selection is THERMISTOR. Check start-up data.
3.08 AW 1 bit 2 Check thermistor connections to digital input
(programmable DI6.
Fault Function
30.04…30.05)
T MEAS ALM Motor temperature measurement is out of Check connections of motor temperature
(FF91) acceptable range. measurement circuit. See chapter Program
3.08 AW 1 bit 6 features for circuit diagram.
UNDERLOAD Motor load is too low due to e.g. release Check for problem in driven equipment.
(FF6A) mechanism in driven equipment. Check Fault Function parameters.
3.09 AW 2 bit 1
(programmable
Fault Function
30.13)
Fault tracing
232
USER L CURVE Integrated motor current has exceeded load Check parameter group 72 USER LOAD
(2312) curve defined by parameters in group 72 CURVE settings.
USER LOAD CURVE. Reduce load.
3.18 AW 5 bit 13
Fault tracing
233
Warning messages generated by the control panel

DOWNLOADING Download function of panel has failed. No data Make sure panel is in local mode.
FAILED has been copied from panel to drive. Retry (there might be interference on link).
Contact ABB representative.
DRIVE IS Downloading is not possible while motor is Stop motor. Perform downloading.
RUNNING running.
DOWNLOADING
NOT POSSIBLE
NO Cabling problem or hardware malfunction on Check Panel Link connections.

COMMUNICATION Panel Link Press RESET key. Panel reset may take up to
(X) half a minute, please wait.
(4) = Panel type not compatible with drive Check panel type and drive application
application program version program version. Panel type is printed on
panel cover. Application program version is
stored in parameter 33.02.
NO FREE ID Panel Link already includes 31 stations. Disconnect another station from link to free ID
NUMBERS ID number.
NUMBER
SETTING NOT
POSSIBLE
NOT UPLOADED No upload function has been performed. Perform upload function before downloading.
DOWNLOADING See chapter Control panel.
NOT POSSIBLE
UPLOADING Upload function of panel has failed. No data Retry (there might be interference on link).
FAILED has been copied from drive to panel. Contact ABB representative.
WRITE ACCESS Certain parameters do not allow changes while Stop motor, then change parameter value.
DENIED motor is running. If tried, no change is
PARAMETER accepted, and warning is displayed.
SETTING NOT
POSSIBLE Parameter lock is on. Open parameter lock (see parameter 16.02).
Fault tracing
234
Fault messages generated by the drive

FAULT CAUSE WHAT TO DO
3.05 FW 1 bit 3 Check heatsink fins for dust pick-up.
ACS TEMP xx y Excessive internal temperature in inverter unit Check ambient conditions.
(4210) of several parallel connected inverter modules. Check air flow and fan operation.
3.05 FW 1 bit 3 and xx (1...12) refers to inverter module number
Check heatsink fins for dust pick-up.
4.01 and y refers to phase (U, V, W).
AI < MIN FUNC Analogue control signal is below minimum Check for proper analogue control signal
(8110) allowed value due to incorrect signal level or levels.
3.06 FW 2 bit 10 failure in control wiring. Check control wiring.
Fault Function
30.01)
BACKUP ERROR Failure when restoring PC stored backup of Retry.

(FFA2) drive parameters. Check connections.
Check that parameters are compatible with
drive.
BC OVERHEAT Brake chopper overload Let chopper cool down.

3.17 FW 5 bit 4 protection function (see parameter group 27
BRAKE CHOPPER).
excessive.
BC SHORT CIR Short circuit in brake chopper IGBT(s) Replace brake chopper.
(7113) Ensure brake resistor is connected and not
3.17 FW 5 bit 2 damaged.
BRAKE ACKN Unexpected state of brake acknowledge signal See parameter group 42 BRAKE CONTROL.
(FF74) Check connection of brake acknowledgement
3.15 FW 4 bit 3 signal.
BR BROKEN Brake resistor is not connected or it is Check resistor and resistor connection.
(7110) damaged. Check that resistance rating meets
3.17 FW 5 bit 0 Resistance rating of brake resistor is too high. specifications. See appropriate drive hardware
manual.
BR OVERHEAT Brake resistor overload Let resistor cool down.

3.17 FW 5 bit 3 protection function (see parameter group 27
BRAKE CHOPPER).
excessive.
Fault tracing
235
BR WIRING Wrong connection of brake resistor Check resistor connection.

(7111) Ensure brake resistor is not damaged.
3.17 FW 5 bit 1
CHOKE OTEMP Excessive temperature of drive output filter. Let drive cool down.
(FF82) Supervision is in use in step-up drives. Check ambient temperature.
Check filter fan rotates in correct direction and
air flows freely.
(7510) master is lost. chapter Fieldbus control, or appropriate
3.06 FW 2 bit 12 fieldbus adapter manual.
(programmable Check parameter settings:
Fault Function - group 51 COMM MODULE DATA (for fieldbus
30.18, 30.19) adapter), or
CTRL B TEMP Control board temperature is above 88°C. Check ambient conditions.
(4110) Check air flow.
3.06 FW 2 bit 7 Check main and additional cooling fans.
CURR MEAS Current transformer failure in output current Check current transformer connections to Main
(2211) measurement circuit Circuit Interface Board, INT.
3.05 FW 1 bit 4 and connected inverter modules. This can be Check that there is no earth fault in motor or
4.01 caused by external fault (earth fault, motor, motor cables:
(programmable motor cabling, etc.) or internal fault (damaged
- measure insulation resistances of motor and
Fault Function inverter component). xx (1...12) refers to
motor cable.
30.17) inverter module number.
DC HIGH RUSH Drive supply voltage is excessive. When Check supply voltage level, drive rated voltage
(FF80) supply voltage is over 124% of unit voltage and allowed voltage range of drive.
rating (415, 500 or 690 V), motor speed rushes
to trip level (40% of nominal speed).
DC OVERVOLT Excessive intermediate circuit DC voltage. Check that overvoltage controller is on

(3210) DC overvoltage trip limit is 1.3 · U1max, where (parameter 20.05).
3.05 FW 1 bit 2 U1max is maximum value of mains voltage Check mains for static or transient overvoltage.
range. For 400 V units, U1max is 415 V. For
Check brake chopper and resistor (if used).
500 V units, U1max is 500 V. Actual voltage in
intermediate circuit corresponding to mains Check deceleration time.
voltage trip level is 728 VDC for 400 V units Use coast-to-stop function (if applicable).
and 877 VDC for 500 V units. Retrofit frequency converter with brake
chopper and brake resistor.
Fault tracing
236
DC UNDERVOLT Intermediate circuit DC voltage is not sufficient Check mains supply and fuses.
(3220) due to missing mains phase, blown fuse or
3.06 FW 2 bit 2 rectifier bridge internal fault.
DC undervoltage trip limit is 0.6 · U1min, where
U1min is minimum value of mains voltage
range. For 400 V and 500 V units, U1min is
380 V. For 690 V units, U1min is 525 V. Actual
voltage in intermediate circuit corresponding to
mains voltage trip level is 307 VDC for 400 V
and 500 V units, and 425 VDC for 690 V units.
EARTH FAULT Drive has detected load unbalance typically Check there are no power factor correction
(2330) due to earth fault in motor or motor cable. capacitors or surge absorbers in motor cable.
3.05 FW 1 bit 4 Check that there is no earth fault in motor or
(programmable motor cables:
Fault Function - measure insulation resistances of motor and
30.17) motor cable.
versa.
3.06 FW 2 bit 5 between module and drive parameter group 50 ENCODER MODULE
settings.
EXTERNAL FLT Fault in external device. (This information is Check external devices for faults.
(9000) configured through one of programmable Check parameter 30.03 EXTERNAL FAULT.
3.06 FW 2 bit 8 digital inputs.)
(programmable
Fault Function
30.03)
FORCED TRIP Generic Drive Communication Profile trip See appropriate communication module
(FF8F) command manual.
GD DISABLED AGPS power supply of parallel connected R8i Check Prevention of Unexpected Start-up
(FF53) inverter module has been switched off during circuit.
run. X (1…12) refers to inverter module Replace AGPS board of R8i inverter module.
number.
ID RUN FAIL Motor ID Run is not completed successfully. Check maximum speed (parameter 20.02). It
(FF84) should be at least 80% of motor nominal speed
(parameter 99.08).
3.17 FW 5 bit 5 Check that fan rotates in correct direction and
air flows freely.
Fault tracing
237
INT CONFIG Number of inverter modules is not equal to Check status of inverters. See signal 04.01
(5410) original number of inverters. FAULTED INT INFO.
03.17 FW 5 bit 10 Check fibre optic cables between APBU and
inverter modules.
If Reduced Run function is used, remove
faulted inverter module from main circuit and
write number of remaining inverter modules
into parameter 95.03 INT CONFIG USER.
Reset drive.
INV DISABLED Optional DC switch has opened while unit was Close DC switch.
03.17 FW 5 bit 7 running or start command was given. Check AFSC-0x Fuse Switch Controller unit.
(3200)
INV OVERTEMP Converter module temperature is excessive. Check ambient temperature. If it exceeds
(4290) 40°C, ensure that load current does not
exceed derated load capacity of drive. See
3.17 FW 5 bit 13
Check that ambient temperature setting is
correct (parameter 95.10).
Check converter module cooling air flow and
fan operation.
Cabinet installation: Check cabinet air inlet
filters. Change when necessary. See
Modules installed in cabinet by user: Check
that cooling air circulation in cabinet has been
prevented with air baffles. See module
installation instructions.
Check inside of cabinet and heatsink of
converter module for dust pick-up. Clean when
necessary.
Reset and restart after problem is solved and
let converter module cool down.
I/O COMM ERR Communication error on control board, Check connections of fibre optic cables on
(7000) channel CH1 channel CH1.
3.06 FW 2 bit 6 Electromagnetic interference Check all I/O modules (if present) connected to
channel CH1.
Check for proper earthing of equipment. Check
for highly emissive components nearby.
LINE CONV Fault on line side converter Shift panel from motor side converter control
(FF51) board to line side converter control board.
See line side converter manual for fault
description.
MOD BOARD T Overtemperature in AINT board of inverter Check inverter fan.

(FF88) module. Check ambient temperature.
MOD CHOKE T Overtemperature in choke of liquid cooled R8i Check inverter fan.
(FF89) inverter module. Check ambient temperature.
Check liquid cooling system.
Fault tracing
238
MOTOR PHASE One of motor phases is lost due to fault in Check motor and motor cable.
(FF56) motor, motor cable, thermal relay (if used) or Check thermal relay (if used).
3.06 FW 2 bit 15 internal fault.
Check Fault Function parameters. Disable this
(programmable protection.
Fault Function
30.16)
3.06 FW 2 bit 14
(programmable
Fault Function
30.10…30.12)
MOTOR TEMP Motor temperature is too high (or appears to be Check motor ratings and load.
(4310) too high) due to excessive load, insufficient Check start-up data.
3.05 FW 1 bit 6 motor power, inadequate cooling or incorrect
(programmable start-up data.
Fault Function
30.04…30.09)
MOTOR 1 TEMP Measured motor temperature has exceeded Check value of fault limit.
(4312) fault limit set by parameter 35.03. Let motor cool down. Ensure proper motor
3.15 FW 4 bit 1 cooling: Check cooling fan, clean cooling
surfaces, etc.
MOTOR 2 TEMP Measured motor temperature has exceeded Check value of fault limit.
(4313) fault limit set by parameter 35.06. Let motor cool down. Ensure proper motor
3.15 FW 4 bit 2 cooling: Check cooling fan, clean cooling
surfaces, etc.
NO MOT DATA Motor data is not given or motor data does not Check motor data parameters
(FF52) match with inverter data. 99.04…99.09.
3.06 FW 2 bit 1
OVERCURR xx Overcurrent fault in inverter unit of several Check motor load.

(2310) parallel connected inverter modules. xx (1...12) Check acceleration time.
3.05 FW 1 bit 1 and refers to inverter module number.
Check motor and motor cable (including
4.01
phasing).
Check encoder cable (including phasing).
Check motor nominal values from group 99
START-UP DATA to confirm that motor model
is correct.
Check that there are no power factor correction
or surge absorbers in motor cable.
OVERCURRENT Output current exceeds trip limit. Check motor load.

(2310) Check acceleration time.
3.05 FW 1 bit 1 Check motor and motor cable (including
phasing).
Check that there are no power factor correction
capacitors or surge absorbers in motor cable.
Check encoder cable (including phasing).
Fault tracing
239
OVERFREQ Motor is turning faster than highest allowed Check minimum/maximum speed settings.
(7123) speed due to incorrectly set minimum/ Check adequacy of motor braking torque.
3.05 FW 1 bit 9 maximum speed, insufficient braking torque or
Check applicability of torque control.
changes in load when using torque reference.
Check need for brake chopper and resistor(s).
Trip level is 40 Hz over operating range
absolute maximum speed limit (Direct Torque
Control mode active) or frequency limit (Scalar
Control active). Operating range limits are set
by parameters 20.01 and 20.02 (DTC mode
active) or 20.07 and 20.08 (Scalar Control
active).
OVER SWFREQ Switching frequency is too high. Check motor parameter settings (parameter
(FF55) group 99 START-UP DATA)
3.06 FW 2 bit 9 Ensure that ID run has been completed
successfully.
PANEL LOSS Control panel or DriveWindow selected as Check panel connection (see appropriate
(5300) active control location for drive has ceased hardware manual).
3.06 FW 2 bit 13 communicating. Check control panel connector.
(programmable Replace control panel in mounting platform.
Fault Function
30.02)
Check DriveWindow connection.
PARAM CRC CRC (Cyclic Redundancy Check) error Switch control board power off and on again.
(6320) Reload firmware to control board.
Replace control board.
POWERFAIL INT board powerfail in several inverter units of Check that INT board power cable is
(3381) parallel connected inverter modules. connected.
3.17 FW 5 bit 9 Check that POW board is working correctly.
Replace INT board.
POWERF INV xx INT board powerfail in inverter unit of several Check that INT board power cable is
(3381) parallel connected inverter modules. xx (1...12) connected.
refers to inverter module number. Check that POW board is working correctly.
3.17 FW 5 bit 9 and
4.01 Replace INT board.
PPCC LINK Fibre optic link to INT board is faulty. Check fibre optic cables or galvanic link. With
(5210) frame sizes R2-R6 link is galvanic.
3.06 FW 2 bit 11 If RMIO is powered from external supply,
ensure that supply is on. See parameter 16.09
CTRL BOARD SUPPLY.
Check signal 03.19. Contact ABB
representative if any of faults in signal 3.19 are
active.
Fault tracing
240
PPCC LINK xx INT board fibre optic connection fault in Check connection from inverter module Main
(5210) inverter unit of several parallel connected Circuit Interface Board, INT to PPCC
inverter modules. xx refers to inverter module Branching Unit, PBU. (Inverter module 1 is
3.06 FW 2 bit 11 and
4.01
number. connected to PBU INT1 etc.)
Check signal 03.19. Contact ABB
representative if any of faults in signal 3.19 are
active.
PP OVERLOAD Excessive IGBT junction to case temperature. Check motor cables.

(5482) This fault protects IGBT(s) and it can be
activated by short circuit at output of long
3.17 FW 5 bit 6
motor cables.
RUN DISABLED No Run enable signal received. Check setting of parameter 16.01. Switch on
(FF54) signal or check wiring of selected source.
3.06 FW 2 bit 4
SC INV xx y Short circuit in inverter unit of several parallel Check motor and motor cable.
(2340) connected inverter modules. xx (1...12) refers Check power semiconductors (IGBTs) of
to inverter module number and y refers to inverter module.
3.05 FW 1 bit 0, 4.01 phase (U, V, W).
and 4.02
SHORT CIRC Short-circuit in motor cable(s) or motor Check motor and motor cable.
(2340) Check there are no power factor correction
3.05 FW 1 bit 0 and capacitors or surge absorbers in motor cable.
4.02
Output bridge of converter unit is faulty. Contact ABB representative.
SLOT OVERLAP Two option modules have same connection Check connection interface selections in group
(FF8A) interface selection. 98 OPTION MODULES.
START INHIBI Optional start inhibit hardware logic is Check start inhibit circuit (AGPS board).
(FF7A) activated.
3.03 bit 8
SUPPLY PHASE Intermediate circuit DC voltage is oscillating Check mains fuses.

(3130) due to missing mains phase, blown fuse or Check for mains supply imbalance.
3.06 FW 2 bit 0 rectifier bridge internal fault.
Trip occurs when DC voltage ripple is 13% of
DC voltage.
TEMP DIF xx y Excessive temperature difference between Check cooling fan.

(4380) several parallel connected inverter modules. xx Replace fan.
(1...12) refers to inverter module number and y
3.17 FW 5 bit 8 and Check air filters.
4.01
refers to phase (U, V, W).
Alarm is indicated when temperature difference

is 15°C. Fault is indicated when temperature
difference is 20°C
Excessive temperature can be caused e.g. by

unequal current sharing between parallel
connected inverters.
THERMAL MODE Motor thermal protection mode is set to DTC See parameter 30.05.
(FF50) for high-power motor.
Fault tracing
241
THERMISTOR Motor temperature is excessive. Motor thermal Check motor ratings and load.
(4311) protection mode selection is THERMISTOR. Check start-up data.
3.05 FW 1 bit 5 Check thermistor connections to digital input
(programmable DI6.
Fault Function
30.04…30.05)
UNDERLOAD Motor load is too low due to e.g. release Check for problem in driven equipment.
(FF6A) mechanism in driven equipment. Check Fault Function parameters.
3.05 FW 1 bit 8
(programmable
Fault Function
30.13…30.15)
USER L CURVE Integrated motor current has exceeded load Check parameter group 72 USER LOAD
(2312) curve defined by parameter group 72 USER CURVE settings.
LOAD CURVE. After motor cooling time specified by
3.17 FW 5 bit 11
parameter 72.20 LOAD COOLING TIME has
elapsed, fault can be reset.
USER MACRO No User Macro saved or file is defective. Create User Macro.
(FFA1)
3.07 SFW bit 1
Fault tracing
242
Fault tracing
243
Chapter overview
The chapter describes the use of analogue extension module RAIO as an speed
reference interface of ACS800 equipped with Standard Control Program.
Speed control through the analogue extension module

Two variants are described:
• Bipolar Input in Basic Speed Control
• Bipolar Input in Joystick Mode
Only the use of a bipolar input (± signal range) is covered here. The use of unipolar
input corresponds to that of a standard unipolar input when:
• the settings described below are done, and
• the communication between the module and the drive is activated by parameter
98.06.
Basic checks
Ensure the drive is:
• installed and commissioned, and
• the external start and stop signals are connected.
Ensure the extension module:
• settings are adjusted. (See below.)
• is installed and reference signal is connected to AI1.
• is connected to the drive.
Settings of the analogue extension module and the drive

• Set the module node address to 5 (not required if installed to the option slot of the
drive).
• Select the signal type for the module input AI1 (switch).
• Select the operation mode (unipolar/bipolar) of the module input (switch).
• Ensure the drive parameter settings correspond to the mode of the module inputs
(parameter 98.13 and 98.14).
• Set the drive parameters (see the appropriate section on the following pages).

244
Parameter settings: bipolar input in basic speed control

The table below lists the parameters that affect the handling of the speed reference
received through the extension module bipolar input AI1 (AI5 of the drive).
Parameter Setting
98.06 AI/O EXT MODULE RAIO-SLOT1
98.13 AI/O EXT AI1 FUNC BIPO AI5
10.03 DIRECTION FORWARD; REVERSE; REQUEST(1
11.02 EXT1/EXT2 SELECT EXT1
11.03 EXT REF1 SELECT AI5
11.04 EXT REF1 MINIMUM minREF1
11.05 EXT REF1 MAXIMUM maxREF1
13.16 MINIMUM AI5 minAI5
13.17 MAXIMUM AI5 maxAI5
13.18 SCALE AI5 100%
13.20 INVERT AI5 NO
30.01 AI<MIN FUNCTION (2
The figure below presents the speed reference corresponding to bipolar input AI1 of
the extension module.
Operation Range
scaled
maxREF1
10.03 DIRECTION =
FORWARD or
REQUEST1)
Speed Reference
minREF1
-minREF1
10.03 DIRECTION =
REVERSE or
REQUEST1)
-scaled
maxREF1

1) For the negative speed range, the drive must receive a separate reverse command.
2) Set if supervision of living zero is used.

245
Parameter settings: bipolar input in joystick mode

The table below lists the parameters that affect the handling of the speed and
direction reference received through the extension module bipolar input AI1 (AI5 of
the drive).
Parameter Setting
98.06 AI/O EXT MODULE RAIO-SLOT1
98.13 AI/O EXT AI1 FUNC BIPO AI5
10.03 DIRECTION FORWARD; REVERSE; REQUEST(1
11.02 EXT1/EXT2 SELECT EXT1
11.03 EXT REF1 SELECT AI5/JOYST
11.04 EXT REF1 MINIMUM minREF1
11.05 EXT REF1 MAXIMUM maxREF1
13.16 MINIMUM AI5 minAI5
13.17 MAXIMUM AI5 maxAI5
13.18 SCALE AI5 100%
13.20 INVERT AI5 NO
30.01 AI<MIN FUNCTION (2
The figure below presents the speed reference corresponding to bipolar input AI1 of
the extension module in joystick mode.
Operation Range
scaled
maxREF1
10.03 DIRECTION =
FORWARD or
REQUEST1)
Speed Reference
minREF1
-minREF1
10.03 DIRECTION =
REVERSE or
REQUEST1)
-scaled
maxREF1

1) Enables the use of both positive and negative speed range.

2) Set if supervision of living zero is used.

246

247
Chapter overview
This chapter lists the actual signal and parameter lists with some additional data. For
the descriptions, see chapter Actual signals and parameters.

Term Definition
PB Profibus equivalent for drive parameters communicating through

the NPBA-12 Profibus Adapter.
FbEq Fieldbus equivalent: The scaling between the value shown on

the panel and the integer used in serial communication.
Absolute Maximum Frequency Value of 20.08, or 20.07 if the absolute value of the minimum limit
is greater than the maximum limit.
Absolute Maximum Speed Value of parameter 20.02, or 20.01 if the absolute value of the
minimum limit is higher than the maximum limit.
W Write access is not allowed when the motor is running.
Fieldbus addresses
Rxxx adapter modules (such as RPBA-01, RDNA-01, etc.)
See the appropriate fieldbus adapter module User’s Manual.
Nxxx adapter modules (such as NPBA-12, NDNA-02, etc.)

NPBA-12 Profibus Adapter:
All versions
• see column PB in the tables below.
Version 1.5 or later
• see NPBA-12 PROFIBUS Adapter Installation and Start-Up
Guide [3BFE64341588 (English)].
NIBA-01 InterBus-S Adapter:
• xxyy · 100 + 12288 converted into hexadecimal, where xxyy = drive parameter
number
Example: The index number for drive parameter 13.09 is 1309 + 12288 = 13597
(dec) = 351D (hex)
NMBP-01 ModbusPlus Adapter and NMBA-01 Modbus Adapter:
• 4xxyy, where xxyy = drive parameter number

248
Actual signals
Index Name Short name FbEq Unit Range PB
01 ACTUAL SIGNALS
01.01 PROCESS VARIABLE PROC VAR 1=1 According to 1
parameter 34.02
01.02 SPEED SPEED -20000 = -100% rpm 2
20000 = 100% of
motor absolute max.
speed
01.03 FREQUENCY FREQ -100 = -1 Hz 100 = 1 Hz 3
Hz
01.04 CURRENT CURRENT 10 = 1 A A 4
01.05 TORQUE TORQUE -10000 = -100% % 5
10000 = 100% of
motor nominal torque
01.06 POWER POWER -1000 = -100% 1000 % 6
= 100% of motor
nominal power
01.07 DC BUS VOLTAGE V DC BUS V 1=1V V 7
01.08 MAINS VOLTAGE MAINS V 1=1V V 8
01.09 OUTPUT VOLTAGE OUT VOLT 1=1V V 9
01.10 ACS800 TEMP ACS TEMP 10 = 1% % 10
01.11 EXTERNAL REF 1 EXT REF1 1 = 1 rpm rpm 11
01.12 EXTERNAL REF 2 EXT REF2 0 = 0% 10000 = % 12
100% 1)
01.13 CTRL LOCATION CTRL LOC (1,2) LOCAL; (3) LOCAL; EXT1; 13
EXT1; (4) EXT2 EXT2
01.14 OP HOUR COUNTER OP HOURS 1=1h h 14
01.15 KILOWATT HOURS KW HOURS 1 = 100 kWh kWh 15
01.16 APPL BLOCK OUTPUT APPL OUT 0 = 0% 10000 = % 16
100%
01.17 DI6-1 STATUS DI6-1 1=1 17
01.18 AI1 [V] AI1 [V] 1 = 0.001 V V 18
01.19 AI2 [mA] AI2 [mA] 1 = 0.001 mA mA 19
01.20 AI3 [mA] AI3 [mA] 1 = 0.001 mA mA 20
01.21 RO3-1 STATUS RO3-1 1=1 21
01.22 AO1 [mA] AO1 [mA] 1 =0.001 mA mA 22
01.23 AO2 [mA] AO2 [mA] 1 = 0.001 mA mA 23
01.24 ACTUAL VALUE 1 ACT VAL1 0 = 0% 10000 = % 24
100%
01.25 ACTUAL VALUE 2 ACT VAL2 0 = 0% 10000 = % 25
100%
01.26 CONTROL DEVIATION CONT DEV -10000 = -100% % 26
10000 = 100%
01.27 APPLICATION MACRO MACRO 1…7 According to 27
parameter 99.02
01.28 EXT AO1 [mA] EXT AO1 1 = 0.001 mA mA 28
01.29 EXT AO2 [mA] EXT AO2 1 = 0.001 mA mA 29
01.30 PP 1 TEMP PP 1 TEM 1 = 1°C °C 30
01.31 PP 2 TEMP PP 2 TEM 1 = 1°C °C 31
01.32 PP 3 TEMP PP 3 TEM 1 = 1°C °C 32
01.33 PP 4 TEMP PP 4 TEM 1 = 1°C °C 33
01.34 ACTUAL VALUE ACT V 0 = 0% 10000 = % 34
100%
01.35 MOTOR 1 TEMP M 1 TEMP 1 = 1°C/ohm °C 35
01.36 MOTOR 2 TEMP M 2 TEMP 1 = 1°C/ohm °C 36
01.37 MOTOR TEMP EST MOTOR TE 1 = 1°C °C 37
01.38 AI5 [mA] AI5 [mA] 1 = 0.001 mA mA 38

249

01.39 AI6 [mA] AI6 [mA] 1 = 0.001 mA mA 39
01.40 DI7-12 STATUS DI7...12 1=1 40
01.41 EXT RO STATUS EXT RO 1=1 41
01.42 PROCESS SPEED REL P SPEED 1=1 % 42
01.43 MOTOR RUN TIME MOTOR RUN TIME 1 = 10 h h 43
01.44 FAN ON-TIME FAN TIME 10 h = 1 h 44
01.45 CTRL BOARD TEMP CTRL B T 1=1 °C 45
02 ACTUAL SIGNALS
02.01 SPEED REF 2 S REF 2 0 = 0% 20000 = rpm 51
02.02 SPEED REF 3 S REF 3 100% of motor rpm 52
absolute max. speed
02.09 TORQUE REF 2 T REF 2 0 = 0% 10000 = % 59
02.10 TORQUE REF 3 T REF 3 100% of motor % 60
02.13 TORQ USED REF T USED R nominal torque % 63
02.14 FLUX REF FLUX REF 0 = 0% 10000 = % 64
100%
02.17 SPEED ESTIMATED SPEED ES 0 = 0% 20000 = rpm 67
02.18 SPEED MEASURED SPEED ME 100% of motor rpm 68
absolute max. speed
02.19 MOTOR MOTOR AC 1 = 1 rpm/s. rpm/s 69
ACCELERATIO
02.20 USER CURRENT USER CUR 10 = 1% % 70
03 ACTUAL SIGNALS 2)
03.01 MAIN CTRL WORD MAIN CW 0...65535 76
(Decimal)
03.02 MAIN STATUS WORD MAIN SW 0...65535 77
(Decimal)
03.03 AUX STATUS WORD AUX SW 0...65535 78
(Decimal)
03.04 LIMIT WORD 1 LIMIT W1 0...65535 79
(Decimal)
03.05 FAULT WORD 1 FAULT W1 0...65535 80
(Decimal)
(Decimal)
03.07 SYSTEM FAULT SYS FLT 0...65535 82
(Decimal)
03.08 ALARM WORD 1 ALARM W1 0...65535 83
(Decimal)
(Decimal)
03.11 FOLLOWER MCW FOLL MCW 0...65535 86
(Decimal)
03.13 AUX STATUS WORD 3 AUX SW 3 0...65535 88
(Decimal)
03.14 AUX STATUS WORD 4 AUX SW 4 0...65535 89
(Decimal)
(Decimal)
(Decimal)
(Decimal)
(Decimal)
03.19 INT INIT FAULT INT INIT 0...65535 94
(Decimal)

250

03.20 LATEST FAULT LAST FLT 0...65535 95
(Decimal)
03.21 2.LATEST FAULT 2.FAULT 0...65535 96
(Decimal)
(Decimal)
(Decimal)
(Decimal)
03.25 LATEST WARNING LAST WRN 0...65535 100
(Decimal)
03.26 2.LATEST WARNING 2.WARN 0...65535
(Decimal)
(Decimal)
(Decimal)
(Decimal)
03.30 LIMIT WORD INV LIMIT WO 0...65535 -
(Decimal)
03.31 ALARM WORD 6 ALARM W6 0...65535 -
(Decimal)
03.32 EXT IO STATUS E IO ST - - 0…65535 -
(Decimal)
04 ACTUAL SIGNALS
04.01 FAULTED INT INFO FLTD INT 0...65535
(Decimal)
04.02 INT SC INFO INT SC 0...65535
(Decimal)
09 ACTUAL SIGNALS
09.01 AI1 SCALED AI1 SCAL 20000 = 10 V 0…20000 -
09.02 AI2 SCALED AI2 SCAL 20000 = 20 mA 0…20000 -
09.06 DS MCW DS MCW 0...65535 (Decimal) 0...65535 -
(Decimal)
09.07 MASTER REF1 M REF1 -32768…32767 -32768…32767 -
09.08 MASTER REF2 M REF2 -32768…32767 -32768…32767 -
09.09 AUX DS VAL1 AUX DSV1 -32768…32767 -32768…32767 -
09.10 AUX DS VAL2 AUX DSV2 -32768…32767 -32768…32767 -
09.11 AUX DS VAL3 AUX DSV3 -32768…32767 -32768…32767 -
09.12 LCU ACT SIGNAL1 LCU ACT1 1=1 - -
09.13 LCU ACT SIGNAL2 LCU ACT2 1=1 - -
1) Percent of motor max. speed / nominal torque / max. process reference (depending on the ACS800
macro selected).
2) The contents of these data words are detailed in chapter Fieldbus control. For the contents of Actual
Signal 3.11, see the Master/Follower Application Guide [3AFE64590430 (English)].

251
Parameters
Index Name/Selection FACTORY HAND/AUTO PID-CTRL T-CTRL SEQ CTRL PB W
10 START/STOP/DIR
10.01 EXT1 STRT/STP/DIR DI1,2 (US: DI1,2 DI1 DI1,2 DI1,2 101 W
DI1P,2P,3)
10.02 EXT2 STRT/STP/DIR NOT SEL DI6,5 DI6 DI1,2 NOT SEL 102 W
10.03 REF DIRECTION FORWARD REQUEST FORWARD REQUEST REQUEST 103 W
10.04 EXT 1 STRT PTR 0 0 0 0 104 W
10.05 EXT 2 STRT PTR 0 0 0 0 0 105 W
10.06 JOG SPEED SELECT NOT SEL NOT SEL NOT SEL NOT SEL NOT SEL 106 W
10.07 NET CONTROL 0 0 0 0 0 107
10.08 NET REFERENCE 0 0 0 0 0 108
11 REFERENCE SELECT
11.01 KEYPAD REF SEL REF1 (rpm) REF1 (rpm) REF1 (rpm) REF1 (rpm) REF1 (rpm) 126
11.02 EXT1/EXT2 SELECT EXT1 DI3 DI3 DI3 EXT1 127 W
11.03 EXT REF1 SELECT AI1 AI1 AI1 AI1 AI1 128 W
11.04 EXT REF 1 MINIMUM 0 rpm 0 rpm 0 rpm 0 rpm 0 rpm 129
11.05 EXT REF 1 MAXIMUM 1500 rpm 1500 rpm 1500 rpm 1500 rpm 1500 rpm 130
11.06 EXT REF2 SELECT KEYPAD AI2 AI1 AI2 AI1 131 W
11.07 EXT REF 2 MINIMUM 0% 0% 0% 0% 0% 132
11.08 EXT REF 2 MAXIMUM 100% 100% 100% 100% 100% 133
11.09 EXT 1/2 SEL PTR 0 0 0 0 0 134
11.10 EXT 1 REF PTR 0 0 0 0 0 135
11.11 EXT 2 REF PTR 0 0 0 0 0 136
12 CONSTANT SPEEDS
12.01 CONST SPEED SEL DI5,6 DI4(SPEED4) DI4(SPEED4) DI4(SPEED4) DI4,5,6 151
12.02 CONST SPEED 1 300 rpm 300 rpm 300 rpm 300 rpm 300 rpm 152
13 ANALOGUE INPUTS
13.01 MINIMUM AI1 0V 0V 0V 0V 0V 176
13.02 MAXIMUM AI1 10 V 10 V 10 V 10 V 10 V 177
13.03 SCALE AI1 100% 100% 100% 100% 100% 178
13.04 FILTER AI1 0.10 s 0.10 s 0.10 s 0.10 s 0.10 s 179
13.05 INVERT AI1 NO NO NO NO NO 180
13.06 MINIMUM AI2 0 mA 0 mA 0 mA 0 mA 0 mA 181
13.07 MAXIMUM AI2 20 mA 20 mA 20 mA 20 mA 20 mA 182
13.08 SCALE AI2 100% 100% 100% 100% 100% 183
13.09 FILTER AI2 0.10 s 0.10 s 0.10 s 0.10 s 0.10 s 184
13.13 SCALE AI3 100% 100% 100% 100% 100% 188
13.14 FILTER AI3 0.10 s 0.10 s 0.10 s 0.10 s 0.10 s 189

252

13.18 SCALE AI5 100% 100% 100% 100% 100% 193
13.19 FILTER AI5 0.10 s 0.10 s 0.10 s 0.10 s 0.10 s 194
13.23 SCALE AI6 100% 100% 100% 100% 100% 198
13.24 FILTER AI6 0.10 s 0.10 s 0.10 s 0.10 s 0.10 s 199
14 RELAY OUTPUTS
14.01 RELAY RO1 OUTPUT READY READY READY READY READY 201 W
14.02 RELAY RO2 OUTPUT RUNNING RUNNING RUNNING RUNNING RUNNING 202 W
14.03 RELAY RO3 OUTPUT FAULT(-1) FAULT(-1) FAULT(-1) FAULT(-1) FAULT(-1) 203 W
14.04 RO1 TON DELAY 0.0 s 0.0 s 0.0 s 0.0 s 0.0 s 204 W
14.05 RO1 TOFF DELAY 0.0 s 0.0 s 0.0 s 0.0 s 0.0 s 205 W
14.10 DIO MOD1 RO1 READY READY READY READY READY 210 W
14.11 DIO MOD1 RO2 RUNNING RUNNING RUNNING RUNNING RUNNING 211 W
14.12 DIO MOD2 RO1 FAULT FAULT FAULT FAULT FAULT 212 W
14.13 DIO MOD2 RO2 WARNING WARNING WARNING WARNING WARNING 213 W
14.14 DIO MOD3 RO1 REF 2 SEL REF 2 SEL REF 2 SEL REF 2 SEL REF 2 SEL 214 W
14.15 DIO MOD3 RO2 AT SPEED AT SPEED AT SPEED AT SPEED AT SPEED 215 W
14.16 RO PTR1 0 0 0 0 0 216 W
14.17 RO PTR2 0 0 0 0 0 217 W
14.18 RO PTR3 0 0 0 0 0 218 W
14.19 RO PTR4 0 0 0 0 0 219 W
14.20 RO PTR5 0 0 0 0 0 220 W
14.21 RO PTR6 0 0 0 0 0 221 W
14.22 RO PTR7 0 0 0 0 0 222 W
14.23 RO PTR8 0 0 0 0 0 223 W
14.24 RO PTR9 0 0 0 0 0 224 W
15 ANALOGUE OUTPUTS
15.01 ANALOGUE OUTPUT1 SPEED SPEED SPEED SPEED SPEED 226 W
15.02 INVERT AO1 NO NO NO NO NO 227
15.03 MINIMUM AO1 0 mA 0 mA 0 mA 0 mA 0 mA 228
15.04 FILTER AO1 0.10 s 0.10 s 0.10 s 0.10 s 0.10 s 229
15.05 SCALE AO1 100% 100% 100% 100% 100% 230
15.06 ANALOGUE OUTPUT2 CURRENT CURRENT CURRENT CURRENT CURRENT 231 W
15.07 INVERT AO2 NO NO NO NO NO 232
15.08 MINIMUM AO2 0 mA 0 mA 0 mA 0 mA 0 mA 233
15.09 FILTER AO2 2.00 s 2.00 s 2.00 s 2.00 s 2.00 s 234
15.10 SCALE AO2 100% 100% 100% 100% 100% 235
15.11 AO1 PTR 0 0 0 0 0 236
15.12 AO2 PTR 0 0 0 0 0 237
16 SYS CTRL INPUTS
16.01 RUN ENABLE YES YES DI5 DI6 YES 251 W
16.02 PARAMETER LOCK OPEN OPEN OPEN OPEN OPEN 252
16.03 PASS CODE 0 0 0 0 0 253
16.04 FAULT RESET SEL NOT SEL NOT SEL NOT SEL NOT SEL NOT SEL 254 W
16.05 USER MACRO IO CHG NOT SEL NOT SEL NOT SEL NOT SEL NOT SEL 255 W
16.06 LOCAL LOCK OFF OFF OFF OFF OFF 256
16.07 PARAMETER SAVE DONE DONE DONE DONE DONE 257
16.08 RUN ENA PTR 0 0 0 0 0 258
16.09 CTRL BOARD SUPPLY INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL 259
24V 24V 24V 24V 24V

253

16.10 ASSIST SEL ON ON ON ON ON 260
16.11 FAULT RESET PTR 0 0 0 0 0 261
20 LIMITS
20.01 MINIMUM SPEED (calculated) (calculated) (calculated) (calculated) (calculated) 351
20.02 MAXIMUM SPEED (calculated) (calculated) (calculated) (calculated) (calculated) 352
20.03 MAXIMUM CURRENT type specific type specific type specific type specific type specific 353
20.04 TORQ MAX LIM1 300% 300% 300% 300% 300% 354
20.05 OVERVOLTAGE CTRL ON ON ON ON ON 355
20.06 UNDERVOLTAGE CTRL ON ON ON ON ON 356
20.07 MINIMUM FREQ - 50 Hz - 50 Hz - 50 Hz - 50 Hz - 50 Hz 357
20.08 MAXIMUM FREQ 50 Hz 50 Hz 50 Hz 50 Hz 50 Hz 358
20.11 P MOTORING LIM 300% 300% 300% 300% 300% 361
20.12 P GENERATING LIM -300% -300% -300% -300% -300% 362
20.13 MIN TORQ SEL NEG MAX NEG MAX NEG MAX NEG MAX NEG MAX 363
TORQ TORQ TORQ TORQ TORQ
20.14 MAX TORQ SEL MAX LIM1 MAX LIM1 MAX LIM1 MAX LIM1 MAX LIM1 364
20.15 TORQ MIN LIM1 0.0% 0.0% 0.0% 0.0% 0.0% 365
20.16 TORQ MIN LIM2 0.0% 0.0% 0.0% 0.0% 0.0% 366
20.17 TORQ MAX LIM2 300.0% 300.0% 300.0% 300.0% 300.0% 367
20.18 TORQ MIN PTR 0 0 0 0 0 368
20.19 TORQ MAX PTR 0 0 0 0 0 369
20.20 MIN AI SCALE 0% 0% 0% 0% 0% 370
20.21 MAX AI SCALE 300% 300% 300% 300% 300% 371
21 START/STOP
21.01 START FUNCTION AUTO AUTO AUTO AUTO AUTO 376 W
21.02 CONST MAGN TIME 500.0 ms 500.0 ms 500.0 ms 500.0 ms 500.0 ms 377 W
21.03 STOP FUNCTION COAST COAST COAST COAST RAMP 378
21.04 DC HOLD NO NO NO NO NO 379
21.05 DC HOLD SPEED 5 rpm 5 rpm 5 rpm 5 rpm 5 rpm 380 W
21.06 DC HOLD CURR 30% 30% 30% 30% 30% 381 W
21.07 RUN ENABLE FUNC COAST STOP COAST STOP COAST STOP COAST STOP COAST STOP 382
21.08 SCALAR FLY START NO NO NO NO NO 383 W
21.09 START INTRL FUNC OFF2 STOP OFF2 STOP OFF2 STOP OFF2 STOP OFF2 STOP 384
21.10 ZERO SPEED DELAY 0.5 s 0.5 s 0.5 s 0.5 s 0.5 s 385
22 ACCEL/DECEL
22.01 ACC/DEC SEL DI4 ACC/DEC 1 ACC/DEC 1 DI5 DI3 401 W
22.02 ACCEL TIME 1 20 s 20 s 20 s 20 s 20 s 402
22.03 DECEL TIME 1 20 s 20 s 20 s 20 s 20 s 403
22.04 ACCEL TIME 2 60.00 s 60.00 s 60.00 s 60.00 s 60.00 s 404
22.05 DECEL TIME 2 60.00 s 60.00 s 60.00 s 60.00 s 60.00 s 405
22.06 ACC/DEC RAMP SHPE 0.00 s 0.00 s 0.00 s 0.00 s 0.00 s 406
22.07 EM STOP RAMP TIME 3.00 s 3.00 s 3.00 s 3.00 s 3.00 s 407
22.08 ACC PTR 0 0 0 0 0 408
22.09 DEC PTR 0 0 0 0 0 409
23 SPEED CTRL
23.01 GAIN 10 10 10 10 10 426
23.02 INTEGRATION TIME 2.50 s 2.50 s 2.50 s 2.50 s 2.50 s 427
23.03 DERIVATION TIME 0.0 ms 0.0 ms 0.0 ms 0.0 ms 0.0 ms 428
23.04 ACC COMPENSATION 0.00 s 0.00 s 0.00 s 0.00 s 0.12 s 429
23.05 SLIP GAIN 100.0% 100.0% 100.0% 100.0% 100.0% 430
23.06 AUTOTUNE RUN NO NO NO NO NO 431
23.07 SP ACT FILT TIME 8 ms 8 ms 8 ms 8 ms 8 ms 432
24 TORQUE CTRL
24.01 TORQ RAMP UP 0.00 s 451
24.02 TORQ RAMP DOWN 0.00 s 452
25 CRITICAL SPEEDS
25.01 CRIT SPEED SELECT OFF OFF OFF OFF OFF 476
25.02 CRIT SPEED 1 LOW 0 rpm 0 rpm 0 rpm 0 rpm 0 rpm 477

254

25.03 CRIT SPEED 1 HIGH 0 rpm 0 rpm 0 rpm 0 rpm 0 rpm 478
26 MOTOR CONTROL
26.01 FLUX OPTIMIZATION NO NO NO NO NO 501 W
26.02 FLUX BRAKING YES YES YES YES YES 502 W
26.03 IR-COMPENSATION 0% 0% 0% 0% 0% 503 W
26.04 IR STEP-UP FREQ 0 0 0 0 0 504 W
26.05 HEX FIELD WEAKEN NO NO NO NO NO 505 W
26.06 FLUX REF PTR C.10000 C.10000 C.10000 C.10000 C.10000 506 W
26.07 FLYSTART CUR REF [%] 60% 60% 60% 60% 60% 507 W
26.08 FLYSTART INIT DLY 25 25 25 25 25 508 W
26.09 FS METHOD ON ON ON ON ON 509 W
26.10 RS20 [mOhm] (Set in ID run.) (Set in ID run.) (Set in ID run.) (Set in ID run.) (Set in ID run.) 510 W
27 BRAKE CHOPPER
27.01 BRAKE CHOPPER CTL OFF OFF OFF OFF
526 W OFF
27.02 BR OVERLOAD FUNC NO NO NO NO
527 NO
27.03 BR RESISTANCE 528
27.04 BR THERM TCONST 0s 0s 0s 0s 0s 529
27.05 MAX CONT BR POWER 0 kW 0 kW 0 kW 0 kW 0 kW 530
27.06 BC CTRL MODE COMMON DC COMMON DC COMMON DC COMMON DC COMMON DC 531
30 FAULT FUNCTIONS
30.01 AI<MIN FUNCTION FAULT FAULT FAULT FAULT FAULT 601
30.02 PANEL LOSS FAULT FAULT FAULT FAULT FAULT 602
30.03 EXTERNAL FAULT NOT SEL NOT SEL NOT SEL NOT SEL NOT SEL 603
30.04 MOTOR THERM PROT NO NO NO NO NO 604
30.05 MOT THERM P MODE DTC/USER DTC/USER DTC/USER DTC/USER DTC/USER 605
MODE MODE MODE MODE MODE
30.06 MOTOR THERM TIME (calculated) (calculated) (calculated) (calculated) (calculated) 606
30.07 MOTOR LOAD CURVE 100.0% 100.0% 100.0% 100.0% 100.0% 607
30.08 ZERO SPEED LOAD 74.0% 74.0% 74.0% 74.0% 74.0% 608
30.09 BREAK POINT 45.0 Hz 45.0 Hz 45.0 Hz 45.0 Hz 45.0 Hz 609
30.10 STALL FUNCTION FAULT FAULT FAULT FAULT FAULT 610
30.11 STALL FREQ HI 20.0 Hz 20.0 Hz 20.0 Hz 20.0 Hz 20.0 Hz 611
30.12 STALL TIME 20.00 s 20.00 s 20.00 s 20.00 s 20.00 s 612
30.13 UNDERLOAD FUNC NO NO NO NO NO 613
30.14 UNDERLOAD TIME 600.0 s 600.0 s 600.0 s 600.0 s 600.0 s 614
30.15 UNDERLOAD CURVE 1 1 1 1 1 615
30.16 MOTOR PHASE LOSS NO NO NO NO NO 616
30.17 EARTH FAULT FAULT FAULT FAULT FAULT FAULT 617
30.18 COMM FLT FUNC FAULT FAULT FAULT FAULT FAULT 618
30.19 MAIN REF DS T-OUT 3.00 s 3.00 s 3.00 s 3.00 s 3.00 s 619
30.20 COMM FLT RO/AO ZERO ZERO ZERO ZERO ZERO 620
30.21 AUX DS T-OUT 3.0 s 3.0 s 3.0 s 3.0 s 3.0 s 621
30.22 IO CONFIG FUNC WARNING WARNING WARNING WARNING WARNING 622
30.23 LIMIT WARNING 0 0 0 0 0 623
31 AUTOMATIC RESET
31.01 NUMBER OF TRIALS 0 0 0 0 0 626
31.02 TRIAL TIME 30.0 s 30.0 s 30.0 s 30.0 s 30.0 s 627
31.03 DELAY TIME 0.0 s 0.0 s 0.0 s 0.0 s 0.0 s 628
31.04 OVERCURRENT NO NO NO NO NO 629
31.05 OVERVOLTAGE NO NO NO NO NO 630
31.06 UNDERVOLTAGE NO NO NO NO 631
31.07 AI SIGNAL<MIN NO NO NO NO NO 632
31.08 LINE CONV NO NO NO NO NO 633

255

32 SUPERVISION
32.01 SPEED1 FUNCTION NO NO NO NO NO 651
32.02 SPEED1 LIMIT 0 rpm 0 rpm 0 rpm 0 rpm 0 rpm 652
32.03 SPEED2 FUNCTION NO NO NO NO NO 653
32.04 SPEED2 LIMIT 0 rpm 0 rpm 0 rpm 0 rpm 0 rpm 654
32.05 CURRENT FUNCTION NO NO NO NO NO 655
32.06 CURRENT LIMIT 0 0 0 0 0 656
32.07 TORQUE 1 FUNCTION NO NO NO NO NO 657
32.08 TORQUE 1 LIMIT 0% 0% 0% 0% 0% 658
32.09 TORQUE 2 FUNCTION NO NO NO NO NO 659
32.10 TORQUE 2 LIMIT 0% 0% 0% 0% 0% 660
32.11 REF1 FUNCTION NO NO NO NO NO 661
32.12 REF1 LIMIT 0 rpm 0 rpm 0 rpm 0 rpm 0 rpm 662
32.13 REF2 FUNCTION NO NO NO NO NO 663
32.14 REF2 LIMIT 0% 0% 0% 0% 0% 664
32.15 ACT1 FUNCTION NO NO NO NO NO 665
32.16 ACT1 LIMIT 0% 0% 0% 0% 0% 666
32.17 ACT2 FUNCTION NO NO NO NO NO 667
32.18 ACT2 LIMIT 0% 0% 0% 0% 0% 668
33 INFORMATION
33.01 SOFTWARE VERSION (Version) (Version) (Version) (Version) (Version) 676
33.02 APPL SW VERSION (Version) (Version) (Version) (Version) (Version) 677
33.03 TEST DATE (Date) (Date) (Date) (Date) (Date) 678
33.04 BOARD TYPE (Control board (Control board (Control board (Control board (Control board 679
type) type) type) type) type)
34 PROCESS VARIABLE
34.01 SCALE 100 100 100 100 100 701
34.02 P VAR UNIT % % % % % 702
34.03 SELECT P VAR 142 142 142 142 142 703
34.04 MOTOR SP FILT TIM 500 ms 500 ms 500 ms 500 ms 500 ms 704
34.05 TORQ ACT FILT TIM 100 ms 100 ms 100 ms 100 ms 100 ms 705
34.06 RESET RUN TIME NO NO NO NO NO 706
35 MOT TEMP MEAS
35.01 MOT 1 TEMP AI1 SEL NOT IN USE NOT IN USE NOT IN USE NOT IN USE NOT IN USE 726
35.02 MOT 1 TEMP ALM L 110 110 110 110 110 727
35.03 MOT 1 TEMP FLT L 130 130 130 130 130 728
35.04 MOT 2 TEMP AI2 SEL NOT IN USE NOT IN USE NOT IN USE NOT IN USE NOT IN USE 729
35.05 MOT 2 TEMP ALM L 110 110 110 110 110 730
35.06 MOT 2 TEMP FLT L 130 130 130 130 130 731
35.07 MOT MOD COMPENSAT YES YES YES YES YES 732
40 PID CONTROL
40.01 PID GAIN 1 1 1 1 1 851
40.02 PID INTEG TIME 60.00 s 60.00 s 60.00 s 60.00 s 60.00 s 852
40.03 PID DERIV TIME 0.00 s 0.00 s 0.00 s 0.00 s 0.00 s 853
40.04 PID DERIV FILTER 1.00 s 1.00 s 1.00 s 1.00 s 1.00 s 854
40.05 ERROR VALUE INV NO NO NO NO NO 855
40.06 ACTUAL VALUE SEL ACT1 ACT1 ACT1 ACT1 ACT1 856
40.07 ACTUAL1 INPUT SEL AI2 AI2 AI2 AI2 AI2 857
40.08 ACTUAL2 INPUT SEL AI2 AI2 AI2 AI2 AI2 858
40.09 ACT1 MINIMUM 0 0 0 0 0 859
40.10 ACT1 MAXIMUM 100% 100% 100% 100% 100% 860
40.11 ACT2 MINIMUM 0% 0% 0% 0% 0% 861
40.12 ACT2 MAXIMUM 100% 100% 100% 100% 100% 862
40.13 PID INTEGRATION ON ON ON ON ON 863
40.14 TRIM MODE OFF OFF OFF OFF 864
40.15 TRIM REF SEL AI1 AI1 AI1 AI1 865
40.16 TRIM REFERENCE 0.0% 0.0% 0.0% 0.0% 0.0% 866
40.17 TRIM RANGE ADJUST 100.0% 100.0% 100.0% 100.0% 100.0% 867

256

40.18 TRIM SELECTION SPEED TRIM 868
40.19 ACTUAL FILT TIME 0.04 s 0.04 s 0.04 s 0.04 s 0.04 s 869
40.20 SLEEP SELECTION not visible not visible OFF not visible not visible 870
40.21 SLEEP LEVEL not visible not visible 0.0 rpm not visible not visible 871
40.22 SLEEP DELAY not visible not visible 0.0 s not visible not visible 872
40.23 WAKE UP LEVEL not visible not visible 0% not visible not visible 873
40.24 WAKE UP DELAY not visible not visible 0.0 s not visible not visible 874
40.25 ACTUAL1 PTR 0 0 0 0 0 875
40.26 PID MINIMUM -100.0% -100.0% -100.0% -100.0% -100.0% -
40.27 PID MAXIMUM 100.0% 100.0% 100.0% 100.0% 100.0% -
40.28 TRIM REF PTR 0 0 0 0 0 -
42 BRAKE CONTROL
42.01 BRAKE CTRL OFF OFF OFF OFF OFF -
42.02 BRAKE ACKNOWLEDGE OFF OFF OFF OFF OFF -
42.03 BRAKE OPEN DELAY 0.0 s 0.0 s 0.0 s 0.0 s 0.0 s -
42.04 BRAKE CLOSE DELAY 0.0 s 0.0 s 0.0 s 0.0 s 0.0 s -
42.05 ABS BRAKE CLS SPD 10 rpm 10 rpm 10 rpm 10 rpm 10 rpm -
42.06 BRAKE FAULT FUNC FAULT FAULT FAULT FAULT FAULT -
42.07 START TORQ REF SEL NO NO NO NO NO -
42.08 START TORQ REF 0% 0% 0% 0% 0% -
42.09 EXTEND RUN T 0.0 s 0.0 s 0.0 s 0.0 s 0.0 s -
42.10 LOW REF BRK HOLD 0.0 s 0.0 s 0.0 s 0.0 s 0.0 s -
50 ENCODER MODULE
50.01 PULSE NR 2048 2048 2048 2048 2048 1001
50.02 SPEED MEAS MODE A --- B --- A --- B --- A --- B --- A --- B --- A --- B --- 1002
50.03 ENCODER FAULT WARNING WARNING WARNING WARNING WARNING 1003
50.04 ENCODER DELAY 1000 1000 1000 1000 1000 1004
50.05 ENCODER DDCS CH CHANNEL 1 CHANNEL 1 CHANNEL 1 CHANNEL 1 CHANNEL 1 1005
50.06 SPEED FB SEL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL 1006
50.07 ENC CABLE CHECK NO NO NO NO NO 1007
51 COMM MOD DATA 1026
...
52 STANDARD MODBUS
52.01 STATION NUMBER 1 1 1 1 1 1051
52.02 BAUDRATE 9600 9600 9600 9600 9600 1052
52.03 PARITY ODD ODD ODD ODD ODD 1053
60 MASTER/FOLLOWER
60.01 MASTER LINK MODE NOT IN USE NOT IN USE NOT IN USE NOT IN USE NOT IN USE 1195
60.02 TORQUE SELECTOR not visible not visible not visible TORQUE not visible 1196
60.03 WINDOW SEL ON not visible not visible not visible NO not visible 1167
60.04 WINDOW WIDTH POS not visible not visible not visible 0 not visible 1198
60.05 WINDOW WIDTH NEG not visible not visible not visible 0 not visible 1199
60.06 DROOP RATE 0 0 0 0 0 1200
60.07 MASTER SIGNAL 2 202 202 202 202 202 1201
60.08 MASTER SIGNAL 3 213 213 213 213 213 1202
70 DDCS CONTROL
70.01 CHANNEL 0 ADDR 1 1 1 1 1 1375
70.02 CHANNEL 3 ADDR 1 1 1 1 1 1376
70.03 CH1 BAUDRATE 4 Mbit/s 4 Mbit/s 4 Mbit/s 4 Mbit/s 4 Mbit/s 1377
70.04 CH0 DDCS HW CONN RING RING RING RING RING 1378
70.05 CH2 HW CONNECTION RING RING RING RING RING
72 USER LOAD CURVE
72.01 OVERLOAD FUNC NO NO NO NO NO 1411
72.02 LOAD CURRENT 1 500 500 500 500 500 1412
72.03 LOAD CURRENT 2 500 500 500 500 500 1413
72.04 LOAD CURRENT 3 500 500 500 500 500 1414
72.05 LOAD CURRENT 4 500 500 500 500 500 1415
72.06 LOAD CURRENT 5 500 500 500 500 500 1416

257

72.07 LOAD CURRENT 6 500 500 500 500 500 1417
72.08 LOAD CURRENT 7 500 500 500 500 500 1418
72.09 LOAD CURRENT 8 500 500 500 500 500 1419
72.10 LOAD FREQ 1 0 0 0 0 0 1420
72.11 LOAD FREQ 2 0 0 0 0 0 1421
72.12 LOAD FREQ 3 0 0 0 0 0 1422
72.13 LOAD FREQ 4 0 0 0 0 0 1423
72.14 LOAD FREQ 5 0 0 0 0 0 1424
72.15 LOAD FREQ 6 0 0 0 0 0 1425
72.16 LOAD FREQ 7 0 0 0 0 0 1426
72.17 LOAD FREQ 8 0 0 0 0 0 1427
72.18 LOAD CURRENT LIMIT 800 800 800 800 800 1428
72.19 LOAD THERMAL TIME 0.0 0.0 0.0 0.0 0.0
72.20 LOAD COOLING TIME 0 0 0 0 0
83 ADAPT PROG CTRL
83.01 ADAPT PROG CMD EDIT EDIT EDIT EDIT EDIT 1609 W
83.02 EDIT COMMAND NO NO NO NO NO 1610
83.03 EDIT BLOCK 0 0 0 0 0 1611
83.04 TIMELEVEL SEL 100ms 100ms 100ms 100ms 100ms 1612
83.05 PASSCODE 0 0 0 0 0 1613
84 ADAPTIVE PROGRAM
84.01 STATUS 1628
84.02 FAULTED PAR 1629
84.05 BLOCK1 NO NO NO NO NO 1630
84.06 INPUT1 0 0 0 0 0 1631
84.07 INPUT2 0 0 0 0 0 1632
84.08 INPUT3 0 0 0 0 0 1633
84.09 OUTPUT 0 0 0 0 0 1634
… … …
1644
84.79 OUTPUT 0 0 0 0 0 -
85 USER CONSTANTS
85.01 CONSTANT1 0 0 0 0 0 1645
85.02 CONSTANT2 0 0 0 0 0 1646
85.03 CONSTANT3 0 0 0 0 0 1647
85.04 CONSTANT4 0 0 0 0 0 1648
85.05 CONSTANT5 0 0 0 0 0 1649
85.06 CONSTANT6 0 0 0 0 0 1650
85.07 CONSTANT7 0 0 0 0 0 1651
85.08 CONSTANT8 0 0 0 0 0 1652
85.09 CONSTANT9 0 0 0 0 0 1653
85.10 CONSTANT10 0 0 0 0 0 1654
85.11 STRING1 MESSAGE1 MESSAGE1 MESSAGE1 MESSAGE1 MESSAGE1 1655
90 D SET REC ADDR
90.01 AUX DS REF3 0 0 0 0 0 1735
90.02 AUX DS REF4 0 0 0 0 0 1736
90.03 AUX DS REF5 0 0 0 0 0 1737
90.04 MAIN DS SOURCE 1 1 1 1 1 1738
90.05 AUX DS SOURCE 3 3 3 3 3 1739
92 D SET TR ADDR
92.01 MAIN DS STATUS WORD 302 302 302 302 302 1771
92.02 MAIN DS ACT1 102 102 102 102 102 1772
92.03 MAIN DS ACT2 105 105 105 105 105 1773
92.04 AUX DS ACT3 305 305 305 305 305 1774

258

92.05 AUX DS ACT4 308 308 308 308 308 1775
92.06 AUX DS ACT5 306 306 306 306 306 1776
92.07 MSW B10 PTR 3.014.09 3.014.09 3.014.09 3.014.09 3.014.09 1777
92.08 MSW B13 PTR 0 0 0 0 0 1778
92.09 MSW B14 PTR 0 0 0 0 0 1779
95 HARDWARE SPECIF
95.01 FAN SPD CTRL MODE CONTROLLED 1825
95.02 FUSE SWITCH CTRL Inverter type dependent 1826
95.03 INT CONFIG USER 0 0 0 0 0 1827
95.04 EX/SIN REQUEST 1 1 1 1 1 1828
95.05 ENA INC SW FREQ 0 0 0 0 0 1829
95.06 LCU Q PW REF 0 0 0 0 0 1830
95.07 LCU DC REF 0 0 0 0 0 1831
95.08 LCU PAR1 SEL 106 106 106 106 106 1832
95.09 LCU PAR2 SEL 110 110 110 110 110 1833
95.10 TEMP INV AMBIENT 40°C 40°C 40°C 40°C 40°C 1834
96 EXTERNAL AO
96.01 EXT AO1 SPEED SPEED SPEED SPEED SPEED 1843
96.02 INVERT EXT AO1 NO NO NO NO NO 1844
96.03 MINIMUM EXT AO1 0 mA 0 mA 0 mA 0 mA 0 mA 1845
96.04 FILTER EXT AO1 0.01 s 0.01 s 0.01 s 0.01 s 0.01 s 1846
96.05 SCALE EXT AO1 100% 100% 100% 100% 100% 1847
96.06 EXT AO2 CURRENT CURRENT CURRENT CURRENT CURRENT 1848
96.07 INVERT EXT AO2 NO NO NO NO NO 1849
96.08 MINIMUM EXT AO2 0 mA 0 mA 0 mA 0 mA 0 mA 1850
96.09 FILTER EXT AO2 2.00 s 2.00 s 2.00 s 2.00 s 2.00 s 1851
96.10 SCALE EXT AO2 100% 100% 100% 100% 100% 1852
96.11 EXT AO1 PTR 0 0 0 0 0 1853
96.12 EXT AO2 PTR 0 0 0 0 0 1854
98 OPTION MODULES
98.01 ENCODER MODULE NO NO NO NO NO 1901 W
98.02 COMM. MODULE LINK NO NO NO NO NO 1902 W
98.03 DI/O EXT MODULE 1 NO NO NO NO NO 1903 W
98.06 AI/O EXT MODULE NO NO NO NO NO 1906 W
98.07 COMM PROFILE ABB DRIVES ABB DRIVES ABB DRIVES ABB DRIVES ABB DRIVES 1907 W
98.09 DI/O EXT1 DI FUNC DI7,8,9 DI7,8,9 DI7,8,9 DI7,8,9 DI7,8,9 1909 W
98.10 DI/O EXT2 DI FUNC DI10,11,12 DI10,11,12 DI10,11,12 DI10,11,12 DI10,11,12 1910 W
98.11 DI/O EXT3 DI FUNC DI11,12 DI11,12 DI11,12 DI11,12 DI11,12 1911 W
98.12 AI/O MOTOR TEMP NO NO NO NO NO 1912 W
98.13 AI/O EXT AI1 FUNC UNIPOLAR UNIPOLAR UNIPOLAR UNIPOLAR UNIPOLAR 1913 W
AI5 AI5 AI5 AI5 AI5
98.14 AI/O EXT AI2 FUNC UNIPOLAR UNIPOLAR UNIPOLAR UNIPOLAR UNIPOLAR 1914 W
AI6 AI6 AI6 AI6 AI6
98.16 SIN FILT SUPERV NO NO NO NO NO 1915 W
99 START-UP DATA
99.01 LANGUAGE ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 1926 W
99.02 APPLICATION MACRO FACTORY HAND/AUTO PID-CTRL T CTRL SEQ CTRL 1927 W
99.03 APPLIC RESTORE NO NO NO NO NO 1928 W
99.04 MOTOR CTRL MODE DTC DTC DTC DTC DTC 1929 W
99.05 MOTOR NOM VOLTAGE 0V 0V 0V 0V 0V 1930 W
99.06 MOTOR NOM CURRENT 0.0 A 0.0 A 0.0 A 0.0 A 0.0 A 1931 W
99.07 MOTOR NOM FREQ 50.0 Hz 50.0 Hz 50.0 Hz 50.0 Hz 50.0 Hz 1932 W
99.08 MOTOR NOM SPEED 1 rpm 1 rpm 1 rpm 1 rpm 1 rpm 1933 W
99.09 MOTOR NOM POWER 0.0 kW 0.0 kW 0.0 kW 0.0 kW 0.0 kW 1934 W
99.10 MOTOR ID RUN MODE ID MAGN ID MAGN ID MAGN ID MAGN ID MAGN 1935 W
99.11 DEVICE NAME 1936

259
Chapter overview
Diagram Related
diagrams
Reference control chain, sheet 1 Continued on

Valid when FACTORY, HAND/AUTO, SEQ CTRL or T CTRL macro is active (see parameter 99.02). sheet 2
Reference control chain, sheet 1 Continued on

Valid when PID CTRL macro is active (see parameter 99.02). sheet 2
Reference control chain, sheet 2 Continued from

Valid with all macros (see parameter 99.02). sheet 1
Handling of Start, Stop, Run Enable Start Interlock -

Valid with all macros (see parameter 99.02).
Handling of Reset and On/Off -

Valid with all macros (see parameter 99.02).

260
Reference control chain, sheet 1: FACTORY, HAND/AUTO, SEQ CTRL and

T CTRL macros (continued on the next page …)

261
… continued from the previous page

262
Reference control chain sheet 1: PID CTRL macro (continued on the next
page …)

263

264
Reference control chain sheet 2: All macros (continued on the next page …)

265

266
Handling of Start, Stop, Run Enable and Start Interlock

267
Handling of Reset and On/Off

The diagram below is a detail to the previous diagram (Handling of Start, Stop, Run
Enable and Start Interlock).
RESET FROM PANEL
RESET FROM FIELDBUS OR MAIN CW / B7 (RESET)
IN LOCAL MODE
16.04 EXT RESET

AND
31 AUTORESET AND
AND
AND MAIN CW / B0 (ON/OFF)
NOT READY TO SWITCH ON

OR
SWITCH ON INHIBITED
FIELDBUS CW / B0

268

269
Index
A Application macros 83
factory 83, 84
ABB drives communication profile 204 hand/auto 83, 86
Absolute maximum frequency 95, 247 PID control 83, 88
Absolute maximum speed 95, 247 reference control chain diagram 262
ACCEL TIME 1 130 sequential control 83, 92
ACCEL/DECEL 129 torque control 83, 90
Acceleration user 83, 94
compensation 133 Application, selection for start-up assistant 41
motor 98 Automatic resets 67
ramps 57 Automatic start 54
settings 57 AUXILIARY STATUS WORD 3 217
speed reference ramps 46 AUXILIARY STATUS WORD 4 218
times 20
times, setting 42
B
Actual signals 53, 248–250
defined 95 Boolean values 40
diagnostics 44, 52, 53
display mode 29 C
displaying the full names 30
parameters 52, 53 Cable connection, monitoring 63
PID control 69 Clearing
settings 52, 53 fault history 30
speed controller 58 Communication
speed controller tuning 58 fault protection 64
user-defined variables 67 profiles 204–212
Actual values 53 using a fieldbus adapter module 187
actual signals 52, 53 Communication profiles 204–212
analogue outputs 50 ABB drives 204
defined 199 generic drive 209
digital inputs 51 Constant speeds 57
relay outputs 52 Control block diagrams 259–267
Adapter module, fieldbus 186 Control board temperature fault 66
Advent controller 191–192 Control panel
AI<Min settings> 61 basic keys 35
ALARM WORD 1 216 display mode 29
ALARM WORD 2 217 downloading drive data 37
ALARM WORD 4 219 drive control 27–28
ALARM WORD 5 220 overview 25–26
ALARM WORD 6 221 setting the display contrast 38
Analogue extension module 243 upload drive data 36
Analogue inputs Control word 197
optional, supervising 64 CSA 2.8/3.0 communication profile 212
Analogue outputs Critical speeds 57
diagnostics 50
optional, supervising 64 D
parameters 50 DC
settings 50 hold 55
APPLICATION MACRO 97, 181
Index
270
intermediate circuit protection 67 clearing 30

magnetising 55 viewing and resetting 30
overvoltage fault 64 FAULT WORD 1 214
undervoltage fault 65 FAULT WORD 2 215
DECEL TIME 1 130 FAULT WORD 4 218
Deceleration FAULT WORD 5 219
compensation 133 FAULTED INT INFO 223
ramps 57 Faults
settings 57 communication, protection 64
Default tasks, start-up assistant 41 DC overvoltage 64
Diagnostics earth, protection 63
actual signals 44, 52, 53 external, settings 61
analogue outputs 50 overcurrent 64
digital inputs 51 preprogrammed 64
relay outputs 52 control board temperature 66
speed controller 58 DC undervoltage 65
supervision of user-defined variables 67 drive temperature 65
Digital inputs Enhanced drive temperature monitoring 65
diagnostics 51 input phase loss 66
optional, supervising 64 internal fault 66
parameters 51 overfrequency 66
settings 51 short circuit 66
Digital outputs Features of the program 41–82
optional, supervising 64 Fieldbus adapter
Display contrast, setting 38 communication parameters 187–188
Displaying module 186
actual signal full names 30 Fieldbus addresses 247
fault history 30 Fieldbus control 185–224
Drive connecting two fieldbuses to a drive 186
changing panel link ID number 39 control word, status word 197
data, downloading to the control panel 37 interface 196–203
data, uploading to the control panel 36 References 197
IR compensation for scalar controlled 60 Fieldbus reference scaling
reference types and processing 46 ABB drives communication profile 208
start-up 15 CSA 2.8/3.0 communication profile 212
temperature fault 65 generic drive 211
Drive control Fieldbus, equivalent, defined 95
parameters 193–195 Flux braking 55, 56
using I/O interface 21 Flux optimisation 56
E G
Earth fault protection 63 Generic drive communication profile 209
EXT IO STATUS 222
External control 44 H
diagnostics 44
reference source diagram 45 Hand/auto macro 83, 86
stop, start, direction diagram 45 Hexagonal motor flux 61
External fault 61
I
F ID run procedure 22–23
Factory macros 83–84 Input bridge protection 67
Fault history Input phase loss fault 66
INT INIT FAULT 220
Index
271
INT SC INFO 224 Parameters

Integer scaling 65 actual signals 52, 53
Internal fault 66 Advent controller 191–192
AI<Min> 61
K analogue outputs 50
automatic reset 67
Keys on the control panel 35 communication fault protection 64
data tables 251
L defined 95
LIMIT WORD 1 214 digital inputs 51
LIMIT WORD INV 221 drive control 193–195
Limits, adjustable 66 earth fault protection 63
Local control 44 external fault 61
fieldbus adapter 187–188
hexagonal motor flux 61
M
IR compensation 60
Macros motor phase loss 63
factory 83, 84 motor stall protection 63
hand/auto 83, 86 motor temperature 62
overview 83 motor underload protection 63
PID control 83, 88 operation limits 66
reference control chain diagram 262 optional analogue inputs and outputs 64
sequential control 92 parameter lock 67
defined 83 reference trimming 47
torque control 83, 90 relay outputs 52
user 94 scalar control 60
defined 83 selecting and changing values 32
Modbus speed controller tuning 58
adapter module 186 standard modbus link 189–190
addressing 190 start-up assistant 41
link, communication parameters 189–190 supervision 67
Motor PB, defined 247
identification 53 Performance figures
phase loss 63 speed controller 58
stall protection 63 torque control 58
temperature measurement using standard I/O PID control
70, 71 block diagrams 68
temperature thermal model 62 macro 83, 88
thermal protection 62 macro, reference control diagram 262
underload protection 63 parameters 69
settings 69
O sleep function 69
Power limit 67
Operation limits 66 Power loss ride-through 54
Overcurrent fault 64 Preprogrammed faults 64
Overfrequency fault 66 control board temperature 66
DC undervoltage 65
P drive temperature 65
Panel link ID number, changing 39 Enhanced drive temperature monitoring 65
Panel loss 61 input phase loss 66
Parameter lock 67 internal fault 66
Parameter settings, bipolar input in joystick mode overfrequency 66
245 short circuit 66
Program features 41–82
Index
272
Programmable local control 44

analogue outputs 50 motor phase loss 63
digital inputs 51 motor stall protection 63
relay outputs 52 motor temperature 62
Protection functions 61 motor underload protection 63
optional analogue inputs 64
R optional analogue outputs 64
optional digital inputs 64
Ramps optional digital outputs 64
acceleration 57 parameter lock 67
deceleration 57 PID control 69
Reference reference trimming 47
control chain diagrams 262 relay outputs 52
handling 198 scalar control 60
source speed controller 58
EXT 1 45 supervision 67
types and processing 46 Short circuit fault 66
trimming 47 Sleep function 69
Relay outputs example 70
diagnostics 52 Speed controller tuning 58
parameters 52 Speed reference
settings 52 acceleration/deceleration ramps 46
Resets, automatic 67 parameters 244
Resetting Stall protection 63
fault history 30 Start-up 15
automatic start 54
S basic settings 17–20
Scalar control 60 guided 15–16
Sequential control macro 92 Start-up assistant
defined 83 application selection 41
Setting, acceleration times 42 default tasks 41
Settings tasks and parameters 41
acceleration 57 Status word 197
actual signals 52, 53 auxiliary 213
AI<Min> 61 CSA 2.8/3.0 communication profile 212
analogue outputs 50 Supervising user-selectable variables 67
automatic reset 67 SYSTEM FAULT WORD 216
automatic start 54 System overview 185
communication fault protection 64
constant speed 57 T
critical speeds 57 Temperature
DC hold 55 calculation method 62
DC magnetising 55 measurement using standard I/O 70, 71
deceleration 57 Torque control
digital inputs 51 macro 83, 90
earth fault protection 63 performance figures 58
external control 44 Tuning the speed controller 58
external fault 61
flux braking 56
U
flux optimisation 56
hexagonal motor flux 61 Underload protection 63
IR compensation 60 User macros 94
limits 66 defined 83
Index
273
user-defined, supervising 67
V
Variables 67
Viewing fault history 30
Index
274
Index
3AFE64527592 REV I / EN
ABB Oy ABB Inc. ABB Beijing Drive Systems Co. Ltd.

AC Drives Automation Technologies No. 1, Block D, A-10 Jiuxianqiao Beilu
P.O. Box 184 Drives & Motors Chaoyang District
FI-00381 HELSINKI 16250 West Glendale Drive Beijing, P.R. China, 100015
FINLAND New Berlin, WI 53151 Telephone +86 10 5821 7788
Telephone +358 10 22 211 USA Fax +86 10 5821 7618
Telefax +358 10 22 22681 Telephone 262 785-3200 Internet www.abb.com
Internet www.abb.com 800-HELP-365
Fax 262 780-5135
NOV PART NO.:
3AFE64590430
ACS800
Master/Follower Application Guide

Supplement to Firmware Manual for
ACS800 Standard Application Program
Master/Follower
Application Guide
Supplement to Firmware Manual

ACS800 Standard Application Program
3AFE 64590430 Rev A

EN

5
Table of Contents
Table of Contents
Overview
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Checklist for a Quick Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
M/F Link Wiring and Specification

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Master/Follower Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Follower Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Follower Fault Information Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Master/Follower Link Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
M/F Communication and Parameter Set-up

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Follower Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
The Follower Control Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Reference 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Reference 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Parameter Settings – Master Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
60.01 MASTER LINK MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
60.02 TORQUE SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
60.03 WINDOW SEL ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
60.04 WINDOW WIDTH POS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
60.05 WINDOW WIDTH NEG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
60.06 DROOP RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
60.07 MASTER SIGNAL 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
60.08 MASTER SIGNAL 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Parameter Settings – Follower Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
10.01 EXT1 STRT/STP/DIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
10.02 EXT2 STRT/STP/DIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
11.02 EXT1/EXT2 SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
11.03 EXT REF1 SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11.06 EXT REF2 SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
16.01 RUN ENABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
16.04 FAULT RESET SEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
30.18 COMM FAULT FUNC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
30.19 MAIN REF DS T-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
60.01 MASTER LINK MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
60.02 TORQUE SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
60.03 WINDOW SEL ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Table of Contents
6
60.04 WINDOW WIDTH POS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

60.05 WINDOW WIDTH NEG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
60.06 DROOP RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fieldbus Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Pulse Encoder Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Follower Control Signal Connections

Follower Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Follower Station, Torque Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Follower Station, Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Examples
Example 1: Master and Follower Drives Coupled Solidly to Each Other . . . . . . . . . . . . . . . . . . . . 33
Example 2: Master and Follower Drives Coupled Flexibly to Each Other . . . . . . . . . . . . . . . . . . . 34
Table of Contents
7
Overview
General
The Master/Follower function is designed for applications in which the system is run
by several ACS800 drives and the motor shafts are coupled to each other via
gearing, chain, belt etc. Thanks to the Master/Follower function, the load can be
evenly distributed between the drives.
The external control signals are connected to the Master only. The Master controls
the Follower(s) via a fibre optic serial communication link.
The Master station is typically speed-controlled and the other drives follow its torque
or speed reference. In general,
• Torque control of the Follower should be used when the motor shafts of the
Master and Follower drives are coupled solidly to each other by gearing, a chain
etc., so that no speed difference between the drives is possible (see Master/
Follower applications, schematic representation.)
• Speed control of the Follower should be used when the motor shafts of the
Master and the Follower drives are coupled flexibly to each other, so that a slight
speed difference between the drives is possible (see Master/Follower
applications, schematic representation.). When both the Master and Followers
are speed-controlled, drooping is also typically used (Parameter 60.06 DROOP
RATE).
In some applications, both speed control and torque control of the Followers are
required. In those cases an “on-the-fly” change between speed and torque control
can be performed via a digital input of the Follower (see M/F Communication and
Parameter Set-up).
• Speed-controlled master • Speed-controlled master

• Follower follows the torque reference • Follower follows the speed reference
of the master of the master
External control External control

signals signals
n 3 n 3
Mains Mains
3 3
supply Master/Follower supply
Master/Follower link
link
Follower fault 2 2 Follower fault 2 2
supervision supervision
3 3
Mains
supply Mains 3
3
supply
Figure 1. Master/Follower applications, schematic representation.
Overview
8
Checklist for a Quick Start-up

The installation and start-up procedure of the drive is explained in its manuals.
A checklist for the Master/Follower function is given below.
• Switch off the power supplies of the drives. Wait for five minutes to ensure that
the intermediate circuits are discharged.
• Install RDCO communication boards onto the RMIO boards of all drives to be
used in Master/Follower communication (if not already installed). Follow the
instructions included in the RDCO package.
• Build the Master/Follower Link. See M/F Link Wiring and Specification.
• Connect the external control signals to the Master. Wire the Run enable signal of
the Master via the fault indicating relay output of the Followers. See M/F Link
Wiring and Specification.
• Switch ON the power to the drives.
• On the Master drive, change Parameter 60.01 MASTER LINK MODE to
MASTER.
• On the Follower drive(s), adjust the parameters according to your application.
(The parameters are listed in M/F Communication and Parameter Set-up.) Switch
all drives to external control with the key on the Control Panel (there should be
LOC
REM
no “L” on the first row of the display).

• Perform a test run with the motors still de-coupled from the driven machinery.
Feed the control signals both through the Master analogue/digital inputs and from
the Master Control Panel. Check the correct operation of the Master and Follower
drives visually (by observing the motor & Control Panel display):
- Start, Stop, Direction and Run enable signals given to the Master are received
by all drives.
- The Master follows the speed reference.
- The Follower follows Master speed reference or torque reference. In torque
control, Window control restricts the excessive speed rise of the motor. Thus the
actual speed of an unloaded Follower is higher than that of the Master, but will not
reach the maximum speed limit.
• Disconnect the Control Panels from the Follower drives to avoid accidental use.
See WARNING! below.
• Switch the power to the drives OFF.
• Couple the motor shafts to the driven machinery and switch on the power
supplies.
WARNING! To avoid conflicting control, drives coupled to the same machinery

should receive the external control signals only via the Master. General rules:
– Connect all external control signals to the Master drive only.
– Never control the Follower(s) with the Control Panel or through a fieldbus system.
Overview
9
Installation
WARNING! Before installation, switch off the drive power supply. Wait for five
minutes to ensure that the intermediate circuit is discharged. Switch off all
dangerous voltages connected from external control circuits to the relay output
terminals of the drive.
WARNING! Do not touch the printed circuits. They are extremely sensitive to
electrostatic discharge.
Master/Follower Link
Master Follower Follower
RMIO-XX RMIO-XX RMIOXX
CH2 RDCO-0X CH2 RDCO-0X CH2 RDCO-0X

V17
V17
V17
V18
V18
T R T R V18
T R
Figure 2. Connections. T = Transmitter; R = Receiver; RMIO = I/O and Control

Board. (Please note that channels CH0/CH2/CH3 are located on the optional RDCO-
0x board.)
The ring configuration can be used in most applications. A parallel connection can
also be implemented by using a branching unit. (For more information, contact your
local ABB representative.)
Handle the fibre optic cables with care. Do not touch the ends with bare hands, as
fibre optic cables are extremely sensitive to dirt.
Note: For best results, all RDCO boards on the link should be of the same type.

10
Follower Supervision
There are two analogue outputs and three relay outputs in the drive for the external
supervision purposes. By default, analogue output AO1 gives the motor speed and
AO2 the motor current as 0 to 20 mA current signal. The relay outputs give the
indications Ready (RO1), Running (RO2) and No fault (RO3).
It is possible to supervise the M/F Link with Parameters 30.18 COMM FAULT FUNC
and 30.19 MAIN REF DS T-OUT. Parameter 30.18 defines the action (NO/FAULT/
WARNING) when an error is detected on the M/F Link. Parameter 30.19 sets the
time between the detection and the action defined by Parameter 30.18. For more
information, see the Firmware Manual.
WARNING! The Follower does not send any feedback data to the Master via the
serial Master/Follower Link. Therefore it is highly recommended to separately wire
the fault information of the Follower to the Master.
Follower Fault Information Wiring

The connection will stop both the Master drive and the Follower drives upon a
Follower fault.
Master Follower Follower

DI6: RUN ENABLE
Relay Output 3
Relay Output 3
RMIO Board
RMIO Board
RMIO Board
FAULT(-1)
FAULT(-1)
+24 V d.c.
X22 1 2 3 4 5 6 7 8 9 X27 1 2 3 X22 1 2 3 4 5 6 7 8 9 X27 1 2 3 X22 1 2 3 4 5 6 7 8 9 X27 1 2 3
Figure 3. Follower fault information wiring.

11
Master/Follower Link Specification

Size of the Link: One Master and max. 10 Follower stations. If more than 10
followers are required, an ABB representative should be consulted.
Transmission medium: Fibre Optic Cable.
• Construction: Plastic core, diameter 1 mm, sheathed with plastic jacket
• Attenuation: 0.23 dB/m
• Maximum Length between Stations: 10 m
• Other:
Parameter Minimum Maximum Unit
Storage Temperature -55 +85 °C
Installation Temperature -20 +70 °C
Short Term Tensile Force 50 N
Short Term Bend Radius 25 mm
Long Term Bend Radius 35 mm
Long Term Tensile Load 1 N
Flexing 1000 cycles
Various lengths of fibre optic cables are available as optional add-on kits.
Connectors: Blue – receiver (HP 9534, T-1521); grey – transmitter (HP 9534, R-
2521)
Serial Communication Type: Synchronous, full Duplex
Transmission Rate: 4 Mbit/s
Transmission Interval: 4 ms
Maximum Transmission Delay: 16 ms
Protocol: ABB Distributed Drives Communication System (DDCS)

12

13
Overview
This chapter describes the communication between the Master station and the
Follower stations, and presents the Master/Follower communication set-up
parameters.
For other parameters, see the Firmware Manual delivered with the drive.
WARNING! The Follower must always be controlled by the Master while the motors
are running and coupled to each other. Do not change the control location of the
Follower to Local, i.e. do not press the key on the Control Panel!
LOC
REM
Follower Control
The Master broadcasts a Follower Control Word and two references (Reference 1
and Reference 2) to all Follower stations.
The Follower Control Word

The Follower Control Word (Actual signal 3.11 FOLLOWER MCW) is a packed 16-bit
word. The commands in the Control Word are effective when the Follower
Parameter 10.01 EXT1 STRT/STP/DIR or 10.02 EXT2 STRT/STP/DIR (whichever
control location is selected) is set to COMM.CW.
Table 1. The Follower Control Word (Actual Signal 3.11 FOLLOWER MCW).
0 OFF1 Not in use
1 OFF2
2 OFF3
3 RUN 0 = Stop (Master not running), 1 = Run (Master running)
4 RAMP_OUT_ZERO Not in use
5 RAMP_HOLD
6 RAMP_IN_ZERO
7 RESET 0 -> 1 Fault Reset (if an active fault exists)
8 INCHING_1 Not in use
9 INCHING_2 Not in use
10 REMOTE_CMD Fieldbus control enabled
11 EXT_CTRL_LOC Not in use
12 … 15 Reserved

14
Reference 1
Reference 1 is a 16-bit word containing a sign bit and a 15-bit integer. It is formed
from the speed reference of the Master using the values of Parameters 20.01
MINIMUM SPEED or 20.02 MAXIMUM SPEED: whichever has the greater absolute
value determines both the positive and negative limits that correspond to Reference
levels +20000 and –20000. See the examples in Figure 4. below.
In the Follower, Reference 1 is decoded as follows: 20000 corresponds to the value
of Follower Parameter 11.05 EXT REF1 MAXIMUM.
Example 1:
20.01 MINIMUM SPEED = 0 rpm
20.02 MAXIMUM SPEED = 1000 rpm
Master Reference Reference 1 Follower Reference
20.02 MAXIMUM SPEED 20000 11.05 EXT REF1 MAXIMUM

(1000 rpm) rpm
20.01 MINIMUM SPEED 0 0 rpm

(0 rpm)
Example 2:
20.01 MINIMUM SPEED = –1500 rpm
20.02 MAXIMUM SPEED 20000 11.05 EXT REF1 MAXIMUM

(3000 rpm)
rpm
1500 rpm 10000
0 rpm 0 0 rpm
20.01 MINIMUM SPEED

-10000
(-1500 rpm)
-20000 –(11.05 EXT REF1 MAXIMUM)

rpm

15
Example 3:
20.01 MINIMUM SPEED = –5000 rpm
20000 11.05 EXT REF1 MAXIMUM

rpm
20.02 MAXIMUM SPEED 10000
(2500 rpm)
0 rpm 0 0 rpm
-2500 rpm -10000
20.01 MINIMUM SPEED –(11.05 EXT REF1 MAXIMUM)

-20000
(-5000 rpm) rpm
Figure 4. Relation between the speed references of the Master and the Follower.
Reference 2
Reference 2 is a 16-bit word containing a sign bit and a 15-bit integer. It is formed
from the relative torque reference of the Master: the motor nominal torque
(calculated by the drive) of the Master corresponds to the Reference value of 10000.
In the Follower Reference 2 is decoded as follows: 10000 corresponds to the
maximum reference setting of the Follower (Parameter 11.08 EXT REF2 MAXIMUM,
given as a percentage of Follower motor nominal torque).
300% of Master 30000 300% of 11.08 EXT REF2

motor nominal torque MAXIMUM
100% of Master 10000 11.08 EXT REF2

motor nominal torque MAXIMUM
0% of Master 0 0% of Follower
motor nominal torque motor nominal torque
Figure 5. Relation between the torque references of the Master and the Follower.

16
Parameter Settings – Master Station

The Master station can be set up and controlled quite like an independent drive.
(Follow the instructions in the Firmware Manual.) In addition, the table below lists the
parameters that need to be adjusted for a Master/Follower application. The
parameters are detailed further in the text.
Parameter Typical Setting
for Master
60.01 MASTER LINK MODE MASTER
60.02 TORQUE SELECTOR TORQUE
60.03 WINDOW SEL ON NO
60.04 WINDOW WIDTH POS 0.0 rpm
60.05 WINDOW WIDTH NEG 0.0 rpm
60.06 DROOP RATE see text
60.07 MASTER SIGNAL 2 202
60.08 MASTER SIGNAL 3 213
60.01 MASTER LINK MODE

This parameter determines the role of the drive on the Master/Follower link. On the
Master station, set this parameter to MASTER. The drive will now start transmitting
the Follower Control Word and the two selected References (see Parameters 60.07
MASTER SIGNAL 2 and 60.08 MASTER SIGNAL 3) through fibre optic channel
CH2.
60.02 TORQUE SELECTOR
The default value of this parameter is TORQUE. Typically, the value needs to be
changed for Follower stations only. For more information, see section Parameter
Settings – Follower Station below.
60.03 WINDOW SEL ON
This parameter selects Window control. Typically, Window control is used in
Follower stations only.
The default value of this parameter is NO (i.e. Window control is OFF). For more
information, see the section Parameter Settings – Follower Station below.
60.04 WINDOW WIDTH POS
See the section Parameter Settings – Follower Station below.
60.05 WINDOW WIDTH NEG
See the section Parameter Settings – Follower Station below.

17
60.06 DROOP RATE

Drooping prevents conflict between the Master and Follower stations by allowing a
slight speed difference between them. The default value is 0%.
The droop rate needs to be adjusted only if both the Master and the Follower are
speed-controlled, i.e.
• external control location 1 (EXT1) is selected (see Parameter 11.02 EXT1/EXT2
SELECT), or
• external control location 2 (EXT2) is selected (see Parameter 11.02 EXT1/EXT2
SELECT) and Parameter 60.02 TORQUE SELECTOR is set to SPEED.
The correct droop rate for a process must be found out case by case in practice. The
droop rate must be set for both the Master and the Follower.
The droop rate is set as a percentage of the nominal speed of the motor. The actual
speed decrease at a certain operating point depends on the droop rate setting and
the drive load (i.e. torque reference / speed controller output). Drooping decreases
the drive speed slightly as the load increases. When the speed controller output is
100%, drooping is at the level specified by Parameter 60.06 DROOP RATE. The
drooping effect decreases linearly to zero along with the decreasing load.
Speed Decrease =
Speed Controller Output × Drooping × Max. Speed
Calculation Example:
DROOP RATE is 1%, Speed Controller output is
Motor Speed 50%, maximum speed of the drive is 1500 rpm. Speed decrease =
% of nominal 0.01 × 0.50 × 1500 rpm = 7.5 rpm
No Drooping
100% } Par. 60.06 DROOP RATE
Drooping
Speed Controller
100% Output /% Drive load

18
60.07 MASTER SIGNAL 2

Selects the signal that is sent by the Master to the Followers as Reference 1 (speed
reference).
The format is as follows: (x)xyy, where (x)x denotes Parameter Group and yy
denotes Index. For example, the default value of 202 corresponds to Group 2, Index
02, i.e. 2.02 SPEED REF 3.
60.08 MASTER SIGNAL 3
Selects the signal that is sent by the Master to the Followers as Reference 2 (torque
reference).
The format is as follows: (x)xyy, where (x)x denotes Parameter Group and yy
denotes Index. For example, the default value of 213 corresponds to Group 2, Index
13, i.e. 2.13 TORQ REF USED.
TORQ REF 1
WINDOW CONTROL SPEED CONTROLLER 60.02 TORQUE

SELECTOR
0
SPEED
EXT2 1 0
SPEED REF 3 + + TORQ REF 2 TORQUE
2 TORQ REF 3
TORQUE
2.02 2.09 MIN 3 2.10 REFERENCE
– – PID EXT1 4 CHAIN
MAX
5
ADD
ACTUAL SPEED
SPEED REF= Speed Reference DROOP

RATE
TORQ REF 1= Torque Reference
EXT1= External control location 1
TORQ REF 2= Speed Controller Output
EXT2= External control location 2
TORQ REF 3= Internal Torque Reference
See Parameter 11.02 EXT1/EXT2 SELECT
Figure 6. Window control, Torque selector and Droop rate settings. For information
on tuning the speed controller, see the Firmware Manual, Parameter Group 23
Speed Control.

19
Parameter Settings – Follower Station

The table below lists the parameters that need to be adjusted for a Master/Follower
application. The parameters are detailed further in the text.
For other parameter settings, see the Firmware Manual.
Parameter Typical Setting for Speed- Typical Setting for Torque-
controlled Follower controlled Follower
10.01 EXT1 STRT/STP/DIR COMM.CW COMM.CW
10.02 EXT2 STRT/STP/DIR COMM.CW COMM.CW
11.02 EXT1/EXT2 SELECT EXT1 EXT2
11.03 EXT REF1 SELECT COMM.REF COMM.REF
11.06 EXT REF2 SELECT COMM.REF COMM.REF
16.01 RUN ENABLE COMM.CW(3) COMM.CW(3)
16.04 FAULT RESET SEL COMM.CW(7) COMM.CW(7)
30.18 COMM FAULT FUNC FAULT FAULT
30.19 MAIN REF DS T-OUT 1.00 s 1.00 s
60.01 MASTER LINK MODE FOLLOWER FOLLOWER
60.02 TORQUE SELECTOR SPEED ADD
60.03 WINDOW SEL ON NO YES
60.04 WINDOW WIDTH POS 0.0 rpm 30.0 rpm
60.05 WINDOW WIDTH NEG 0.0 rpm 30.0 rpm
60.06 DROOP RATE see text see text
10.01 EXT1 STRT/STP/DIR

This parameter defines the source of the Start, Stop and Direction commands for the
Follower when it has EXT1 selected as the active control location.
The direction of rotation is determined as in fieldbus control; see the Firmware
Manual.
COMM.CW
This is the typical setting for a Follower. The Follower Control Word, received from
the Master station through channel CH2, is the signal source of the Start and Stop
commands when EXT1 is the active control location for the Follower.
For information on the selection between speed and torque control, see the
description of Parameter 11.02 EXT1/EXT2 SELECT.
(ALL OTHER SELECTIONS)
See the Firmware Manual.

20
10.02 EXT2 STRT/STP/DIR

Defines the source of Start, Stop and Direction commands for External control
location 2 (EXT2). See Parameter 10.01 EXT1 STRT/STP/DIR above for the
alternative settings.
11.02 EXT1/EXT2 SELECT
This parameter sets the input used for selecting the External control location, or fixes
it to EXT1 or EXT2. The parameter determines the active External control location
for both the Start/Stop/Direction commands and the reference.
EXT1; EXT2; DI1 … DI6; COMM.CW(11)
Note: The Follower Control Word sent by the Master does not contain control
location selection information. Thus, do not set this parameter to COMM.CW(11) on
a Follower station.
The selection between EXT1 and EXT2 is illustrated in the control connection
diagrams (see the chapter Follower Control Signal Connections):
When EXT1 is selected,
• the control commands are read from the source defined with Parameter 10.01
STRT/STP/DIR
• the external speed reference is read from the source defined with Parameter
11.03 EXT REF1 SELECT
• the drive is speed-controlled; Window control is not possible.
When EXT2 is selected,
• the control commands are read from the source defined with Parameter 10.02
STRT/STP/DIR
• the external speed reference is read from the source defined with Parameter
11.03 EXT REF1 SELECT (Note that the critical speeds (Parameter Group 25)
are ignored in the speed control chain.)
• the external torque reference is read from the source defined with Parameter
• the drive is speed-controlled or torque-controlled depending on the value of
Parameter 60.02 TORQUE SELECTOR which selects the internal torque
reference. The parameter fixes it to the speed controller output (SPEED) or direct
torque reference (TORQUE), or the MINIMUM, MAXIMUM or ADD function is
used to automatically switch between speed and torque control. See description
of Parameter 60.02 TORQUE SELECTOR below.

21
WARNING! The Follower should always be controlled by the Master while the
motors are coupled to each other. Do not change the control location if this activates
a control signal source other than Master:
• Do not change the External control location if Parameter 10.01, 10.02, 11.03 or
11.06 is set to a value other than COMM.CW or COMM.REF.
• Do not switch to local control (do not press the key on the Control Panel).
LOC
REM
If the Master and Follower are controlled with different control signals, the drives will
conflict with each other.
Hint: In some applications, both speed control and torque control of the Followers
are required, e.g. if it is necessary to accelerate all drives along the same speed
ramp up to a certain speed before torque control can be implemented. In those
cases, “on-the-fly” switching between speed and torque controls is required. The
switching can be done through a digital input on the Follower. One solution is to set
Parameter 11.02 EXT1/EXT2 SELECT to DI3, 60.02 TORQUE SELECTOR to
TORQUE and 60.03 WINDOW SEL ON to OFF. With these settings,
• 0 V d.c connected to DI3 External control location 1 is selected and the
Follower follows the speed reference of the Master. Window control is disabled.
• +24 V d.c. connected to DI3 External control location 2 is selected and the
Follower follows the torque reference of the Master. Window control is enabled.

This parameter selects the signal source of External reference 1 (speed reference).
The selection is illustrated in the control connection diagrams (see the chapter
Follower Control Signal Connections).
COMM.REF
Reference 1 received from the Master is External reference 1.
COMMREF1+AI1; COMMREF1*AI1; COMMREF1+AI5; COMMREF1*AI5
Reference 1 received from the Master is added to or multiplied by the rpm value
converted from the signal connected to Analogue input AI1 or AI5. The effect of the
correction on the reference is as with a fieldbus reference signal; see the Firmware
Manual.
FAST COMM
Reference 1 received from the Master is External reference 1. With FAST COMM,
the reference is transferred to the core motor control program every 2 milliseconds
(as opposed to 6 ms with COMM.REF). However, the motor rotation direction cannot
be controlled through the interfaces defined by Parameter 10.01 EXT1 STRT/STP/
DIR or from the Control Panel. Furthermore, critical speeds (Group 25) are not
effective.

22
Note: If any of the following selections is TRUE, the selection FAST COMM is not
effective, and the operation is as with COMM. REF:
• 99.02 APPLICATION MACRO is PID
• 99.04 MOTOR CTRL MODE is SCALAR
• 40.14 TRIM MODE is PROPORTIONAL or DIRECT

This parameter selects the signal source of External reference 2 (torque reference).
The selection is illustrated in the control connection diagrams (see the chapter
Follower Control Signal Connections).
COMM.REF
Reference 2 received from the Master is External reference 2.
COMMREF2+AI1; COMMREF2*AI1; COMMREF2+AI5; COMMREF2*AI5
Reference 2 received from the Master is added to or multiplied by the % value
converted from the signal connected to Analogue input AI1 or AI5. The effect of the
correction on the reference is as with a fieldbus reference signal; see the Firmware
Manual.
FAST COMM
Reference 2 received from the Master is External reference 2. With FAST COMM,
the reference is transferred to the core motor control program every 2 milliseconds
(as opposed to 6 ms with COMM. REF). However, the motor rotation direction
cannot be controlled through the interface defined by Parameter 10.02 EXT2 STRT/
STP/DIR or from the Control Panel. Furthermore, critical speeds (Group 25) are not
effective.
Note: If any of the following selections is TRUE, the selection FAST COMM is not
effective, and the operation is as with COMM. REF:
• 99.02 APPLICATION MACRO is PID
• 99.04 MOTOR CTRL MODE is SCALAR
• 40.14 TRIM MODE is PROPORTIONAL or DIRECT

16.01 RUN ENABLE
This parameter selects the source of the Run enable signal. The selection is
illustrated in the control connection diagrams in the chapter Follower Control Signal
Connections.
YES; DI1; … ; DI12

23
COMM.CW(3)
The Run enable signal is read from Bit 3 of the Follower Control Word received from
the Master.
16.04 FAULT RESET SEL
NOT SEL; DI1; …; DI12; ON STOP
COMM.CW(7)
The fault reset signal is read from Bit 7 of the Follower Control Word received from
the Master.
Defines the action in case communication with the Master is lost. The supervision is
based on monitoring of received Follower Control data sets. For the available
selections, see the Firmware Manual.
30.19 MAIN REF DS T-OUT
60.01 MASTER LINK MODE
This parameter determines the role of the drive on the Master/Follower link. On
Follower stations, set this parameter to FOLLOWER. The drive will now start reading
the Follower Control Word and the two References through fibre optic channel CH2.
Note: Selecting FOLLOWER does not mean that data received from the Master
takes effect at once. The data only becomes available as one possible source of
control, and is accessible by parameters as “COMM.CW” or “COMM.REF”.
60.02 TORQUE SELECTOR

This parameter is only visible when Parameter 99.02 APPLICATION MACRO is set
to T CTRL (Torque Control). The parameter selects the reference used in motor
torque control, and only affects External control location 2 (EXT2).
SPEED
The Follower speed controller output is used as the reference for motor torque
control. The drive is speed-controlled. This setting can be used both in the Master
and the Follower if the motor shafts of the Master and the Follower have a flexible
connection, so that a slight speed difference is possible/allowable between them.
TORQUE
The drive is torque-controlled. This is the default value.
This selection should be used in the Follower(s) when the motor shafts of the Master
and the Follower(s) are coupled solidly (e.g. by gearing or a chain), so that no speed
difference is possible/allowable between them.

24
Note: If TORQUE is selected, the drive does not restrict the speed variation as long
as the speed is within the limits defined by Parameters 20.01 MINIMUM SPEED and
20.02 MAXIMUM SPEED. More definite speed supervision is often needed. In these
cases, the selection ADD should be used instead.
MINIMUM
The torque selector compares the torque reference and the speed controller output,
the smaller of which is used as the motor torque reference. Used in special cases
only.
MAXIMUM
The torque selector compares the torque reference and the speed controller output,
the greater of which is used as the motor torque reference. This setting is used in
special cases only.
ADD
The torque selector adds the speed controller output to the torque reference. The
drive is torque-controlled within the normal operating range.
The selection ADD, together with Window control, forms a speed supervision
function for a torque-controlled Follower station as follows:
• Within the normal operating range, the Follower follows the torque reference of
the Master (TORQ REF 1)
• Window control keeps the speed controller input and output to zero as long as
speed error (speed reference minus actual speed) remains within the
parameterised window.
• If the speed error moves out of the window, Window control connects the error to
the speed controller. The speed controller output increases or decreases the
internal torque reference, stopping the change in actual speed.
ZERO
Forces the torque selector output to zero.
60.03 WINDOW SEL ON
Window control, together with selection ADD at Parameter 60.02 TORQUE
SELECTOR, forms a speed supervision function for a torque-controlled drive.
The parameter is visible only when Parameter 99.02 APPLICATION MACRO is set
to T CTRL. External control location 2 (EXT2) must be active to enable Window
control.
NO
Window control is off. This is the default value.
YES
Window control is on. Use this setting only when Parameter 60.02 TORQUE
SELECTOR is set to ADD.
Window control supervises the speed error value (speed reference minus actual
speed). Within the normal operating range, Window control keeps the speed
controller input to zero. The speed controller is active only when

25
• speed error exceeds the value of Parameter 60.04 WINDOW WIDTH POS or
• absolute value of the negative speed error exceeds the value of Parameter 60.05
WINDOW WIDTH NEG.
When the speed error moves outside the window, the exceeding part of the error
value is connected to the speed controller. The speed controller produces a
reference term relative to the input and gain of the speed controller (Parameter
23.01 GAIN) which the torque selector adds to the torque reference. The result is
used as the internal torque reference for the drive.
For example in a load loss condition, the internal torque reference of the drive
decreases, preventing the excessive rise of motor speed (see Window control.). If
Window control were deactivated, the motor speed would rise until speed limit of the
drive was reached. (Parameters 20.01 MINIMUM SPEED and 20.02 MAXIMUM
SPEED define the speed limits.)
See Parameter 60.03 WINDOW SEL ON. The parameter is only visible when
Parameter 99.02 APPLICATION MACRO is set to T CTRL.
0 … 1500 rpm
Default: 0.
60.05 WINDOW WIDTH NEG
See Parameter 60.03 WINDOW SEL ON. The parameter is only visible when
Parameter 99.02 APPLICATION MACRO is set to T CTRL.
0 … 1500 rpm
Default: 0.
60.06 DROOP RATE
See section Parameter Settings – Master Station above.
WARNING! Follower speed control or drooping should not be used if the motor
shafts of the Master and the Follower are coupled solidly by a mechanical
construction (gearing, chain etc.).

26
Window Control
Speed Reference 60.05 WINDOW WIDTH NEG

Actual Speed
e
Torque Reference
Internal Torque Reference =

Torque Reference + Speed Controller Output
G = Speed controller gain G·e
e = Value connected to speed Speed Controller Output
controller Time
Example 1: Window Control Off Example 2: Window Control On

in a Load Loss Condition in a Load Loss Condition
% %
20.02 SPEED MAXIMUM 3. Actual Speed
Actual Speed
3.
60.05 WINDOW
Speed Reference WIDTH NEG Speed Reference
1. 2. 1. 2.
Torque Reference
Torque Reference
Internal Torque Reference

Internal Torque Reference
Load Load
torque torque
Time Time
The Follower drive is torque-controlled. Parameter 11.02 EXT1/ The Follower drive is torque-controlled. Parameter 11.02 EXT1/
EXT2 SELECT is set to EXT2 and 60.02 TORQUE SELECTOR EXT2 SELECT is set to EXT2 and 60.02 TORQUE SELECTOR
to TORQUE. to ADD.
1. Normal operating range. The Follower is controlled by torque 1. Normal operating range. Window Control keeps the speed
reference of the Master. controller input zero. The Follower is controlled by torque
2. Load loss occurs. Follower actual speed starts to rise. reference of the Master.
3. The speed increases until the maximum speed limit of the 2. Load loss occurs. Follower actual speed starts to rise.
drive is reached (Parameter 20.02 MAXIMUM SPEED). Internal 3. The speed increases until the absolute value of the negative
torque reference is restricted to stop the speed increase. speed error exceeds WINDOW WIDTH NEG. Window Control
connects the value outside the window to the speed controller.
Negative speed controller output value is produced and added to
torque reference received from the Master. Internal torque
reference is restricted to stop the speed increase.
Figure 7. Window control.

27
Fieldbus Connection
A fieldbus adapter can be used for monitoring the Follower, but not for controlling it.
The Master can be controlled through a fieldbus system as described in the
Firmware Manual.
Pulse Encoder Connection

If speed measurement is required with Master or Follower stations, a pulse encoder
must be used. The encoder is connected to the drive through an optional pulse
encoder module. For more information, see the appropriate module manual.

28

29
Follower Control
ACTUAL
SIGNAL/
PARAMETER
TABLE
1.01
1.02
CH2
FOLLOWER NOT IN USE (I/O Link)
••• CONTROL MASTER
FOLLOWER
DATA SET
MCW FOLLOWER
FOLLOWER
3.11 3.11 60.01
CONTROL WORD
REFERENCE 1
•••
REFERENCE 2
3.99
60.07
•••
10.01
60.08
•••
Fibre Optic Link
99.99
MASTER

30.19 MAIN REF DS T-OUT
FOLLOWER NOT IN USE FOLLOWER Continues on Fig.

CH2 CONTROL
(I/O Link) MASTER Figure 9. or Figure
DATA SET
FOLLOWER 10..
FOLLOWER
60.01 CONTROL WORD
REFERENCE 1
REFERENCE 2
Figure 8. Follower control data transfer.

30
Follower Station, Torque Control
Reference Selection
EXT1/EXT2 KEYPAD REF

SELECT 11.02 SELECT 11.01
DI3
Reference Source Selection Speed Control
EXT REF2 EXT REF1 CRITICAL SPEEDS

SELECT 11.06 SELECT 11.03 Group 25
Analogue EXT1
& Digital External

Inputs MINIMUM SPEED 20.01 2.01
EXT2
MAXIMUM SPEED 20.02 SPEED
AI/DI
REF 2
COMM. REF EXT1 Local
KEYPAD External ACCEL/DECEL 2.02
EXT2 Group 22 SPEED
CH2 Local
REF 3
FOLLOW- Window Control 2.09

ER CTRL AI/DI TORQ
DATA COMM. REF REF 2
External
SET EXT1
KEYPAD REF (%)
from SPEED CTRL
Local
Fig. Figure Group 23
REF1 (rpm)
EXT2
EXT1
CDP 60.02 TORQUE
External
SELECTOR
Control EXT2 0
Panel SPEED
TORQUE 1 0
2
Local
MIN 3
4
REF MAX
ADD
REF (%)
REF1 (rpm)
Torque Controller
LOC
Maximum torque 2.10
REM Group 24 TORQ
REF 3
TORQUE CTRL 2.13

Group 24 TORQ
REF USED
NOT SEL
DI Start/Stop
Local
COMM.CW EXT1 REQUEST
KEYPAD External FORWARD Direction
NOT SEL REVERSE
EXT2
DI
COMM.CW
KEYPAD
COMM. MODULE
Start/Stop/
Direction EXT1 STRT/STP/ EXT2 STRT/STP/ DIRECTION RUN ENABLE
Source DIR 10.01 DIR 10.02 10.03 16.01
Selection
Figure 9. Control signal connections for the Follower station when the Follower
Torque Control settings of the parameters are valid and local control (Control Panel)
is not active.

31
Follower Station, Speed Control
Reference Selection
EXT1/EXT2 KEYPAD REF

SELECT 11.02 SELECT 11.01
DI3
Reference Source Selection Speed Control
EXT REF2 EXT REF1 CRITICAL SPEEDS

SELECT 11.06 SELECT 11.03 Group 25
Analogue EXT1
& Digital External

Inputs MINIMUM SPEED 20.01
EXT2 2.01
MAXIMUM SPEED 20.02 SPEED
AI/DI
REF 2
COMM. REF EXT1 Local
KEYPAD External ACCEL/DECEL 2.02
EXT2 Group 22 SPEED
CH2 REF 3
FOLLOW- Local
Window Control 2.09
ER CTRL AI/DI TORQ
DATA REF 2
COMM. REF External
SET EXT1
KEYPAD REF (%)
from SPEED CTRL
Local
Fig. Figure Group 23
REF1 (rpm)
EXT2
EXT1
CDP 60.02 TORQUE
External
SELECTOR
Panel EXT2 0
SPEED
TORQUE 0
2
Local
MIN 3
4
REF MAX
5
ADD
REF (%)
REF1 (rpm)
Torque Controller
LOC
Maximum torque 2.10
REM Group 24 TORQ
REF 3
TORQUE CTRL 2.13

Group 24 TORQ
REF USED
NOT SEL
DI Start/Stop
Local
COMM.CW EXT1 REQUEST
KEYPAD External FORWARD Direction
NOT SEL REVERSE
EXT2
DI
COMM.CW
KEYPAD
COMM. MODULE
Start/Stop/
Direction EXT1 STRT/STP/ EXT2 STRT/STP/ DIRECTION RUN ENABLE
Source DIR 10.01 DIR 10.02 10.03 16.01
Selection
Figure 10. Control signal connections for the Follower station when the Follower
Speed Control settings of the parameters are valid and local control (Control Panel)
is not active.

32

Example 1: Master and Follower Drives Coupled Solidly to Each Other
Master
START/STOP
0 L 1242.0 rpm I
FREQ 45.00 Hz DIRECTION
CURRENT 80.00 A TO MASTER
AC PA FU DRI
RUN ENABLE
FAULT RESET SPEED TORQUE REFER- TORQUE REFER- INVERTER
EN
TO FOLLOWER CONTROLLER ENCE SELECTOR ENCE CONTROL CONTROL
LO RE RE 0
RE
SPEED
Examples
SPEED REF 3 + TORQUE 0

2
2.02 MIN 3
EXTERNAL – =
PID 4
MAX 5
CONTROL I/O
SIGNALS ADD ~
Inverter
EXTERNAL
SUPERVISION
SIGNALS 2.09 2.10
RUN ENABLE (DI6) ACTUAL SPEED TORQ REF 2 TORQ REF 3
+24 V DC
TORQ REF USED

2.13
Follower
WINDOW SPEED TORQUE REFER- TORQUE REFER- INVERTER

CONTROL CONTROLLER ENCE SELECTOR ENCE CONTROL CONTROL
0
SPEED
SPEED REF 3 + TORQUE 1 0
2
2.02 MIN 3
– =
PID MAX 4
I/O 5
ADD ~
Inverter
2.09 2.10 2.13

NO FAULT (RO3)
ACTUAL SPEED TORQ REF 2 TORQ REF 3 TORQ REF USED
Example 1: Master and Follower are coupled solidly by a mechanical construction Operation:
(gearing, chain etc.) When driven at normal operating conditions, the speed controller output (TORQ REF 2) of the
To equalise the load between the Master and the Follower, Master is speed controlled and Follower is zero due to Window Control. The Follower follows the torque reference of the Master
Follower follows the torque reference of the Master. (TORQ REF 1).
For parameter settings, see M/F Communication and Parameter Set-up. In a Follower load loss condition, Window Control activates the speed controller, thus preventing
the Follower drive from rushing up to the maximum speed limit:
–Follower actual speed starts to rise rapidly.
–Absolute value of the speed error (SPEED REF 3 - ACTUAL SPEED) exceeds the value set by
Parameter 60.05 WINDOW WIDTH NEG. As a consequence, the Window Control block
connects the error to the speed controller.
–The speed controller starts adding a negative term to the torque reference (TORQ REF 1). The
motor torque is limited and speed rise prevented.
The Run enable signal to the master is wired through Relay Output RO3 of the Follower. By
default, RO3 switches off the Run enable signal upon a Follower fault or power loss.
33
Examples
34
Example 2: Master and Follower Drives Coupled Flexibly to Each Other
Master
Examples
START/STOP
0 L 1242.0 rpm I
FREQ 45.00 Hz DIRECTION
CURRENT 80.00 A TO MASTER
AC PA FU DRI
RUN ENABLE
FAULT RESET SPEED TORQUE REFER- TORQUE REFER- INVERTER
EN
TO FOLLOWER CONTROLLER ENCE SELECTOR ENCE CONTROL CONTROL
LO RE RE 0
RE
SPEED
SPEED REF 3 + TORQUE 0
2
2.02 MIN 3
EXTERNAL – =
PID 4
MAX 5
CONTROL I/O
SIGNALS ADD ~
Inverter
EXTERNAL
SUPERVISION
SIGNALS 2.09 2.10
RUN ENABLE (DI6) ACTUAL SPEED TORQ REF 2 TORQ REF 3
+24 V DC
TORQ REF USED

2.13
Follower
SPEED TORQUE REFER- TORQUE REFER- INVERTER

CONTROLLER ENCE SELECTOR ENCE CONTROL CONTROL
0
SPEED
SPEED REF 3 + + TORQUE 0
2
2.02 MIN 3
– – =
PID MAX 4
I/O 5
ADD ~
Inverter
2.09 TORQ REF 2 2.10 2.13

NO FAULT (RO3)
ACTUAL SPEED TORQ REF 3 TORQ REF USED
DROOP
RATE
Example 2: Master and Follower are coupled flexibly. Operation:

To equalise the load between the Master and the Follower, they are controlled with the same The Follower follows the same speed reference as the Master (SPEED REF 3). Drooping
speed reference. Torque control of the Follower cannot be used due to varying friction of the belt ensures even load distribution in all operating conditions. An example:
driven; a sudden fall in friction of the follower wheel would cause the motor to rush as the drive –Friction under the follower wheel drops, causing slipping. The torque is decreased to prevent
would be trying to retain a certain torque level. Drooping should be used to ensure smooth the speed rise.
operation and even load distribution between the Master and the Follower.
–The load of the master increases -> Internal torque reference increases to keep the speed
For parameter settings, see M/F Communication and Parameter Set-up. constant -> Drooping in the Master increases -> Speed decreases slightly.
–The Follower now runs a little faster than the Master. When the friction returns to normal, the
Follower load increases, causing a rise in the internal torque reference. Drooping in the Follower
increases -> Follower actual speed decreases. The Master load increases. This cycle is
repeated until the balance is regained.
The Run enable signal to the master is wired through Relay Output RO3 of the Follower. By
default, RO3 switches off the Run enable signal upon a Follower fault or power loss.
EFFECTIVE: 12.03.2002 EN
3AFE 64590430 Rev A
ABB Oy ABB Inc.

AC Drives Drives and Power Electronics
FIN-00381 HELSINKI New Berlin, WI 53151
FINLAND USA
Telephone +358 10 22 11 Telephone 262 785-8378
Fax +358 10 22 22681 800 243-4384
Internet http://www.abb.com Fax 262 780-5135
NOV PART NO.:
3AFE64783742
Technical Manual
ABB - Installation Manual
ACS800 Multidrive

3AFE64783742 C
www.nov.com
Revision C
Page 2
REVISION HISTORY

www.nov.com
ACS800
Planning the Electrical Installation

ACS800 Multidrive and ACS800 Multidrive Modules
ACS800 Multidrive Manuals
Codes refer to English manuals.
General drive manuals – in all deliveries

ACS800 Liquid-cooled Multidrive and Multidrive Modules Safety
Instructions (3AFE68715318)
ACS800 Liquid-cooled Multidrive and Multidrive Modules Planning the
Electrical Installation (3AFE68715423)
ACS800 Liquid-cooled Multidrive Mechanical Installation
(3AFE68715466)
Line-side converter manuals – in deliveries which include the
corresponding line-side converter type
ACS800-307LC, -507LC, -1107LC, -1207LC User's Manual
(3AFE68715474)
Motor-side converter hardware manuals – in all deliveries
ACS800-107LC Hardware Manual (3AFE68715491)
Motor-side converter firmware manuals, supplements and guides
– in deliveries which include the corresponding program
ACS800 System Application Program Firmware Manual
(3AFE64670646)
ACS800 Standard Application Program Firmware Manual
(3AFE64527592)
and Adaptive Program Application Guide (3AFE64527274)
Crane Control Program Firmware Manual (3BSE11179)
Master/Follower Application Guide (3AFE64590430)
Pump Control Application Program Firmware Manual
(3AFE68478952)
Extruder Control Program Supplement (3AFE64648543)
Centrifuge Control Program Supplement (3AFE64667246)
Traverse Control Program Supplement (3AFE64618334)
etc.
Option device manuals – in deliveries which include the
corresponding optional device
RAIO-01 Analogue I/O Extension User's Manual (3AFE64484567)
RDIO-01 Digital I/O Extension User's Manual (3AFE64485733)
etc.
ACS800 Multidrive and Multidrive Modules
Planning the Electrical Installation
3AFE64783742 REV C
EN

5
Table of contents
ACS800 Multidrive Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

............................................................................. 2
Planning the electrical installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Supply transformer for a drive equipped with an IGBT Supply Unit, or Thyristor Supply Unit . . . . . 8
Motor selection and checking the compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Basic rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Permanent magnet synchronous motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Thermal overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Protection against short-circuit in motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Protection against short-circuit inside the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Protection against short-circuit in the supply (AC line) cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Earth fault (Ground fault) protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Prevention of Unexpected Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Power factor compensation capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Equipment connected to the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation of safety switches, contactors, connection boxes, etc. . . . . . . . . . . . . . . . . . . . . . . . 22
Bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Before opening a contactor (DTC control mode selected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Coaxial cable (for use with Advant Controllers AC80/AC800) . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Protecting the relay output contacts and attenuating disturbances in case of inductive loads . . . . 24
Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PELV and installation sites above 2000 metres (6562 feet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6
Standards and markings

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Compliance with the EN 61800-3 (2004), category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Compliance with the Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
UL and CSA markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
UL and CSA notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
“C-tick” marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Compliance with EN 61800-3 (2004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Product protection in the USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7
What this chapter contains

This chapter contains the instructions that you must follow when selecting the motor,
the cables, the protections, the cable routing and the way of operation for the drive
system. If the recommendations given by ABB are not followed, the drive may
experience problems that the warranty does not cover.
The information is valid for ACS800 multidrive. It is also valid for ACS800 multidrive
modules if they are equipped with corresponding auxiliary devices.
Note: The installation must always be designed and made according to applicable
local laws and regulations. ABB does not assume any liability whatsoever for any
installation which breaches the local laws and/or other regulations. Furthermore, if
the recommendations given by ABB are not followed, the drive may experience
problems that the warranty does not cover.
Supply disconnecting device

Cabinet-installed ACS800 multidrive: The drive is equipped with a supply
disconnecting device as default.
ACS800 multidrive modules: Always equip the drive with a supply disconnecting
device which meets the local safety regulations.
• Europe: To meet the European Union Directives, according to standard
EN 60204-1, Safety of Machinery, the disconnecting device must be one of the
following types:
- switch-disconnector of utilization category AC-23B (EN 60947-3)
- disconnector that has an auxiliary contact that in all cases causes switching
devices to break the load circuit before the opening of the main contacts of the
disconnector (EN 60947-3)
- circuit breaker suitable for isolation in accordance with EN 60947-2.
• USA: The disconnecting device must conform to the applicable safety
regulations.
• Other regions: The disconnecting device must conform to the applicable safety
regulations.

8
Supply transformer for a drive equipped with an IGBT Supply Unit, or

Thyristor Supply Unit
WARNING! Drive equipped with an IGBT Supply Unit (ACS800-207) or Thyristor

Supply Unit (ACS800-407, or -807) larger than 500 kVA must be supplied with a
transformer dedicated to drives and motors or equipment of equal or higher power,
or with a transformer equipped with two secondary windings, one of which is
dedicated to drives and motors. Resonances might occur if there is capacitive load
(e.g. lighting, PC, PLC, small power factor compensation capacitors) in the same
network as the drive. The resonance current may damage a unit in the network.
Medium voltage network

Supply transformer
Neighbouring network
Low voltage Low voltage
Other load than

Motors DRIVE
drives and motors
Other drives
or Medium voltage network

Supply transformer
Low voltage
Other load than DRIVE
drives and motors
Other drives and

motors

9
Motor selection and checking the compatibility
Basic rules
1. Select the motor according to the rating tables in chapter Technical Data of the
Inverter Unit Hardware Manual. Use the DriveSize PC tool if the default load
cycles are not applicable.
2. Check that the motor ratings lie within the allowed ranges of the drive control
program:
• motor nominal voltage is 1/2 … 2 · UN of the drive
• motor nominal current is 1/6 … 2 · Ihd of the inverter in DTC control and
0 ... 2 · Ihd in scalar control. The control mode is selected by an inverter
parameter.
3. Check that the motor voltage rating meets the application requirements:
If the drive is equipped … and … … then the motor voltage
with … rating should be …
Diode Supply Unit no resistor braking is in use UN
ACS800-307 or -507
(modules ACS800-304 or
-704)
Brake Unit no frequent or long term brake cycles UN
ACS800-607 are needed
frequent or long term brake cycles will UACeq1
be used
IGBT Supply Unit DC bus voltage will not be increased UN
ACS800-207 from nominal (parameter setting)
(module ACS800-204) DC bus voltage will be increased from UACeq2
nominal (parameter setting)
Thyristor Supply Unit no resistor braking is in use UN
ACS800-407 or -807
(module ACS800-404)
UN = Rated input voltage of the drive

UACeq1 = UDC/1.35
UACeq2 = UDC/1.41
UACeq is the equivalent AC power source voltage of the drive in VAC.

UDC is the maximum DC link voltage of the drive in VDC.
For resistor braking: UDC= 1.21 × nominal DC link voltage (= 1.21 × 1.35 × UN).
For IGBT and Thyristor Supply Units: See the parameter value (1.41 × UN as
default).
4. Consult the motor manufacturer before using a motor in a drive system where the
motor nominal voltage differs from the AC power source voltage.
5. Ensure that the motor insulation system withstands the maximum peak voltage in
the motor terminals. See section Protecting the motor insulation and bearings on
page 10 for the required motor insulation system and drive filtering.

10
Protecting the motor insulation and bearings

The output of the drive comprises – regardless of output frequency – pulses of approximately 1.35
times the equivalent mains network voltage with a very short rise time. This is the case with all drives
employing modern IGBT inverter technology.
The voltage of the pulses can be almost double at the motor terminals, depending on the attenuation
and reflection properties of the motor cable and the terminals. This causes additional stress on the
motor and motor cable insulation.
Modern variable speed drives with their fast rising voltage pulses and high switching frequencies can
generate current pulses that flow through the motor bearings, which can gradually erode the bearing
races and rolling elements.
The stress on motor insulation can be avoided by using optional ABB du/dt filters. du/dt filters also
reduce bearing currents.
To avoid damage to motor bearings, the cables must be selected according to the instruction given in
section Selecting the power cables on page 17, and installed according to the instructions given in
Inverter Unit Hardware Manual. In addition, insulated N-end (non-driven end) bearings and output filters
from ABB must be used according to the following table. Two types of filters are used individually or in
combinations:
• optional du/dt filter (protects motor insulation system and reduces bearing currents).
• common mode filter (mainly reduces bearing currents).
Requirements table
The following table shows how to select the motor insulation system and when an optional ABB du/dt
filter, insulated N-end (non-driven end) motor bearings and ABB common mode filters are required. The
motor manufacturer should be consulted regarding the construction of the motor insulation and
additional requirements for explosion-safe (EX) motors. Failure of the motor to fulfil the following
requirements or improper installation may shorten motor life or damage the motor bearings.
Motor type Nominal mains Requirement for

voltage (AC line
Motor insulation ABB du/dt filter, insulated N-end bearing and ABB common
voltage)
system mode filter
Manufacturer
PN < 100 kW 100 kW < PN < PN > 350 kW

and 350 kW or or
frame size < IEC 315 frame size > IEC 315 frame size > IEC 400
PN < 134 HP 134 HP < PN < PN > 469 HP
and frame size < 469 HP or frame size >
NEMA 500 or frame size > NEMA 580
NEMA 500
A Random- UN < 500 V Standard - +N + N + CMF
B wound M2_ 500 V < UN < 600 V Standard + du/dt + du/dt + N + du/dt + N + CMF
and M3_
B
or
Reinforced - +N + N + CMF
600 V < UN < 690 V Reinforced + du/dt + du/dt + N + du/dt + N + CMF
Form-wound 380 V < UN < 690 V Standard n.a. + N + CMF PN < 500 kW: + N +
HX_ and AM_ CMF
PN > 500 kW: + N +
CMF + du/dt
Old* form- 380 V < UN < 690 V Check with the motor + du/dt with voltages over 500 V + N + CMF
wound HX_ manufacturer.
and modular
Random- 0 V < UN < 500 V Enamelled wire with + N + CMF
wound HX_ fibre glass taping
500 V < UN < 690 V + du/dt + N + CMF
and AM_ **

11

voltage (AC line
Motor insulation ABB du/dt filter, insulated N-end bearing and ABB common
voltage) system mode filter
Manufacturer
PN < 100 kW 100 kW < PN < PN > 350 kW

and 350 kW or or
frame size < IEC 315 frame size > IEC 315 frame size > IEC 400
PN < 134 HP 134 HP < PN < PN > 469 HP
and frame size < 469 HP or frame size >
NEMA 500 or frame size > NEMA 580
NEMA 500
N Random- UN < 420 V Standard: ÛLL = - + N or CMF + N + CMF
O wound and 1300 V
form-wound
N 420 V < UN < 500 V Standard: ÛLL = 1300 + du/dt + du/dt + N + du/dt + N + CMF
- V
or
A
+ du/dt + CMF
B
or
B
Reinforced: ÛLL = - + N or CMF + N + CMF
1600 V, 0.2
microsecond rise time
500 V < UN < 600 V Reinforced: ÛLL = + du/dt + du/dt + N + du/dt + N + CMF
1600 V or
+ du/dt + CMF
or
Reinforced: ÛLL = - + N or CMF + N + CMF
1800 V
600 V < UN < 690 V Reinforced: ÛLL = + du/dt + du/dt + N + du/dt + N + CMF
1800 V
Reinforced: ÛLL = - N + CMF N + CMF
2000 V, 0.3
microsecond rise time
***
* manufactured before 1.1.1998

** For motors manufactured before 1.1.1998, check for additional instructions with the motor
manufacturer.
*** If the intermediate DC circuit voltage of the drive is increased from the nominal level by resistor
braking or by the IGBT supply unit control program (parameter selectable function), check with the
motor manufacturer if additional output filters are needed in the applied drive operation range.

12
Note 1: The abbreviations are defined below. The table also instructs how to implement the du/dt and
common mode filtering.
Abbrev. Definition
UN nominal voltage of the supply network
ÛLL peak line-to-line voltage at motor terminals which the motor insulation must withstand
PN motor nominal power
du/dt du/dt limitation or filter
Inverter of frame size R2i to R7i:
• Cabinet-installed inverter unit (ACS800-107) must be equipped with option +E205 if it is
used in an application where du/dt limitation or filter is required (see the table above).
• For the inverter modules (ACS800-104), no option +E205 is available but the filter must be
acquired and installed separately if the inverter is used in an application where the filter is
required (see the table above). For the order codes, see ACS800-104 Hardware Manual
(3AFE64809032 [English]).
Inverter of frame size R8i:
• With 690 V units and units with parallel connected modules, internal du/dt limitation is
included as standard equipment.
• 400 V, 500 V and single inverter units must be equipped with option +E205 if it is used in
an application where the du/dt limitation or filter is required (see the table above).
CMF common mode filter
Inverter of frame size R6i and R7i:
• Cabinet-installed unit (ACS800-107) must be equipped with option +E208 if it is used in an
application where the common mode filter is required (see the table above).
• For inverter modules (ACS800-104), no option +E208 is available but the filter must be
acquired and installed separately if the inverter is used in an application where the filter is
required (see the table above). For the order codes, see ACS800-104 Hardware Manual
Inverter of frame size R8i:
• Included as default for the cabinet-installed units (ACS800-107).
• For inverter modules (ACS800-104), no filter is included but it must be acquired and
installed separately if the inverter is used in an application where the filter is required (see
the table above). For the order codes, see ACS800-104 Hardware Manual
N N-end bearing: insulated motor non-driven end bearing
n.a. Motors of this power range are not available as standard units. Consult the motor
manufacturer.
Note 2: Explosion-safe (EX) motors
The motor manufacturer should be consulted regarding the construction of the motor insulation and
additional requirements for explosion-safe (EX) motors.

13
Note 3: High-output motors and IP 23 motors

For motors with higher rated output than what is stated for the particular frame size in EN 50347 (2001)
and for IP 23 motors, the requirements of ABB random-wound motor series M3AA, M3AP, M3BP are
given below. For other motor types, see the Requirements table above. Apply the requirements of
range 100 kW < PN < 350 kW to motors with PN < 100 kW. Apply the requirements of range PN >
350 kW to motors within the range 100 kW < PN < 350 kW. In other cases, consult the motor
manufacturer.

voltage (AC line
Manufacturer
Motor ABB du/dt filter, insulated N-end bearing and ABB

voltage)
insulation common mode filter
system PN < 55 kW 55 kW < PN < PN > 200 kW
200 kW
PN < 74 HP 74 HP < PN < PN > 268 HP
268 HP
A Random- UN < 500 V Standard - +N + N + CMF
B wound M3AA,
500 V < UN < 600 V Standard + du/dt + du/dt + N + du/dt + N +
M3AP, M3BP
B CMF
or
Reinforced - +N + N + CMF
600 V < UN < 690 V Reinforced + du/dt + du/dt + N + du/dt + N +
CMF
Note 4: HXR and AMA motors

All AMA machines (manufactured in Helsinki) for drive systems have form-wound windings. All HXR
machines manufactured in Helsinki starting 1.1.1998 have form-wound windings.
Note 5: ABB motors of types other than M2_, M3_, HX_ and AM_
Use the selection criteria given for non-ABB motors.
Note 6: Resistor braking of the drive
When the drive is in braking mode for a large part of its operation time, the intermediate circuit DC
voltage of the drive increases, the effect being similar to increasing the supply voltage by up to
21 percent. The voltage increase should be taken into consideration when determining the motor
insulation requirement.
Example: Motor insulation requirement for a 400 V application must be selected as if the drive were
supplied with 480 V.
Note 7: Drives with an IGBT supply unit
If the intermediate circuit DC voltage increased form the nominal (this is a parameter selectable
function), select the motor insulation system according to the increased DC voltage level, especially in
the 500 V supply voltage range.
Note 8: Calculating the rise time and the peak line-to-line voltage
The peak line-to-line voltage at the motor terminals generated by the drive as well as the voltage rise
time depend on the cable length. The requirements for the motor insulation system given in the table
are “worst case” requirements covering installations with 30 metre and longer cables. The rise time can
be calculated as follows: t = 0.8 · ÛLL/(du/dt). Read ÛLL and du/dt from the diagrams below. Multiply
the values of the graph by the supply voltage (UN). In case of drives with an IGBT supply unit or resistor
braking, the ÛLL and du/dt values are approximately 20 % higher.

14
3.0 5.5
ÛLL/UN 5.0
2.5 du/dt
------------- (1/μs)
4.5 UN
2.0 4.0
3.5
1.5
3.0
ÛLL/UN
1.0 2.5
du/dt
------------- (1/μs)
UN 2.0
0.5
1.5
0.0 1.0
100 200 300 100 200 300
Cable length (m) Cable length (m)
With du/dt Filter Without du/dt Filter
Note 9: Sine filters protect the motor insulation system. Therefore, du/dt filter can be replaced with a
sine filter. The peak phase-to-phase voltage with the sine filter is approximately 1.5 × UN.
Permanent magnet synchronous motor

Only one permanent magnet motor can be connected to the inverter output.
It is recommended to install a safety switch between the permanent magnet
synchronous motor and the motor cable. The switch is needed to isolate the motor
during any maintenance work on the drive. See also ACS800 Multidrive Safety
Instructions (3AFE64760432 [English]).

15
Thermal overload and short-circuit protection
Thermal overload protection

The drive protects itself and the input and motor cables against thermal overload
when the cables are dimensioned according to the nominal current of the drive. No
additional thermal protection devices are needed.
WARNING! If an inverter is connected to multiple motors, a separate thermal

overload switch or a circuit breaker must be used for protecting each cable and
motor. These devices may require a separate fuse to cut off the short-circuit current.
Protection against short-circuit in motor cable

The drive protects the motor cable and the motor in a short-circuit situation when the
motor cable is dimensioned according to the nominal current of the drive. No
additional protection devices are needed.
Protection against short-circuit inside the drive

Cabinet-installed ACS800 Multidrive: The drive is equipped with input fuses that
restrict drive damage and prevent damage to adjoining equipment in case of a short-
circuit inside the drive.
ACS800 Multidrive modules: Equip the drive with input fuses listed in the Technical
Data of the Supply Unit Hardware/User’s Manual. The fuses restrict drive damage
and prevent damage to adjoining equipment in case of a short-circuit inside the
drive.
Protection against short-circuit in the supply (AC line) cable

Equip the input cable with fuses. Size the fuses according to local safety regulations,
appropriate input voltage and the rated current of the drive. Note: When placed at
the distribution board, the drive input fuses will also provide protection for the input
cable.
Earth fault (Ground fault) protection

Both the supply unit and the inverter unit are equipped with an internal earth fault
protective function to protect the drive against earth faults in the drive, motor and
motor cable. (This is not a personal safety or a fire protection feature.) Both earth
fault protective functions can be disabled; refer to Supply Unit Hardware/User’s
Manual and ACS800 Firmware Manual of the inverter application program
respectively.
The drive can also be equipped with an optional insulation monitoring device (option
code +Q953, +Q954). Consult an ABB representative for more information.
The EMC filter (if present) includes capacitors connected between the main circuit
and the frame. These capacitors and long motor cables increase the earth leakage
current and may cause fault current circuit breakers to function.

16
Emergency stop devices

For safety reasons, install the emergency stop devices at each operator control
station and at other operating stations where emergency stop may be needed.
Note: Pressing the stop key ( ) on the control panel of the drive does not generate
an emergency stop of the motor or separate the drive from dangerous potential.
An emergency stop function is optionally available for the cabinet-installed drives.
Two modes are available: immediate removal of power (Category 0) and controlled
emergency stop (Category 1).
Prevention of Unexpected Start

The drive can be equipped with an optional Prevention of Unexpected Start function
according to standards IEC/EN 60204-1: 1997; ISO/DIS 14118: 1996 and
EN 1037: 1996. The option code is +Q950.
The Prevention of Unexpected Start function disables the control voltage of the
power semiconductors, thus preventing the inverter from generating the AC voltage
required to rotate the motor. By using this function, short-time operations (like
cleaning) and/or maintenance work on non-electrical parts of the machinery can be
performed without switching off the AC power supply to the drive.
The operator activates the Prevention of Unexpected Start function by opening a
switch on a control desk. An indicating lamp on the control desk will light, signalling
that the prevention is active. The switch can be locked out.
The user must install on a control desk near the machinery:
• switching/disconnecting device for the circuitry. “Means shall be provided to
prevent inadvertent, and/or mistaken closure of the disconnecting device.”
EN 60204-1: 1997.
• indicating lamp; on = starting the drive is prevented, off = drive is operative.
For connections to the drive, see the circuit diagram delivered with the drive.
WARNING! The Prevention of Unexpected Start function does not disconnect the
voltage of the main and auxiliary circuits from the drive. Therefore maintenance work
on electrical parts of the drive or the motor can only be carried out after isolating the
drive system from the main supply.
Note: When a running drive is stopped by using the Prevention of Unexpected Start
function, the drive will stop by coasting. If this is not acceptable (e.g. causes danger),
the drive and machinery must be stopped using the appropriate stopping mode
before using this function.

17
Selecting the power cables

This subsection contains the general cable selection rules.
Note: The converter configuration may require multiple supply and/or motor cabling.
See the connection diagrams in the electrical installation instructions of the Supply
Unit Hardware/User’s Manual and Inverter Unit Hardware Manual. For example, in
Diode Supply Unit module size D4, there are two diode bridges in parallel. Both
bridges need to be fed through individual fuses. If the fuses are placed at the
distribution board, each bridge needs individual input cabling.
General rules
Dimension the mains (input power) and motor cables according to local
regulations:
• The cable must be able to carry the drive load current. See chapter Technical
data in Supply Unit Hardware/User’s Manual and Inverter Unit Hardware Manual
for the rated currents.
• The cable must be rated for at least 70 °C maximum permissible temperature of
conductor in continuous use. For US, see Additional US requirements.
• The inductance and impedance of the PE conductor/cable (grounding wire) must
be rated according to permissible touch voltage appearing under fault conditions
(so that the fault point voltage will not rise excessively when a ground fault
occurs).
• 600 VAC cable is accepted for up to 500 VAC. 750 VAC cable is accepted for up
to 600 VAC. For 690 VAC rated equipment, the rated voltage between the
conductors of the cable should be at least 1 kV.
For inverter frame size R5i and larger, or motors larger than 30 kW (40 HP),
symmetrical shielded motor cable must be used (figure below). A four-conductor
system can be used up to frame size R4i with up to 30 kW (40 HP) motors, but
shielded symmetrical motor cable is recommended.
A four-conductor system is allowed for input cabling, but shielded symmetrical cable
is recommended. To operate as a protective conductor, the shield conductivity must
be as follows when the protective conductor is made of the same metal as the phase
conductors:
Cross-sectional area of the phase Minimum cross-sectional area of the
conductors corresponding protective conductor
S (mm2) Sp (mm2)
S < 16 S
16 < S < 35 16
35 < S S/2
Compared to a four-conductor system, the use of symmetrical shielded cable

reduces electromagnetic emission of the whole drive system as well as motor
bearing currents and wear.

18
The motor cable and its PE pigtail (twisted shield) should be kept as short as
possible in order to reduce electromagnetic emission.
Typical power cable sizes

Tables below give current carrying capacity (ILmax) for aluminium and copper
PVC/XLPE insulated cables. A correction factor K = 0.70 is used (cables laid on the
cable trays side by side, max 9 cables per tray, three ladder support trays, one on
top of the other, ambient temperature 30°C, EN 60204-1 and IEC 364-5-52).
Aluminium cable PVC insulation XLPE insulation
Conductor temperature 70° Conductor temperature 90°
Size ø [mm] ILmax [A] Temp const [S] ILmax [A] Temp const [S]
3 × 35 + 10 Cu 26 69 70 86 70
3 × 50 + 15 Cu 29 83 93 104 93
3 × 70 + 21 Cu 32 107 123 134 123
3 × 95 + 29 Cu 38 130 150 163 150
3 × 120 + 41 Cu 41 151 180 189 180
3 × 150 + 41 Cu 44 174 215 218 215
3 × 185 + 57 Cu 49 199 255 249 255
3 × 240 + 72 Cu 54 235 330 294 330
2 × (3 × 70 + 21 Cu) 2 × 32 214 123 171 123

2 × (3 × 95 + 29 Cu) 2 × 38 260 150 208 150
2 × (3 × 120 + 41 Cu) 2 × 41 302 180 242 180
2 × (3 × 150 + 41 Cu) 2 × 44 348 215 278 215
2 × (3 × 185 + 57 Cu) 2 × 49 398 255 318 255
2 × (3 × 240 + 72 Cu) 2 × 54 470 330 376 330
3 × (3 × 150 + 41 Cu) 3 × 44 522 215 418 215

3 × (3 × 185 + 57 Cu) 3 × 49 597 255 478 255
3 × (3 × 240 + 72 Cu) 3 × 54 705 330 564 330
4 × (3 × 185 + 57 Cu) 4 × 49 796 255 637 255

4 × (3 × 240 + 72 Cu) 4 × 54 940 330 752 330
5 × (3 × 185 + 57 Cu) 5 × 49 995 255 796 255

5 × (3 × 240 + 72 Cu) 5 × 54 1175 330 940 330
6 × (3 × 240 + 72 Cu) 6 × 54 1410 330 1128 330
7 × (3 × 240 + 72 Cu) 7 × 54 1645 330 1316 330
8 × (3 × 240 + 72 Cu) 8 × 54 1880 330 1504 330
9 × (3 × 240 + 72 Cu) 9 × 54 2115 330 1692 330
10 × (3 × 240 + 72 Cu) 10 × 54 2350 330 1880 330

19
Copper cable PVC insulation XLPE insulation

Conductor temperature 70° Conductor temperature 90°
Size ø [mm] ILmax [A] Temp const [S] ILmax [A] Temp const [S]
3 × 1.5 + 1.5 13 13 85 16 85
3 × 2.5 + 2.5 14 18 123 23 123
(3 × 4 + 4) 16 24 177 30 177
3×6+6 18 30 255 38 255
3 × 10 + 10 21 42 354 53 354
3 × 16 + 16 23 56 505 70 505
3 × 25 + 16 24 71 773 89 773
3 × 35 + 16 26 88 970 110 970
3 × 50 + 25 29 107 1268 134 1268
3 × 70 + 35 32 137 1554 171 1554
3 × 95 + 50 38 167 1954 209 1954
3 × 120 + 70 41 193 2313 241 2313
3 × 150 + 70 44 223 2724 279 2724
3 × 185 + 95 50 255 3186 319 3186
3 × 240 + 120 55 301 3904 376 3904
2 × (3 × 70 + 35) 2 × 32 274 1554 342 1554

2 × (3 × 95 + 50) 2 × 38 334 1954 418 1954
2 × (3 × 120 + 70) 2 × 41 386 2313 482 2313
2 × (3 × 150 + 70) 2 × 44 446 2724 558 2724
2 × (3 × 185 + 95) 2 × 50 510 3186 638 3186
2 × (3 × 240 + 120) 2 × 55 602 3904 752 3904
3 × (3 × 120 + 70) 3 × 41 579 2313 723 2313

3 × (3 × 150 + 70) 3 × 44 669 2724 837 2724
3 × (3 × 185 + 95) 3 × 50 765 3186 957 3186
3 × (3 × 240 + 120) 3 × 55 903 3904 1128 3904
4 × (3 × 150 + 70) 4 × 44 892 2724 1116 2724

4 × (3 × 185 + 95) 4 × 50 1020 3186 1276 3186
4 × (3 × 240 + 120) 4 × 55 1204 3904 1504 3904
5 × (3 × 185 + 95) 5 × 50 1275 3186 1595 3186

5 × (3 × 240 + 120) 5 × 55 1505 3904 1880 3904
6 × (3 × 185 + 95) 6 × 50 1530 3186 1914 3186

6 × (3 × 240 + 120) 6 × 55 1806 3904 2256 3904
7 × (3 × 240 + 72) 7 × 55 2107 3904 2632 3904
8 × (3 × 240 + 72) 8 × 55 2408 3904 3008 3904

20
Alternative power cable types

Power cable types that can be used with the drive are represented below.
Recommended
Symmetrical shielded cable: three phase conductors A separate PE conductor is required if the conductivity
and a concentric or otherwise symmetrically of the cable shield is < 50 % of the conductivity of the
constructed PE conductor, and a shield phase conductor.
PE conductor Shield
and shield Shield
PE
PE
PE Shield
A four-conductor system:
three phase conductors
and a protective
conductor
Not allowed for motor cables Not allowed for motor cables with phase
conductor cross section larger than 10 mm2
[motors > 30 kW (40 HP)].
Motor cable shield

To effectively suppress radiated and conducted radio-frequency emissions, the
shield conductivity must be at least 1/10 of the phase conductor conductivity. The
requirements are easily met with a copper or aluminium shield. The minimum
requirement of the motor cable shield of the drive is shown below. It consists of a
concentric layer of copper wires with an open helix of copper tape. The better and
tighter the shield, the lower the emission level and bearing currents.
Copper wire screen Helix of copper tape Inner insulation

Insulation jacket
Cable core

21
Additional US requirements
Type MC continuous corrugated aluminum armor cable with symmetrical grounds or
shielded power cable must be used for the motor cables if metallic conduit is not
used. For the North American market, 600 VAC cable is accepted for up to 500 VAC.
1000 VAC cable is required above 500 VAC (below 600 VAC). For drives rated over
100 amperes, the power cables must be rated for 75 °C (167 °F).
Conduit
Where conduits must be coupled together, bridge the joint with a ground conductor
bonded to the conduit on each side of the joint. Bond the conduits also to the drive
enclosure. Use separate conduits for input power, motor, brake resistors, and control
wiring. Do not run motor wiring from more than one drive in the same conduit.
Armored cable / shielded power cable
The motor cables can be run in the same cable tray as other 460 V or 600 V power
wiring. Control and signal cables must not be run in the same tray as power cables.
Six conductor (3 phases and 3 ground) type MC continuous corrugated aluminum
armor cable with symmetrical grounds is available from the following suppliers (trade
names in parentheses):
• Anixter Wire & Cable (Philsheath)
• BICC General Corp (Philsheath)
• Rockbestos Co. (Gardex)
• Oaknite (CLX).
Shielded power cables are available from Belden, Lapp Kabel (ÖLFLEX) and Pirelli.

22
Power factor compensation capacitors

Power factor compensation is not needed with AC drives. However, if a drive is to be
connected in a system with compensation capacitors or tuned harmonic filters
installed, note the following restrictions.
WARNING! Do not connect power factor compensation capacitors to the motor

cables (between the drive and the motor). They are not meant to be used with AC
drives and can cause permanent damage to the drive or themselves.
If there are power factor compensation capacitors in parallel with the three phase
input of the drive (on low voltage or medium voltage side of the supply transformer):
1. Do not connect a high-power capacitor to the power line while the drive is
connected. The connection will cause voltage transients that may trip or even
damage the drive.
2. If capacitor load is increased/decreased step by step when the AC drive is
connected to the power line: Ensure that the connection steps are low enough not
to cause voltage transients that would trip the drive.
3. Check that the power factor compensation unit is suitable for use in systems with
AC drives i.e. harmonic generating loads. In such systems, the compensation unit
should typically be equipped with a blocking reactor or harmonic filter.
Equipment connected to the motor cable
Installation of safety switches, contactors, connection boxes, etc.

To minimize the emission level when safety switches, contactors, connection boxes
or similar equipment are installed in the motor cable between the drive and the
motor:
• Europe: Install the equipment in a metal enclosure with 360 degrees grounding
for the shields of both the incoming and outgoing cable, or connect the shields of
the cables otherwise together.
• USA: Install the equipment in a metal enclosure in a way that the conduit or motor
cable shielding runs consistently without breaks from the drive to the motor.
• Other regions: See the section Europe above.
Bypass connection
WARNING! Never connect the supply power to the drive output terminals U2, V2
and W2. If frequent bypassing is required, employ mechanically connected switches
or contactors. Mains (line) voltage applied to the output can result in permanent
damage to the unit.

23
Before opening a contactor (DTC control mode selected)

Stop the drive and wait for the motor to stop before opening a contactor between the
output of the drive and the motor when the DTC control mode is selected. See
ACS800 Firmware Manual for the required parameter settings. Otherwise, the
contactor will be damaged. In scalar control, the contactor can be opened with the
drive running.
Selecting the control cables

All control cables must be shielded.
Use a double-shielded twisted pair cable (Figure a) for analogue signals. This type of
cable is recommended for the pulse encoder signals also. Employ one individually
shielded pair for each signal. Do not use common return for different analogue
signals.
A double-shielded cable is the best alternative for low-voltage digital signals but
single-shielded twisted pair cable (Figure b) is also usable.
a b
A double-shielded twisted A single-shielded twisted
pair cable pair cable
Run analogue and digital signals in separate, shielded cables.

Relay-controlled signals, providing their voltage does not exceed 48 V, can be run in
the same cables as digital input signals. It is recommended that the relay-controlled
signals be run as twisted pairs.
Never mix 24 VDC and 115/230 VAC signals in the same cable.
Relay cable
The cable type with braided metallic screen (e.g. ÖLFLEX by Lapp Kabel, Germany)
has been tested and approved by ABB.
Control panel cable

In remote use, the cable connecting the control panel to the drive must not exceed 3
metres (10 ft). The cable type tested and approved by ABB is used in control panel
option kits.
Coaxial cable (for use with Advant Controllers AC80/AC800)

• 75 ohm
• RG59, diameter 7 mm or RG11, diameter 11 mm
• Maximum cable length: 300 m (1000 ft)

24
Protecting the relay output contacts and attenuating disturbances in case

of inductive loads
Inductive loads (such as relays, contactors, motors) cause voltage transients when
switched off.
The relay contacts of the RMIO board are protected with varistors (250 V) against
overvoltage peaks. In spite of this, it is highly recommended to equip inductive loads
with noise attenuating circuits (varistors, RC filters [AC] or diodes [DC]) in order to
minimize the electromagnetic emission at switch-off. If not suppressed, the
disturbances may connect capacitively or inductively to other conductors in the
control cable and form a risk of malfunction in other parts of the system.
Install the protective component as close to the inductive load as possible. Do not
install the protective components at the terminal block of the converter control board.
Relay outputs
Varistor
RO (NC)
RO (C)
230 VAC
RO (NO)
RC filter
RO (NC)
230 VAC RO (C)
RO (NO)
Diode
RO (NC)
24 VDC RO (C)
RO (NO)
Connection of a motor temperature sensor to the drive I/O
WARNING! IEC 60664 requires double or reinforced insulation between live parts
and the surface of accessible parts of electrical equipment which are either non-
conductive or conductive but not connected to the protective earth.
To fulfil this requirement, the connection of a thermistor (and other similar
components) to the digital inputs of the drive can be implemented in three alternate
ways:
1. There is double or reinforced insulation between the thermistor and live parts of
the motor.
2. Circuits connected to all digital and analogue inputs of the drive are protected
against contact and insulated with basic insulation (the same voltage level as the
drive main circuit) from other low voltage circuits.
3. An external thermistor relay is used. The insulation of the relay must be rated for
the same voltage level as the main circuit of the drive. For connection, see
ACS800 Firmware Manual.

25
PELV and installation sites above 2000 metres (6562 feet)

The drive does not fulfil the Protective Extra Low Voltage (PELV) requirements
stated in EN 50178 at altitudes above 2000 m (6562 ft).
WARNING! Wear appropriate protection when installing, operating or servicing the

RMIO board wiring and optional modules attached to the board.

26
Routing the cables

Route the motor cable away from other cable routes. Motor cables of several drives
can be run in parallel installed next to each other. It is recommended that the motor
cable, input power cable and control cables be installed on separate trays. Avoid
long parallel runs of motor cables with other cables in order to decrease
electromagnetic interference caused by the rapid changes in the drive output
voltage.
Where control cables must cross power cables make sure they are arranged at an
angle as near to 90 degrees as possible. Do not run extra cables through the drive.
The cable trays must have good electrical bonding to each other and to the
grounding electrodes. Aluminium tray systems can be used to improve local
equalizing of potential.
A diagram of the cable routing is shown below.
Motor cable
Drive
min 300 mm (12 in.)
Power cable
Input power cable Motor cable
min 200 mm (8 in.) 90 ° min 500 mm (20 in.)
Control cables
Control cable ducts

24 V 230 V 24 V 230 V
Not allowed unless the 24 V cable is Lead 24 V and 230 V control cables in
insulated for 230 V or insulated with an separate ducts inside the cabinet.
insulation sleeving for 230 V.

27

This chapter
• lists the applicable standards, and the markings attached to ACS800 multidrive
• describes the conditions and limitations related to each marking
• refers to additional information within the product documentation.
The information is valid for the cabinet-installed ACS800 multidrive and ACS800
multidrive modules to be installed into cabinet by the user.
Applicable standards
The drive complies with the following standards.
C M Standard Information
× × EN 50178 (1997) Electronic equipment for use in power installations.
× × EN 60204-1 (1997) Safety of machinery. Electrical equipment of machines. Part 1:

General requirements.
× × EN 61800-5-1 Power drive system product standard - Safety requirements
× × EN 60529: 1991 Degrees of protection provided by enclosures (IP code).
× × IEC 60664-1 (1992) Insulation coordination for equipment within low-voltage

systems. Part 1: Principles, requirements and tests.
× EN 61800-3 (2004) EMC product standard including specific test methods
× UL 508C UL Standard for Safety, Power Conversion Equipment
× UL 508A UL Standard for Safety, Industrial Control Panels
× × CSA C22.2 No. 14-905 Industrial control equipment
C = Cabinet-installed ACS800 multidrive, M = ACS800 multidrive modules

28
CE marking
A CE mark is attached to the drive to verify that the unit follows the provisions of the
European Low Voltage and EMC Directives (Directive 73/23/EEC, as amended by
93/68/EEC and Directive 89/336/EEC, as amended by 93/68/EEC).
Compliance with the European Low Voltage Directive

The compliance with the European Low Voltage Directive has been verified according to standards
EN 50178, EN 61800-5-1 and EN 60204-1.
Compliance with the European EMC Directive

Cabinet-installed ACS800 multidrive: The compliance with the European EMC Directive has been
verified according to the EMC product standard (EN 61800-3 [2004]) as described in Compliance with
the EN 61800-3 (2004), category C2; Compliance with the EN 61800-3 (2004), category C3 and
Compliance with the EN 61800-3 (2004), category C4 below.
ACS800 multidrive modules: The cabinet builder is in charge for the compliance of the drive with the
European EMC Directive. For information on items to consider, see:
• Subsections Compliance with the EN 61800-3 (2004), category C2; Compliance with the EN
61800-3 (2004), category C3 and Compliance with the EN 61800-3 (2004), category C4 below.
• ACS800 Multidrive Modules Planning the Cabinet Installation (3AFE64783572 [English]).
Technical guide 3: EMC Compliant Installation and Configuration for a Power Drive System
Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to
operate without problems within an electromagnetic environment. Likewise, the equipment must not
disturb or interfere with any other product or system within its locality.
First environment includes domestic premises. It also includes establishments directly connected
without intermediate transformers to a low-voltage power supply network which supplies buildings used
for domestic purposes.
Second environment includes all establishments other than those directly connected to a low-voltage
power supply network which supplies buildings used for domestic purposes
Drive of category C2. PDS of rated voltage less than 1000 V, which is neither a plug in device nor a
movable device and, when used in the first environment, is intended to be installed and commissioned
only by a professional.
Drive of category C3. PDS of rated voltage less than 1000 V, intended for use in the second
environment and not intended for use in the first environment.
Drive of category C4. PDS of rated voltage equal to or above 1000 V, or rated current equal to or above
400 A, or intended for use in complex systems in the second environment.
Compliance with the EN 61800-3 (2004), category C2
The 400 and 500 V drives meet the requirements of the EMC Directive as follows:
4. Drive is equipped with Diode Supply Unit (ACS800-307 or -507) or IGBT Supply Unit
(ACS800-207).
5. The drive is equipped with EMC filter +E202.
6. The motor and control cables are selected as specified in chapter Planning the electrical installation.
7. The drive is installed according to the instructions given in the manuals:
- ACS800 Multidrive Mechanical Installation (3AFE68233402 [English])
- Appropriate Supply Unit Manual
- ACS800-107 Inverter Unit Hardware Manual (3AFE68233453 [English]).
8. Motor cables do not exceed 100 metres (328 ft).
Note: It is not allowed to install a drive equipped with EMC filter +E202 on IT (unearthed) systems. The
supply network becomes connected to earth potential through the EMC filter capacitors which may
cause danger or damage the unit.

29
WARNING! The drive may cause radio interference if used in a residential or domestic environment.
The user is required to take measures to prevent interference, in addition to the requirements for CE
compliance listed above, if necessary.

The drive meets the requirements of the EMC Directive as follows:
1. Drive is equipped with Diode Supply Unit (ACS800-307 or -507) or IGBT Supply Unit
(ACS800-207).
2. The motor and control cables are selected as specified in chapter Planning the electrical installation.
- Appropriate Supply Unit Manual
4. Motor cables do not exceed 100 metres (328 ft).
The requirements of the EMC Directive can be met as follows:
1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In
some cases, the natural suppression in transformers and cables is sufficient. If in doubt, the supply
transformer with static screening between the primary and secondary windings can be used.
Medium voltage network

Supply transformer
Neighbouring network
Static screen
Point of measurement
Low voltage Low voltage

Equipment
Drive
(victim)
Equipment Equipment
2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available
from the local ABB representative.
3. The motor and control cables are selected as specified in the chapter Planning the electrical
installation.
- Appropriate Supply Unit Hardware Manual
Compliance with the Machinery Directive

The drive is intended to be incorporated into machinery to constitute machinery
covered by Machinery Directive (98/37/EC) and does therefore not in every respect
comply with the provisions of the directive. For more information, see the Declaration
of Incorporation by ABB Drives (code 64652770).

30
UL and CSA markings

Cabinet-installed ACS800 multidrive: The drive is cULus listed and cCSAus
certified. The approvals are valid with rated voltages up to 600 V. The markings are
attached to the drives when options +C129 (cULus) or +C134 (cCSAus) are
selected.
ACS800 multidrive modules: The drive is cULus listed and cCSAus certified. The
approvals are valid with rated voltages up to 600 V.
UL and CSA notes

Input power connection – Prospective short-circuit current (IEC 60439-1) is 65 kA (Icf). The drive is
suitable for use in a circuit capable of delivering not more than 65,000 symmetrical amperes (rms) at
600 V maximum when protected with the US fuses given in Supply Unit Manual.
Disconnecting device (disconnecting means) – See page 7.
Ambient conditions – The drive is to be used in a heated indoor controlled environment. For the
specifications, see Supply Unit Manual or Inverter Unit Manual.
Input cable fuses – For installation in the United States, branch circuit protection must be provided in
accordance with National Electric Code (NEC) and any applicable local codes. To fulfil this requirement,
use the US fuses given in Supply Unit Manual.
For installation in Canada, branch circuit protection must be provided in accordance with Canadian
Electrical Code and any applicable provincial codes. To fulfil this requirement, use the UL classified
fuses given in Supply Unit Manual or Inverter Unit Manual.
Power cable selection – See chapter Planning the electrical installation, page 17.
Power cable connections – For the connection diagram and tightening torques, see Supply Unit
Manual or Inverter Unit Manual.
Control connections – For the connection diagram and tightening torques, see Inverter Unit Manual.
Overload protection – The drive provides overload protection in accordance with the National
Electrical Code (US). See ACS800 Firmware Manual for setting. Default setting is off, must be activated
at start-up.
Brake unit – The drive can be equipped with a brake unit that will allow the drive to dissipate
regenerative energy (normally associated with quickly decelerating a motor). Proper application of the
brake unit is defined in the ACS800-607 Brake Unit Hardware Manual (3AFE68392519 [English]).
UL standards – See section Applicable standards on page 27.
“C-tick” marking
Cabinet-installed ACS800 multidrive: A “C-tick” mark is attached to each drive in
order to verify compliance with the EMC product standard (EN 61800-3 [2004]),
required under the Trans-Tasman Electromagnetic Compatibility Scheme for levels
1, 2 and 3 in Australia and New Zealand.
Compliance with EN 61800-3 (2004)

See section Compliance with the European EMC Directive on page 28.

31
Product protection in the USA

This product is protected by one or more of the following US patents
4,920,306 5,301,085 5,463,302 5,521,483 5,532,568 5,589,754 5,654,624 5,799,805 5,940,286 5,942,874
5,952,613 6,094,364 6,147,887 6,175,256 6,184,740 6,195,274 6,229,356 6,252,436 6,265,724 6,305,464
6,313,599 6,316,896 6,335,607 6,370,049 6,396,236 6,448,735 6,498,452 6,552,510 6,597,148 6,741,059
6,774,758 6,844,794 6,856,502 6,859,374 6,922,883 6,940,253 6,934,169 6,956,352 6,958,923 6,967,453
6,972,976 6,977,449 6,984,958 6,985,371 6,992,908 6,999,329 7,023,160 7,034,510 7,036,223 7,045,987
D503,931 D510,319 D510,320 D511,137 D511,150 D512,026 D512,696
Other patents pending.

32

3AFE64783742 REV C / EN
ABB Oy ABB Inc. ABB Beijing Drive Systems Co. Ltd.

AC Drives Automation Technologies No. 1, Block D, A-10 Jiuxianqiao Beilu
P.O. Box 184 Drives & Motors Chaoyang District
FIN-00381 HELSINKI 16250 West Glendale Drive Beijing, P.R. China, 100015
FINLAND New Berlin, WI 53151 Telephone +86 10 5821 7788
Telephone +358 10 22 11 USA Fax +86 10 5821 7618
Fax +358 10 22 22681 Telephone 262 785-3200 Internet http://www.abb.com
Internet http://www.abb.com 800-HELP-365
Fax 262 780-5135
NOV PART NO.:
3AFE64809032
Technical Manual
ABB - Hardware Manual
ACS800-104 Inverter Modules

3AFE64809032 E
www.nov.com
Revision E
Page 2
REVISION HISTORY

www.nov.com
ACS800
Hardware Manual
ACS800-104 Inverter Modules
ACS800-104 (1.5 to 2000 kW) Inverter Modules
Hardware Manual
3AFE64809032 REV E
EN

5
Table of contents
Table of contents
Introduction to this manual

Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Related publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hardware description
Typical drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inverter module hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Frames R2i to R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Module layout (Frame size R3i pictured) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Module layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Frame R8i and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Reduced run capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Module layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Basic code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Option codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cabinet construction
Frame R2i to R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Guiding the cooling air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Layout examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Mounting examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
LH mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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RH mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Frame R8i and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Module extraction/insertion ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Mounting examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Single R8i module in a Rittal TS 8 cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Two R8i modules in a Rittal TS 8 cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Three R8i modules in a Rittal TS 8 cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Three R8i modules side by side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Cabinet ventilation (all frame sizes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
IP54, 400 mm wide Rittal TS 8 cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
IP54, 800 mm wide generic cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
IP42, 800 mm wide generic cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Door fan, 400/600 mm wide cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Door fans, 800 mm wide cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Notes on Optical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Power connections – Frame R2i to R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Conductor stripping lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Connection box kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Frame R2i to R4i power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Frame R5i power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Power connections – Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
DC and motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Charging circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Common mode filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Power connections – Frame R8i and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Charging circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Direct motor cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Common motor terminal cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Frame R2i to R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Frame R2i to R4i (R3i pictured) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Frame R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
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External +24 V power supply for the RMIO board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Drive control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Control connections of the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Frame R8i and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Drive control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Control connections of the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
360 degrees grounding of I/O cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
When the outer surface of the shield is covered with non-conductive material . . . . . . 80
Connecting the shield wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Cabling of I/O and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Pulse encoder module cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Installation of optional modules and PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Fibre optic links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Installation of NLMD-01 LED Monitoring Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Control panel with monitoring display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Monitoring display only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Motor control and I/O board (RMIO)

To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Note on cabinet-installed ACS800 drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Note on terminal labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
External control connections (non-US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
External control connections (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
RMIO board specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Constant voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Auxiliary power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
DDCS fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
24 VDC power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Installation checklist
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
External +24 V power supply for the RMIO board (Frames R2i to R5i)
When to use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Connecting +24 V external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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Maintenance
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Inverter module replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Reduced run capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Checking and replacing the air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Heatsinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Fan replacement (R2i, R3i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Fan replacement (R4i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Additional fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Replacement (R2i, R3i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Replacement (R4i, R5i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Power connections (R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Capacitor reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
ACS800-104 ordering information

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Inverter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Frame sizes R2i to R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Frame size R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Frame size R8i and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
DC fuses and fuse bases; DC switch fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Mounting plates for R2i to R5i modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Inclined mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Vertical mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Mounting parts for R7i modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Common mode filters for R7i modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Installation parts for R8i modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Quick connector chassis socket kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
DC busbar kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Upper and lower guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Common mode filters for R8i modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Cabinet ventilation kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
PPCS branching units for n×R8i inverter units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Output (du/dt) filters for frame R2i to R7i inverter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Other options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Technical data
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
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Frame R2i to R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Frame R8i and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Dimensions, noise, DC capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Power loss and cooling characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Cable terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Auxiliary power consumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Circuit diagrams
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Frame R2i to R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
R2i/R3i – Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
R4i – Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
R5i – Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Example – Three frame R2i to R5i inverter units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Connection diagram (400/500 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Connection diagram (690 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Frame R8i and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
R8i – Internal diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Charging circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
I/O and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Cooling fan control (inverter modules without optional speed-controlled fan) . . . . . . . . . . . 156
Auxiliary voltage distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Example – Emergency stop (Category 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Example – Prevention of unexpected start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Dimension drawings
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Frame R2i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Table of contents
10
Module dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162

Frame R3i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Frame R4i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
Frame R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
Frame R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Quick connector chassis socket kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Kit #68239427 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Kit #68239435 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
Kit #68242231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
Module extraction/insertion ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
Control electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
RDCU-02(C) control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
NPBU-42C branching unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
APBU-44C branching unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
Fuse bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
SB series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
Switch fuses, charging components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
OESA00-160D2PL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
OS160D02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
OS250D02P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
OESA630D2PL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
OESL630/32D02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
OESL630/32D04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
OESL630/32D06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
ASFC-01C switch fuse controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187
ZRF charging resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
Diverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Output (du/dt) filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Common mode filter toroids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Table of contents
11

This chapter gives the basic information on the manual.
Compatibility
The manual is compatible with the ACS800-104 inverter modules intended for user-
defined cabinet installations.
Safety instructions
Follow all safety instructions delivered with the drive.
Intended audience
The reader of the manual is expected to know the standard electrical wiring
practices, electronic components, and electrical schematic symbols.
Contents
• Hardware description
• Cabinet construction
• Electrical installation
• External +24 V power supply for the RMIO board (Frames R2i to R5i)
• Installation checklist
• Motor control and I/O board (RMIO)
• Maintenance
• ACS800-104 ordering information
• Technical data
• Circuit diagrams
• Dimension drawings.

12
Related publications
• ACS800 MultiDrive Safety Instructions (3AFE64760432 [English])
• ACS800 MultiDrive; Planning the Electrical Installation (3AFE64783742 [English])
• ACS800 MultiDrive Modules; Planning the Cabinet Installation (3AFE64783572
[English])
• ACS800-304 and ACS800-704 Diode Supply Units User’s Manual
(3AFE64494023 [English])
• ACS800 Multidrive Modules Product Reference (3AFE64813340 [English]).
Contains descriptions of ACS800 drive products and information on generic
options
• Firmware manuals
• Option-specific manuals.

13

Term/ Explanation
Abbreviation
AGPS Gate driver Power Supply board. An optional board within inverter modules used to
implement the Prevention of Unexpected Start function.
APBU Types of optical branching unit used for connecting parallel-connected inverter
(or NDBU) modules to the RDCU.
CMF Common mode filtering.
DDCS Distributed Drives Communication System; a protocol used in optical fibre

communication inside and between ABB drives.
Drive unit See Inverter unit.
DSU Diode supply unit (consisting of one or more diode supply modules).
DTC Direct Torque Control.
EMC Electromagnetic Compatibility.
Frame (size) Relates to the construction type of the component in question. For example,
several supply modules with different nominal powers may have the same basic
construction. The term is often used in reference to a group of components that
share a similar mechanical construction.
To determine the frame size of a component, refer to the rating tables in chapter
Technical data.
IGBT Insulated Gate Bipolar Transistor; a voltage-controlled semiconductor type widely

used in inverters due to their easy controllability and high switching frequency.
Inverter unit An entity containing all inverter modules controlling a motor, together with their
control electronics, and I/O and auxiliary components.
I/O Input/Output.
NDBU Types of optical branching unit for fibre links between the drive control unit and the
inverter modules.
PLC Programmable Logic Controller.
PPCS Power Plate Communication System; a protocol used in the optical fibre link that
controls the output semiconductors of an inverter module.
RDCU Drive control unit. The RDCU is a separate unit consisting of an RMIO board built
in a plastic housing. Module sizes R2i to R5i have the RMIO board built-in.
RFI Radio-Frequency Interference.
RMIO Motor control and I/O board. Contains the principal inputs and outputs of the drive.
Module sizes R2i to R5i have the RMIO board built-in; with larger units, the RMIO
is contained within a separate RDCU drive control unit.

14

15

This chapter describes a typical drive system and the hardware of the inverter
modules. The information is valid for all ACS800-104 inverter modules.
Typical drive system

The diagram below depicts a common DC bus drive system.
M
2 5 5 6
M M M
M M
3~ 3~
1
1 – Input (AC) fuses
2 – Supply unit (in this example, consisting of two supply modules)
3 – DC bus
4 – Inverter DC fuses
5 – Inverter units (in this example, one of the units consists of two
inverter modules connected in parallel)
6 – Brake chopper(s) (optional)
16
Inverter module hardware

The ACS800-104 range of inverter modules contains components for building the
inverter unit(s) of a common DC bus system drive.
The chapter ACS800-104 ordering information lists the order codes of the inverter
module components. See also the Dimension drawings for dimensions of the
modules and related equipment.
The section Control interfaces below shows the available control and I/O options.
The ACS800-104 inverter modules have coated circuit boards as standard. A
Prevention of Unexpected Start feature is optionally available, consisting of a built-in
AGPS board.
Frames R2i to R5i

The DC input and motor output cables are connected to screw terminal blocks at the
bottom of the module, covered by a metal housing.
Frame R2i to R5i modules do not require an external charging circuit.
External du/dt filters are available; see the chapter ACS800-104 ordering
information.
Module layout (Frame size R3i pictured)
Item Explanation
1 1 Control panel mounting platform and CDP

312R control panel (optional). Can be
turned aside.
2 DC (input) connections
4
3 Motor (output) connection
4 Slots for optional I/O modules

4
5 I/O terminal blocks on RMIO (obscured)
4
2 3
17
Cabinet layout
Several modules can be installed in one cubicle. The modules can be mounted
vertically, or in a slightly inclined position to save more vertical space. See the
chapter Cabinet construction. Drawings of mounting accessories for both vertical
and inclined mounting, suitable for common cabinet systems, are shown under
Dimension drawings. (The plates for inclined mounting can be ordered from ABB.)
Vertical mounting Inclined mounting
Cool area Hot area

Cool area Hot area
Inverter Inverter
modules modules
Airflow guides
Mounting
plates
Mounting
plates
Air baffle
18
Frame R7i
The frame R7i module has the DC input connection at the top, while the AC
connection is at the bottom. The DC voltage is connected to the input busbars either
through fuses only or through a switch fuse. If a switch fuse is to be used, the
module must be equipped with an internal charging circuit (option code +F272).
The drive control unit (type RDCU) containing the RMIO board is to be installed
separately.
The modules can be ordered with a 230 V (50 Hz) or 115 V AC (60 Hz) cooling fan
depending on the desired auxiliary voltage.
Module layout
Front view with

cooling fan removed
1 Item Explanation
1 DC (input) connections.
5 2 Motor (output) connection.
7
3 Cooling fan.
7 4 Power connection for cooling fan (X41).
5 Fan control terminals (X50).
6 Fibre optic connectors.
7 Prevention of unexpected start connector.

6
4
2
Cabinet layout
See the chapter Cabinet construction.
19
Frame R8i and multiples

Frame R8i modules are used to achieve output powers from approximately 200 kW
upwards in single or parallel configurations. R8i modules run on wheels, and can
easily be removed from the cubicle for cable installation or service.
The DC input is located on the top front part of the module. The DC voltage is
connected to the input busbars either through fuses only or through a switch fuse
with charging control circuitry. Common mode filtering is implemented by running the
DC busbars through ferrite cores (optionally available).
The motor connection is via a quick connector at the back of the module that couples
when the module is inserted into the cubicle. From the connector, the cables can be
run directly through the bottom plate of the cubicle. Each parallel module is cabled
separately to the motor, or connected to a common output cubicle by busbars or
cables of equal length.
The modules are available with either an internally-supplied, speed-controlled fan, or
a fan supplied from an external three-phase (400 V 50 Hz or 320 V 60 Hz) source.
Internal du/dt filters are also available. For information on whether du/dt filtering is
necessary, see the document ACS800 MultiDrive; Planning the Electrical Installation
(3AFE 64783742 [English]). (du/dt filtering must be selected if a common motor
terminal cubicle is used. See the chapter Electrical installation.)
The drive control unit (type RDCU) containing the RMIO board is to be installed
separately.
Reduced run capability
If one of two or more parallel-connected modules fails, the drive can continue to be
run at reduced power using the remaining modules. See page 100 for information on
utilising this feature.
Cooling fan
The cooling fan at the base of the inverter module is usually fed from the auxiliary
voltage supply of the cabinet. A speed-controlled fan is optionally available, involving
an additional power supply board and a fan inverter board that outputs a frequency
in the range of 5 to 55 Hz to the fan. The fan is regulated according to the
temperature of the output stage of the module. Through drive parameters, other
operating modes, such as constant speed, may also be available; see the
appropriate Firmware Manual delivered with the drive.
20
Module layout
8
7
1
3
5
2
Item Explanation
1 DC (input) connections
2 Output busbars. To be aligned with the quick connector socket mounted in the cubicle.
Direct connection of cables without using the quick connector is also possible.
3 Fibre optic connectors of the AINT board. Connected to the RDCU drive control unit (via
an NPBU branching unit in case of parallel inverter modules).
4 Retractable support legs
5 Handle
6 Cooling fan
7, 8 Lifting points
21
Cabinet layout
Inverter modules can be installed side by side. The DC fuses and/or switch fuse are
to be installed above the modules. The control electronics (RDCU control unit, PPCS
branching unit [for parallel modules only], relays and other auxiliary voltage
equipment) are to be installed in a separate cubicle. See examples in the chapter
Cabinet construction.
Using the quick connectors at the motor output enables quick replacement of a
module for maintenance, even though direct connection of cables to the module
output is also possible.
22
Control interfaces
The following diagram shows the control interfaces and I/O options of the inverter
unit.
The front cover of frame R5i has a platform for the CDP 312R control panel; frames
R2i to R4i require an additional platform kit if the panel needs to be mounted on the
module.
For frame R7i to R8i (and multiples), the control panel is to be installed on a door
platform, available as a separate kit.
See the chapter Electrical installation for more information.
*Drive control unit

(RDCU)
CDP 312R Control panel Optional module 1: I/O extension (RAIO,

*Motor control
and related accessories RDIO), pulse encoder interface (RTAC), or
and I/O board
(RMIO) fieldbus adapter (e.g. RMBA, RDNA, RPBA)
Optional module 2: I/O extension (RAIO,

External control via RDIO) or pulse encoder interface (RTAC)
analogue/digital inputs Optional module 3: DDCS communication
and outputs option (RDCO-0x)
*In frame sizes R2i to
The fibre optic channels provided by the
R5i, the RMIO board is
RDCO module can be used for I/O extension
built in the inverter
(using NAIO/NDIO modules), pulse encoder
module instead of a
connection (NTAC module), fieldbus
separate RDCU unit.
connection (Nxxx fieldbus adapter modules),
PC connection (DriveWare® PC tools), or
master/follower connection.
= ~
~
Input power
= To motor
Supply unit Inverter unit
Brake choppers and

resistors (optional)
23
Type code
Each module has a type designation label attached, containing e.g. the type code of
the unit. The type code contains information on the specifications and configuration
of the unit.
• The first 17 digits form the basic code. It describes the basic construction of the
unit. The fields in the basic code are separated with hyphens.
• The option codes follow the basic code. Each option code starts with an
identifying letter (common for the whole product series), followed by descriptive
digits. The option codes are separated by plus signs.
The main selections are described below. Not all options are necessarily available
for all types. For more information, contact your local ABB representative.
Basic code
Digit no. Name/Description Alternatives Description
1…6 Product series ACS800
8…10 Construction 104 Inverter module
12…14 Size 0003 and up 3 kVA and up
16 Voltage rating 3 380/400/415 V. Nominal voltage: 400 V.
5 380/400/415/440/460/480/500 V. Nominal
voltage: 500 V.
7 525/575/600/660/690 V. Nominal voltage: 690 V.
Option codes
Ident. Name/Description Alternatives Description
letter
C +C126 Speed-controlled cooling fan supplied

from the DC bus. Frame R8i only.
E Filters +E205 Internal output (du/dt) filters. Frame R8i

only.
F +F272 Internal charging circuit. To be used with

a DC fuse switch. Frame R7i only.
G Control voltage +G304 115 V AC control voltage. Frame R7i

only.
P Protection class +P901 Coated circuit boards. This feature is

standard.
Q Safety features +Q950 Prevention of unexpected start (built-in

AGPS board).
24
25

This chapter contains instructions for constructing the cabinet for ACS800-104
inverter units.
Also refer to the document ACS800 MultiDrive Modules; Planning the Cabinet
Installation (3AFE64783572 [English]).
26
Frame R2i to R5i
Guiding the cooling air flow

The hot air from an inverter module must not be allowed to enter another module. In
a cubicle with multiple modules, a practical way of achieving this is to install a
mounting plate to separate the cool area (at the front part of the cubicle) from the hot
area (back part). The mounting plate can be fastened to two vertical pillars on both
left and right. Since the air outlet at the top of the modules points directly upwards,
the air must be guided to the hot area. See the example below.
SIDE VIEW
Cool area Hot area
Inverter modules
Airflow guides
Mounting plates
27
To save vertical space, the inverter modules can be mounted by their flanges in an
inclined position as exemplified below.
SIDE VIEW
Cool area Hot area
Inverter modules
Mounting plates
Air baffle
Dimension drawings of the mounting plates are available from ABB by request.
The mounting plates are directly mountable in a 400 mm-wide Rittal TS 8 cabinet
system; the outer dimensions and fastening holes can easily be adapted for another
system.
28
Layout examples
The drawing below is a front view of a cubicle with three R2i modules installed on top
of each other.
DC switch fuse
DC fuses
du/dt filter
Inverter modules
Motor cable entries
29
This drawing is a side view of three R3i modules in a 400 mm-wide cubicle.
DC bus
DC fuse bases
Airflow guides
Inverter modules
Motor cable entries
30
Frame R7i
General
See the chapter Technical data for module-specific cooling requirements.
Cooling
In a typical cabinet construction, the air inlet is at the bottom of the cabinet, while the
outlet is at the top. The inlet may be filtered.
Note: Do not install a filter in the air outlet.
Circulation of air within the cabinet must be prevented. Lateral airflow should be
blocked with an air baffle at the bottom of the module. The mounting parts kits
available for the R7i module include an air baffle (see the chapter ACS800-104
ordering information).
Mounting examples
The following pages contain examples of an R7i module installed on the left and the
right in a 400 mm wide Rittal TS 8 cubicle.
31
LH mounting
32
RH mounting
33
General
See the chapter Technical data for module-specific cooling requirements.
Cooling
In a typical cabinet construction, the air inlet is at the bottom of the cabinet, while the
outlet is at the top, ideally on the roof. The inlet may be filtered.
Note: Do not install a filter in the air outlet.
Circulation of air within the cabinet must be prevented. With R8i inverter modules,
lateral airflow should be blocked with a collar-type air baffle at the top of each
module. Special attention must be paid to covering the gap between the guide at the
top of the module and the side wall of the cubicle.
Module extraction/insertion ramp

The inverter module is to be inserted into and extracted from the cabinet along a
suitable ramp. A dimension drawing of the ramp is available from ABB by request.
Mounting examples
The following pages contain examples of 1, 2 and 3 R8i modules installed into a
Rittal TS 8 cabinet frame. In addition, there is an example of 3 R8i modules installed
side-by-side.
See also the chapter ACS800-104 ordering information.
34
Single R8i module in a Rittal TS 8 cubicle
35
Single R8i module in a Rittal TS 8 cubicle (continued from previous page)
36
37
38
39
Two R8i modules in a Rittal TS 8 cubicle
40
Two R8i modules in a Rittal TS 8 cubicle (continued from previous page)
41
42
43
44
Three R8i modules in a Rittal TS 8 cabinet
45
Three R8i modules in a Rittal TS 8 cabinet (continued from previous page)
46
Three R8i modules in a Rittal TS 8 cabinet (continued from previous page)
47
Three R8i modules side by side
48
Three R8i modules side by side (continued from previous page)
49
Cabinet ventilation (all frame sizes)
General
The following drawings show how the ventilation kits (see the chapter ACS800-104
ordering information) are installed in the cubicle.
50
IP54, 400 mm wide Rittal TS 8 cubicle
51
52
53
54
IP54, 800 mm wide generic cubicle
55
IP42, 800 mm wide generic cubicle
56
Door fan, 400/600 mm wide cubicle
57
Door fans, 800 mm wide cubicle
58
59

This chapter describes the electrical installation procedure of ACS800-104 inverter
modules.
The wiring diagrams in this chapter are simplified presentations. See the chapter
Circuit diagrams for details.
General
WARNING! Make sure that the drive system is disconnected from the mains (input
power) during installation. If the drive system is already connected to the mains, wait
for 5 min after disconnecting mains power. Measure the voltage between the L+ and
L– terminals with a multimeter (impedance at least 1 Mohm) to ensure that the drive
system is discharged before beginning work.
WARNING! Circuit boards contain components sensitive to electrostatic discharge

(ESD). Wear an earthing wrist band when handling the boards. Do not touch the
boards unnecessarily.
60
Notes on Optical Components

Handle fibre optic cables with care. When unplugging optic cables, always grab the
connector, not the cable itself. Do not touch the ends of the fibres with bare hands as
the fibre is extremely sensitive to dirt. The specifications of the optic cable are as
follows:
• Storage temperature: -55 … +85 °C
• Installation temperature: -20 … +70 °C
• Maximum short-term tensile force: 50 N
• Minimum short-term bend radius: 25 mm
• Minimum long-term bend radius: 35 mm
• Maximum long-term tensile load: 1 N
• Flexing: Max. 1000 cycles
ABB drive products in general utilise 5 and 10 MBd (megabaud) optical components
from Agilent Technologies’ (Hewlett-Packard) Versatile Link range. Please note that
the optical component type is not directly related to the actual communication speed.
Note: The optical components (transmitter and receiver) on a fibre optic link must be
of the same type.
Plastic optical fibre (POF) cables can be used with both 5 MBd and 10 MBd optical
components. 10 MBd components also enable the use of Hard Clad Silica (HCS®)
cables, which allow longer connection distances thanks to their lower attenuation.
HCS® cables cannot be used with 5 MBd optical components.
The maximum lengths of fibre optic links for POF and HCS® cables are 20 and 50
metres respectively.
HCS® is a trademark of SpecTran Corporation.
Checking the insulation of the assembly

Every ACS800-104 inverter module has been tested for insulation between the main
circuit and the chassis (2500 V rms 50 Hz for 1 second) at the factory. Therefore, do
not make any voltage tolerance or insulation resistance tests (e.g. hi-pot or megger)
on the inverter units or modules. Check the insulation of the assembly as follows.
WARNING! Check the insulation before connecting the drive to the main supply.
Make sure that the drive is disconnected from the mains (input power).
1. Check that the motor cable is disconnected from the drive output terminals U2,
V2 and W2.
M 2. Measure the insulation resistances of the motor cable and the motor between
ohm each phase and the Protective Earth by using a measuring voltage of 1 kV DC.
PE
The insulation resistance must be higher than 1 Mohm.
61
Power connections – Frame R2i to R5i
Diagram
Inverter module
INPUT OUTPUT
UDC+ UDC- U2 V2 W2
1)
2)
U1 V1 W1
L+ L- 3~
Motor
1) 360 degrees grounding Grounding of the motor cable shield at the motor end
For minimum radio frequency interference:
• ground the cable shield 360 degrees at the lead-through of
the motor terminal box
2) Use a separate grounding cable if the 360 degrees grounding

conductivity of the cable shield is less than 50%
of the conductivity of the phase conductor in a
cable with no symmetrically constructed Conductive gaskets
grounding conductor (see the document
ACS 800 MultiDrive; Planning the Electrical • or ground the cable by twisting the shield as follows:
Installation [3AFE 64783742, English]). flattened width > 1/5 × length.
Note:
If there is a symmetrically constructed grounding
conductor in the motor cable in addition to the b > 1/5 × a
conductive shield, connect the grounding conductor
to the grounding terminal at the drive and motor
b
ends. a
Do not use an asymmetrically constructed motor
cable. Connecting its fourth conductor at the motor
end increases bearing currents and causes extra
wear.
62
Conductor stripping lengths

Strip the conductor ends as follows to fit them inside the power cable connection
terminals.
Stripping length
Frame size
mm in.
R2i, R3i 10 0.4
R4i, R5i 16 0.6
Connection box kit

The inverter module is supplied with a connection box kit containing the following
items:
• back plate
• cover
• 3 clamps
• lug terminals (frame sizes R2i and R3i only)
• screws.
The kit also contains a shroud for covering the relay outputs of the RMIO board.
Cable connection procedure

Refer to the diagram below.
1. Insert the hooks of the connection box back plate to the two corresponding slots
in the bottom plate of the inverter module.
2. Fasten the back plate to the module frame with two screws.
3. Strip off the plastic sheaths of the input (DC) cable (if of shielded type) and motor
cables under the cable clamps. Fasten the clamps onto the stripped part of the
cable.
4. (Frame sizes R2i and R3i) Crimp a lug terminal (supplied in the connection box
kit) onto the twisted shields of the cables.
(All frame sizes) Connect the shields to the grounding terminals.
5. Connect the conductors of the input (DC) cable to the UDC+ and UDC– terminals
and the phase conductors of the motor cable to the U2, V2 and W2 terminals.
6. Secure the cables outside the unit mechanically.
7. Connect the control cables as described in section Control connections.
8. Fasten the cover to the back plate with two screws.
63
Cover
Cable clamps
8
3
3 2
4
Back plate 4 8
Frame R2i to R4i power connections

Frame R3i pictured.
Item No. Information
UDC+ UDC– 1 Connect to PE busbar of cabinet.
2…4 Prevention of unexpected start (optional).

4 3 2 See also the chapter Circuit diagrams.
U2 V2 W2
2 L (95…265 V AC). Voltage must be ON for
the inverter to start.
3 N
1 4 PE
5 Strip off the outer sheathing of the cable at

the clamp.
Input (DC) power Motor cable

cable clamp clamp
64
Frame R5i power connections
Item No. Information
1 Connect to PE busbar of cabinet.
UDC+ UDC– 2…4 Prevention of unexpected start (optional).

See also the chapter Circuit diagrams.
U2 V2 W2
2 L (95…265 V AC). Voltage must be ON
for the inverter to start.
1 3 N
4
2 3 4 PE
5 Strip off the outer sheathing of the cable at

the clamp.
Input (DC) power Motor cable

cable clamp clamp
65
Power connections – Frame R7i
Diagram
Inverter module
INPUT OUTPUT
UDC+ UDC- U2 V2 W2
Cabinet PE
**) *)
V1
U1 W1
3~
Motor
L+ L-
*Use a separate grounding cable if the conductivity Grounding of the motor cable shield at the motor end
of the cable shield is less than 50% of the For minimum radio frequency interference:
conductivity of the phase conductor in a cable with
• ground the cable shield 360 degrees at the lead-through of
no symmetrically constructed grounding conductor
the motor terminal box
(see the document ACS 800 MultiDrive; Planning
the Electrical Installation [3AFE 64783742,
English]).
Note: 360 degrees grounding
If there is a symmetrically constructed grounding
conductor in the motor cable in addition to the
conductive shield, connect the grounding conductor Conductive gaskets
to the grounding terminal at the drive and motor
ends. • or ground the cable by twisting the shield as follows:
flattened width > 1/5 × length.
Do not use an asymmetrically constructed motor
cable. Connecting its fourth conductor at the motor
end increases bearing currents and causes extra
wear. b > 1/5 × a
**The inverter module can be connected to the DC
bus through a switch fuse or through fuses only. b
Using a switch fuse requires internal charging a
control (option code +F272).
66
DC and motor connections
DC input L+ (UDC+) L– (UDC–)
Motor output
U2 V2 W2
Charging circuit
Installing a switch fuse between the inverter module(s) and the DC link necessitates
a charging circuit. Frame R7i modules are optionally available with an internal
charging circuit (option +F272).
67
Common mode filtering

A common mode filter kit is available, consisting of three toroidal cores with the
necessary mounting parts (see the chapter ACS800-104 ordering information). The
drawings below show how the common mode filters are installed.
68
69
Power connections – Frame R8i and multiples

See also the document ACS800 MultiDrive; Planning the Electrical
Installation (3AFE 64783742 [English]).
Wiring diagram
Inverter module
INPUT OUTPUT
UDC+ UDC- U2 V2 W2
Common mode filtering (optional)

PE
V1
U1 W1
PE
ASFC-01C
Switch fuse controller
3~
Motor
L+ L-
DC connection
The DC connection busbars are located at the top of the module. See the
dimensional diagrams for the exact location. Busbar sets for the DC connection with
holders for common mode filter toroids are available, and pictured in the chapter
Cabinet construction.
WARNING! Make sure the M12 screws used for connecting the DC link to the
inverter module do not extend into the module farther than 20 mm.
70
Charging circuit
Installing a switch fuse between the inverter module(s) and the DC link necessitates
a charging circuit. The charging circuit contains two resistors per inverter module
and a switch fuse controller (type ASFC-01C). The resistors and the controller are
included in the switch fuse kits.
The minimum wire sizes to be used in the charging circuit are as follows:
• DC bus to fuses: 2.5 mm2 (AWG 14), double-insulated
• ASFC to ground: 2.5 mm2 (AWG 14)
• From fuses/ASFC to charging resistors: 1.5 mm2 (AWG 14)
• Switch fuse auxiliary contact/solenoid wiring; auxiliary voltage supply to ASFC:
0.75 mm2 (AWG 18).
The ASFC is also to be connected to the AINT board of the inverter module(s) by a
fibre optic link. See section Control connections of the module on page 79.
Motor connection
The motor connection of frame R8i inverter modules is located at the back of the
module so that a quick connector can be used, enabling easy extraction of the
module from the cabinet for maintenance. The chassis socket – available separately
with different mounting parts – is attached to the rear part of the cubicle (see the
examples in the chapter Cabinet construction). The picture below shows a cabling
example.
Chassis socket with

mounting plate
Output busbars
Cable entries
Lower module
guide
71
Direct motor cabling

The diagram below shows the connection of the motor when the inverter unit
consists of one inverter module only.
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
Inverter unit cubicle
If a common motor terminal cubicle is not used, all the inverter modules in a parallel
configuration (2×R8i, 3×R8i, etc.) are to be cabled separately to the motor as shown
in the diagram below.
PE
U2
V2
W2
U1
V1
M
W1 3~
U2 PE
V2
W2
72
WARNING! The cabling from all inverter modules to the motor must be physically
identical considering cable type, cross-sectional area, and length. For example,
“jumpering” the cables from one inverter module to another (and then to the motor) is
not allowed.
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
U2
V2
W2
PE
U2
V2
W2
U1
V1
M
W1 3~
U2 PE
V2
W2
73
Common motor terminal cubicle

Instead of direct cabling from each inverter module to the motor, it is also possible to
build a common motor terminal cubicle.
WARNING! If a common motor terminal cubicle is constructed, the inverter modules

must be equipped with the +E205 option (internal du/dt filters).
Note that the distance from both modules to the common output should be of roughly
equal length.
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
Inverter unit cubicle Common motor terminal

cubicle
74
Control connections
Frame R2i to R5i

These inverter modules have a built-in RMIO (Motor control and I/O) board. For
descriptions of the terminals, see the chapter Motor control and I/O board (RMIO).
Frame R2i to R4i (R3i pictured)
Detachable I/O terminals (pull upwards)

The control cable connection
terminals are exposed when the
RMIO X39 for control
control panel platform (if present) is
panel cable
turned aside by pulling this lever. Be
careful – do not use excess force
when pulling.
Optional module slot 1
I/O cables: Ground the
control cable shields in the
holes with screws. See 360 Optional module slot 2
degrees grounding of I/O
cables on page 74
DDCS communication
option module slot 3:
RDCO
Install shroud
(included) on the relay
4
3
outputs if voltage at the

2
1
terminals exceeds
50 V AC
Prevention of unexpected start

(optional) – see Frame R2i to R4i
power connections on page 63
75
Frame R5i

RMIO X39 for
control panel cable
DDCS communication option
module slot 3: RDCO
Control cable Install shroud (included) on the

grounding: see 360 relay outputs if voltage at the
degrees grounding terminals exceeds 50 V AC
of I/O cables on
page 80
Detachable I/O terminals (pull
upwards)
Prevention of unexpected
start (optional) – see
Frame R5i power
connections on page 64
External +24 V power supply for the RMIO board

The RMIO board of the inverter module can be powered from an external 24 V DC
supply. This is practical if the board needs to be kept live even if the main power to
the drive is off. The 24 V supply can be fed by a UPS if necessary.
Refer to chapter External +24 V power supply for the RMIO board (Frames R2i to
R5i), starting on page 95.
76
Frame R7i
Drive control unit
Inverter units consisting of a frame R7i inverter module employ a separate control
unit, RDCU-02C, containing the RMIO board. For the terminals of the RMIO board,
see the chapter Motor control and I/O board (RMIO). For further information on the
RDCU-02C, see the document RDCU-02(C) Drive Control Unit Hardware Manual
(3AFE 64636324 [English]).
24 V DC power Optional module 1 Optional module 2

input
Optical link to AINT
board of inverter module
RMIO X39 for

control panel
connection
DDCS communication
option module 3: RDCO
LED indicators
Detachable I/O terminals
A fibre optic link is used to connect the RDCU to the AINT board in the inverter
module.
The connections between the control unit and the inverter module are shown in the
chapter Circuit diagrams.
77
Control connections of the module

The fibre optic connectors on the AINT board of the inverter module are accessible
through an opening on the front. The connectors of the AGPS board (units equipped
with the Prevention of unexpected start option) are also accessible through the front
of the module.
The auxiliary voltage for the cooling fan is to be connected to terminal block X42.
The voltage can be wired through terminal block X50 for temperature-based on/off
control.
X50
Terminal no. Information
1 Fan control - AC in.
2 Fan control - AC out.
3 Not connected.
AGPS/X1
1 2 3
AINT/V1
1…3 Prevention of unexpected start (optional).

AINT/V2 See also the chapter Circuit diagrams.
1 PE
2 N
3 L
95…132 V AC (with jumper set to “115V”);
185…265 V AC (with jumper set to “230V”).
Voltage must be ON for the inverter to start.
X42
1…4 Cooling fan power input.

230 V AC (115 V AC with option +G304)
1 L
2 N
3 Not connected.
4 PE
78

Drive control unit
Inverter units consisting of frame R8i inverter modules employ a separate control
unit, RDCU-02C, containing the RMIO board. For the terminals of the RMIO board,
see the chapter Motor control and I/O board (RMIO). For further information on the
RDCU-02C, see the document RDCU-02(C) Drive Control Unit Hardware Manual
(3AFE 64636324 [English]).
24 V DC power Optional module 1 Optional module 2

input
Optical link to AINT/NINT
board of inverter module
(or branching unit)
RMIO X39 for

control panel
connection
DDCS communication
option module 3: RDCO
LED indicators
Detachable I/O terminals
A fibre optic link is used to connect the RDCU to the AINT board in the inverter
module. In case of parallel-connected inverter modules, a PPCS branching unit (type
NPBU or APBU) distributes the optical control link to all the modules.
The switch fuse controller board (ASFC), used in conjunction with R8i modules, also
connects to the AINT board of each inverter module through a fibre optic link.
The connections between the control unit, branching unit (if present), switch fuse
controller and the inverter module are shown in the chapter Circuit diagrams.
79
Control connections of the module

The fibre optic connectors (for connections to both the RDCU and the ASFC boards)
on the AINT board of the inverter module are accessible through an opening on the
front.
Optical cable
routing
Access to fibre
optic connectors
of AINT board
If the inverter module is equipped with the Prevention of unexpected start option
(+Q950), or not equipped with a speed-controlled fan (option +C126), the necessary
connections are made via a detachable terminal block (X50). The counterpart –
included in the delivery – can be installed near the top of the module. In the picture
below, the terminal block is installed on the mounting plate on the upper guide of the
module.
DC busbars
Terminal block
X50
Inverter module
80
360 degrees grounding of I/O cables
Insulation
4
3
2
1
Double shielded cable Single shielded cable
When the outer surface of the shield is covered with non-conductive material
• Strip the cable carefully (do not cut the grounding wire and the shield)
• Turn the shield inside out to expose the conductive surface.
• Wrap the grounding wire around the conductive surface.
• Slide a conductive clamp onto the conductive part.
• Fasten the clamp to the grounding plate with a screw as close as possible to the
terminals where the wires are about to be connected.
Connecting the shield wires

Single shielded cables: Twist the grounding wires of the outer shield and connect
them through the shortest possible route to the nearest grounding hole with a cable
lug and a screw. Double shielded cables: Connect each pair cable shield (twisted
grounding wires) with other pair cable shields of the same cable to the nearest
grounding hole with a cable lug and a screw.
Do not connect shields of different cables to the same cable lug and grounding
screw.
Leave the other end of the shield unconnected or ground it indirectly via a few
nanofarads high-frequency capacitor (e.g. 3.3 nF / 630 V). The shield can also be
grounded directly at both ends if they are in the same ground line with no significant
voltage drop between the end points.
Keep the signal wire pairs twisted as close to the terminals as possible. Twisting the
wire with its return wire reduces disturbances caused by inductive coupling.
81
Cabling of I/O and fieldbus modules
Module
Keep as short as
possible
Shield
4
3
2
1
Note: The RDIO module does not

include a terminal for cable shield
grounding. Ground the pair cable
shields here.
Pulse encoder module cabling
As short as
possible
Note 1: If the encoder is of
1
2 unisolated type, ground the encoder
3
4 cable at the drive end only. If the
encoder is galvanically isolated
from the motor shaft and the stator
frame, ground the encoder cable
Shield
shield at the drive and the encoder

RTAC end.
Note 2: Twist the pair cable wires.
Wrap copper tape around the

stripped part of the cable under the
clamp. Be careful not to cut the
grounding wire. Clamp as close to
the terminals as possible.
82
Installation of optional modules and PC

Optional modules (such as fieldbus adapters, I/O extension modules and the pulse
encoder interface) are inserted in the optional module slot of the RMIO board and
fixed with two screws. See the appropriate optional module manual for cable
connections.
Fibre optic links

DDCS fibre optic links are provided by the RDCO module (optional) for PC tools,
master/follower link, NDIO, NTAC, NAIO and fieldbus adapter modules of type Nxxx.
See RDCO User’s Manual for the connections. Observe colour coding when
installing fibre optic cables: blue connectors go to blue terminals, and grey
connectors to grey terminals.
When installing multiple devices on the same channel, connect them in a ring.
83
Installation of NLMD-01 LED Monitoring Display
64152955
84
Wiring
Control panel with monitoring display
X3
Monitoring Display NLMD-01
X4
Control Panel CDP 312R
X1 X4
X1 X3
Panel Interface ADPI-01 RMIO
X2 X39
X5
Monitoring display only
RMIO
X3 X39
NLMD-01
X4
85
Earthing
Each NLMD-01 board is to be individually earthed. The earthing wires are included
in the control panel platform and LED display kits.
NLMD-01
DIN 7981 F 3,5×6,5
TORX, St/Zn
NLMD-01
NLMD-01
X3
ADPI-01
X2
X5
86
87

This chapter shows
• external control connections to the RMIO board for the the ACS 800 Standard
Application Program (Factory Macro)
• specifications of the inputs and outputs of the board.
To which products this chapter applies

This chapter applies to ACS800 units which employ the RMIO-01 board (revision J
or later) or the RMIO-02 board (revision H or later).
Note on cabinet-installed ACS800 drives

The terminals of the RMIO board are optionally wired to terminal block X2. The
connections shown below apply also to terminal block X2 (the markings are identical
to the ones on the RMIO board).
Terminals of X2 accept cables from 0.5 to 4.0 mm2 (22 to 12 AWG). The tightening
torque for screw terminals is 0.4 to 0.8 Nm (0.3 to 0.6 lbf.ft). For disconnecting wires
from spring terminals, use a screwdriver with a blade thickness of 0.6 mm (0.024”)
and width of 3.5 mm (0.138”), e.g. Phoenix Contact SZF 1-0,6X3,5.
Note on terminal labelling

Optional modules (type Rxxx) may have terminal designations that coincide with
those on the RMIO board.

88
External control connections (non-US)

External control cable connections to the RMIO board for the ACS 800 Standard
Application Program (Factory Macro) are shown below. For external control
connections of other application macros and programs, see the appropriate
Firmware Manual.
X20
Terminal block size: 1 VREF- Reference voltage -10 VDC, 1 kohm < RL <
cables 0.3 to 3.3 mm2 (22 to 12 AWG) 2 AGND 10 kohm
Tightening torque: X21
0.2 to 0.4 Nm (0.2 to 0.3 lbf ft) 1 VREF+ Reference voltage 10 VDC, 1 kohm < RL <
2 AGND 10 kohm
3 AI1+ Speed reference 0(2) ... 10 V, Rin >
4 AI1- 200 kohm
5 AI2+ By default, not in use. 0(4) ... 20 mA, Rin =
6 AI2- 100 ohm
8 AI3- 100 ohm
rpm 9 AO1+ Motor speed 0(4)...20 mA = 0...motor nom.
A 11 AO2+ Output current 0(4)...20 mA = 0...motor
X22
1 DI1 Stop/Start
1) Only effective if par. 10.03 is set to 2 DI2 Forward/Reverse 1)
REQUEST by the user. 3 DI3 Not in use
2)
0 = open, 1 = closed 5 DI5 Constant speed select 3)
DI4 Ramp times according to 6 DI6 Constant speed select 3)
0 parameters 22.02 and 22.03 7 +24VD +24 VDC max. 100 mA
1 parameters 22.04 and 22.05 8 +24VD
3)
See par. group 12 CONSTANT
SPEEDS.
11 DIIL Start interlock (0 = stop) 4)
DI5 DI6 Operation
0 0 Set speed through AI1
X23
1 0 Constant speed 1 1 +24V Auxiliary voltage output/input, non-isolated,
0 1 Constant speed 2 2 GND 24 VDC 250 mA 5)
1 1 Constant speed 3 X25
1 RO1 Relay output 1: ready
4) See parameter 21.09 START INTRL 2 RO1
FUNC. 3 RO1
5) Total maximum current shared
X26
between this output and optional
modules installed on the board. 1 RO2 Relay output 2: running
2 RO2
3 RO2
X27
1 RO3 Relay output 3: fault (-1)
Fault 2 RO3
3 RO3

89
External control connections (US)

External control cable connections to the RMIO board for the ACS 800 Standard
Application Program (Factory Macro US version) are shown below. For external
control connections of other application macros and programs, see the appropriate
Firmware Manual.
X20
Terminal block size: 1 VREF- Reference voltage -10 VDC, 1 kohm < RL <
cables 0.3 to 3.3 mm2 (22 to 12 AWG) 2 AGND 10 kohm
Tightening torque: X21
0.2 to 0.4 Nm (0.2 to 0.3 lbf ft) 1 VREF+ Reference voltage 10 VDC, 1 kohm < RL <
2 AGND 10 kohm
3 AI1+ Speed reference 0(2) ... 10 V, Rin >
4 AI1- 200 kohm
6 AI2- 100 ohm
8 AI3- 100 ohm
rpm 9 AO1+ Motor speed 0(4)...20 mA = 0...motor nom.
A 11 AO2+ Output current 0(4)...20 mA = 0...motor
X22
1 DI1 Start ( )
1) Only effective if par. 10.03 is set to 2 DI2 Stop ( )
REQUEST by the user. 3 DI3 Forward/Reverse 1)
2)
0 = open, 1 = closed 5 DI5 Constant speed select 3)
DI4 Ramp times according to 6 DI6 Constant speed select 3)
0 parameters 22.02 and 22.03 7 +24VD +24 VDC max. 100 mA
1 parameters 22.04 and 22.05 8 +24VD
3) See par. group 12 CONSTANT
SPEEDS.
11 DIIL Start interlock (0 = stop) 4)
DI5 DI6 Operation
0 0 Set speed through AI1
X23
1 0 Constant speed 1 1 +24V Auxiliary voltage output/input, non-isolated,
0 1 Constant speed 2 2 GND 24 VDC 250 mA 5)
1 1 Constant speed 3 X25
1 RO1 Relay output 1: ready
4) See parameter 21.09 START INTRL 2 RO1
FUNC. 3 RO1
5) Total maximum current shared
X26
between this output and optional
modules installed on the board. 1 RO2 Relay output 2: running
2 RO2
3 RO2
X27
1 RO3 Relay output 3: fault (-1)
Fault 2 RO3
3 RO3

90
RMIO board specifications

Analogue inputs
With Standard Application Program two programmable differential current inputs
(0 mA / 4 mA ... 20 mA, Rin = 100 ohm) and one programmable differential voltage
input (-10 V / 0 V / 2 V ... +10 V, Rin > 200 kohm).
The analogue inputs are galvanically isolated as a group.
Isolation test voltage 500 VAC, 1 min
Max. common mode voltage ±15 VDC
between the channels
Common mode rejection ratio > 60 dB at 50 Hz
Resolution 0.025 % (12 bit) for the -10 V ... +10 V input. 0.5 % (11 bit) for the 0 ... +10 V and 0 ...
20 mA inputs.
Inaccuracy ± 0.5 % (Full Scale Range) at 25 °C (77 °F). Temperature coefficient: ± 100 ppm/°C
(± 56 ppm/°F), max.
Constant voltage output

Voltage +10 VDC, 0, -10 VDC ± 0.5 % (Full Scale Range) at 25 °C (77 °F). Temperature
coefficient: ± 100 ppm/°C (± 56 ppm/°F) max.
Maximum load 10 mA
Applicable potentiometer 1 kohm to 10 kohm
Auxiliary power output

Voltage 24 VDC ± 10 %, short circuit proof
Maximum current 250 mA (shared between this output and optional modules installed on the RMIO)
Analogue outputs
Two programmable current outputs: 0 (4) to 20 mA, RL < 700 ohm
Resolution 0.1 % (10 bit)
Inaccuracy ± 1 % (Full Scale Range) at 25 °C (77 °F). Temperature coefficient: ± 200 ppm/°C
(± 111 ppm/°F) max.
Digital inputs
With Standard Application Program six programmable digital inputs (common ground:
24 VDC, -15 % to +20 %) and a start interlock input. Group isolated, can be divided in
two isolated groups (see Isolation and grounding diagram below).
Thermistor input: 5 mA, < 1.5 kohm “1” (normal temperature), > 4 kohm “0”
(high temperature), open circuit “0” (high temperature).
Internal supply for digital inputs (+24 VDC): short circuit proof. An external 24 VDC
supply can be used instead of the internal supply.
Isolation test voltage 500 VAC, 1 min
Logical thresholds < 8 VDC “0”, > 12 VDC “1”
Input current DI1 to DI 5: 10 mA, DI6: 5 mA
Filtering time constant 1 ms

91
Relay outputs
Three programmable relay outputs
Switching capacity 8 A at 24 VDC or 250 VAC, 0.4 A at 120 VDC
Minimum continuous current 5 mA rms at 24 VDC
Maximum continuous current 2 A rms
Isolation test voltage 4 kVAC, 1 minute
DDCS fibre optic link

With optional communication adapter module RDCO. Protocol: DDCS (ABB
Distributed Drives Communication System)
24 VDC power input
Voltage 24 VDC ± 10%
Typical current consumption 250 mA
(without optional modules)
Maximum current consumption 1200 mA (with optional modules inserted)
The terminals on the RMIO board as well as on the optional modules attachable to the board fulfil the Protective Extra
Low Voltage (PELV) requirements stated in EN 50178 provided that the external circuits connected to the terminals also
fulfil the requirements, and that the installation site is below 2000 m (6562 ft) in altitude.

92
Isolation and grounding diagram
(Test voltage: 500 V AC)

X20
1 VREF-
2 AGND
X21
1 VREF+
2 AGND
3 AI1+
4 AI1- Common mode
voltage between
5 AI2+
channels ±15 V
6 AI2-
7 AI3+
8 AI3-
9 AO1+
10 AO1-
11 AO2+
12 AO2-
X22
1 DI1
2 DI2
3 DI3
4 DI4
Jumper J1 settings:
9 DGND1
5 DI5 All digital inputs share a common

J1
6 DI6 ground. This is the default setting.
7 +24VD
8 +24VD Grounds of input groups
11 DIIL DI1…DI4 and DI5/DI6/DIIL
or
are separate (isolation
10 DGND2 voltage 50 V).
X23
1 +24 V
2 GND
X25
1 RO1
2 RO1
3 RO1
X26
1 RO2
2 RO2
3 RO2
X27
1 RO3
2 RO3
3 RO3
(Test voltage:
4 kV AC)
Ground

93
Checklist
Check the mechanical and electrical installation of the drive before start-up. Go
through the checklist below together with another person.
Check that…
MECHANICAL INSTALLATION
The ambient operating conditions are allowed. (See Technical data.)
The unit is properly fastened on a non-flammable base. (See Cabinet construction, and
separate document ACS800 MultiDrive Modules; Planning the Cabinet Installation
[3AFE 64783531, English])
The cooling air is able to flow freely.
The motor and the driven equipment are ready for start. (See Technical data: Motor
connection, and separate document ACS800 MultiDrive; Planning the Electrical Installation
[3AFE 64783742, English])
ELECTRICAL INSTALLATION (See Electrical installation, and separate document ACS800
MultiDrive Modules; Planning the Cabinet Installation [3AFE 64783531, English])
The capacitors are reformed if stored over one year (refer to ACS 600/800 Capacitor
Reforming Guide [64059629, English]).
The module is grounded properly.
The input voltage matches the nominal input voltage of the module.
The power connections at UDC+ and UDC– and their tightening torques are OK.
Appropriate DC fuses are installed.
The motor connections at U2, V2 and W2 and their tightening torques are OK.
The RDCU control unit is loaded with the appropriate application program (see the label on
the unit).
R7i and R8i modules with Prevention of unexpected start option only: The voltage selection
jumper on the AGPS board is correctly set (230 or 115 V).
Inverter units with parallel-connected modules and an APBU branching unit only: Memory
backup battery is enabled on the APBU (actuator 6 of switch S3 is ON).
The motor cable is routed away from other cables.
There are no power factor compensation capacitors in the motor cable.
The external control connections to the inverter unit are OK.
94
Check that…
There are no tools, foreign objects or dust from drilling inside the module or cubicle.
All shrouds and covers are in place.
The Prevention of unexpected start circuit is completed (See Electrical installation).
95
External +24 V power supply for the RMIO board

(Frames R2i to R5i)

This chapter describes how to connect external +24 V power supply for the RMIO
board.
When to use
External +24 V power supply for the RMIO board is recommended if
• the application requires fast start after connecting the input power supply
• fieldbus communication is required when the input power supply is disconnected.
For current consumption of the RMIO board, see the chapter Motor Control and I/O
Board (RMIO).
Parameter settings
In Standard Application Program, set parameter 16.09 CTRL BOARD SUPPLY to
EXTERNAL 24V if the RMIO board is powered from an external supply.
96
Connecting +24 V external power supply

1. Break off the tab covering the +24 VDC power input connector with pliers.
2. Lift the connector upwards.
3. Disconnect the wires from the connector (keep the connector for later use).
4. Isolate the ends of the wires individually with insulating tape.
5. Cover the isolated ends of the wires with insulating tape.
6. Push the wires inside the skeleton.
7. Connect the wires of the +24 V external power supply to the disconnected
connector: + wire to terminal 1 and - wire to terminal 2.
8. Plug the connector in.
Frame sizes R2i to R4i Frame size R5i
4
4
3
97
6 7
5
98
99
Maintenance

This chapter contains preventive maintenance instructions, and a description of the
LEDs of the drive.
Safety instructions
Only a qualified electrician is allowed to perform the maintenance.
Before starting work on the drive system,
• isolate the drive system from the main supply
• open the switch-disconnectors and lock them out in the open position
• switch off any voltages connected to the I/O terminals
• wait for 5 minutes to let the intermediate circuit capacitors discharge
• ensure there is no dangerous voltage present by measuring the voltage on the
input, I/O and intermediate circuit terminals.
Inverter module replacement
WARNING! When replacing an inverter module, make sure the replacement module
has exactly the same type code (see the type designation label) as the old module. If
it does not, consult ABB for more information.
Maintenance
100
Maintenance intervals
This table lists the routine maintenance intervals recommended by ABB.
Capacitor reforming Every year when stored See Capacitor reforming.
Depending on the dustiness of

Heatsink temperature check
the environment, every 6 to 12 See Heatsinks.
and cleaning
months
Cabinet air filter check; See Checking and replacing

Every year
replacement if necessary the air filters.
Frame R4i and R5i inverter

modules: Change of Every 3 years See Cooling fans.
additional cooling fan
Frame R8i inverter modules:

Check and cleaning of power Every 3 years See Power connections (R8i).
connections
Main cooling fan change Every 6 years See Cooling fans.
Units with parallel- Locate the APBU unit. Switch

connected inverter off the power to the unit.
modules: APBU branching Every 6 years Remove cover. Replace
unit – Memory backup battery battery with a new CR 2032
renewal battery.
Frame R4i and larger

inverter modules: capacitor Every 10 years See Capacitors.
renewal
Reduced run capability
Note: This section applies to drives equipped with the APBU branching unit only.
If one of the parallel-connected inverter modules of an inverter unit must be taken

out of the cabinet for service, it is possible to continue operation at reduced power
using the remaining modules. Follow the steps below.
1. Read and repeat the steps in the safety instructions above.
2. Extract the module to be serviced from the cabinet.
3. Block the airflow through the empty module bay with an air baffle made of sheet
metal.
Maintenance
101
4. Units with DC switch fuses only: On the ASFC switch fuse controller, set the fibre
optic link to the absent module to “disabled” using the appropriate switch (S1, S2
or S3).
Fibre optic links to 1 to 3 inverter modules
5. Make the necessary parameter adjustments in the drive firmware. Refer to the
appropriate Firmware Manual.
6. Reconnect the module after service in reverse order.
Checking and replacing the air filters

Before replacing the air filters of the cabinet, read and repeat the steps in the safety
instructions above.
Heatsinks
Heatsink fins pick up dust from the cooling air. Inverter modules run into
overtemperature warnings and faults if the heatsink is not clean. In a “normal”
environment (not dusty, not clean) the heatsink should be checked annually, in a
dusty environment more often.
Clean the heatsink as follows (when necessary):
1. Remove the cooling fan as described in Cooling fans elsewhere in this chapter.
2. Blow clean, dry compressed air from bottom to top and simultaneously use a
vacuum cleaner at the air outlet to trap the dust. Note: Prevent the dust from
entering adjoining equipment.
3. Refit the cooling fan.
Maintenance
102
Cooling fans
The cooling fan lifespan is about 50 000 operating hours. The actual lifespan
depends on the drive usage and ambient temperature. See the appropriate ACS 800
firmware manual for an actual signal which indicates the hours of usage of the fan.
Fan failure can be predicted by the increasing noise from fan bearings and the
gradual rise in the heatsink temperature in spite of heatsink cleaning. If the drive is
operated in a critical part of a process, fan replacement is recommended once these
symptoms start appearing. Replacement fans are available from ABB. Do not use
other than ABB-specified spare parts.
Fan replacement (R2i, R3i)

To remove the fan, release the retaining clips. Disconnect the cable. Install the fan in
reverse order.
Bottom view
Fan replacement (R4i)

1. Loosen the screws that fasten the fan mounting plate to the frame.
2. Shift the fan mounting plate to the left and pull the fan assembly out.
3. Disconnect the fan power cable.
4. Undo the screws that fasten the fan to the fan mounting plate.
5. Install the new fan in reverse order.
2 2
1 1 4 4
4 4
Maintenance
103

To remove the fan, undo the fixing screws. Disconnect the cable. Install the fan in
reverse order.
Bottom view
Additional fan
Types -0004-2, 0005-2, -0011-2 to -0020-2, -0006-3, -0009-3, -0020-3 to -0030-3,
-0009-5, 0011-5, -0025-5 to -0040-5 have an additional fan.
Replacement (R2i, R3i)
Remove the front cover. To remove the fan, release the retaining clip (1). Disconnect
the cable (2, detachable terminal). Install the fan in reverse order.
Top view
1
2
Replacement (R4i, R5i)

Remove the front cover. The fan is located on the lower right-hand side of the unit
(R4) or on the right-hand side of the control panel (R5). Lift the fan out and
disconnect the cable. Install the fan in reverse order.
Maintenance
104

1. Disconnect the wire plug.
2. Remove the two screws holding the fan unit.
3. To free the fan, pull it slightly outwards, then downwards.
4. Install new fan in reverse order.
Maintenance
105

2. Open the inverter cubicle doors.
3. Disconnect the fan wiring plug (1).
4. Remove the locking screws (2).
5. Pull the fan out along its sliding rails (3).
6. Install a new fan in reverse order.
Maintenance
106
Power connections (R8i)

2. Open the cabinet doors.
3. Extract one inverter module from the cabinet.
4. Check the tightness of the cable connections at the quick connector. Use the
tightening torque table in Technical data.
5. Clean all contact surfaces of the quick connector and apply a layer of suitable
joint compound (e.g. Isoflex® Topas NB 52 from Klüber Lubrication) onto them.
6. Re-insert the inverter module.
7. Repeat steps 3 to 6 for all remaining R8i inverter modules.
Capacitors
The drive intermediate circuit employs several electrolytic capacitors. Their lifespan
is from 45 000 to 90 000 hours depending on drive loading and ambient
temperature. Capacitor life can be prolonged by lowering the ambient temperature.
It is not possible to predict a capacitor failure. Capacitor failure is usually followed by
a mains fuse failure or a fault trip. Contact ABB if capacitor failure is suspected.
Replacements are available from ABB. Do not use other than ABB-specified spare
parts.
Capacitor reforming
Reform (re-age) spare part capacitors once a year according to ACS 600/800
Capacitor Reforming Guide (code: 64059629).
LEDs
This table describes LEDs of the drive.
Where LED When the LED is lit
RMIO board (not visible in frame Red The drive is in fault state
sizes R2i to R5i)
Green The power supply on the board is OK.
Control panel mounting platform Red The drive is in fault state
Green The main +24 V power supply for the control panel and the
RMIO board is OK.
APBU board TXD (Yellow) Data is being sent by the APBU to the drive control unit.
RXD (Yellow) Data is being received by the APBU from the drive control unit.
PWR (Green) APBU logic voltage is OK.
BAT (Green) The memory backup battery is OK. The LED is off if the battery
is disabled.
Maintenance
107

This chapter lists the components and accessories specific to the ACS800-104
inverter module range.
See the ACS800 Product Reference (3AFE 64813340 [English]) for generic
equipment for the ACS800 product family such as control panels, I/O options,
application programs and PC tools.
Inverter modules
The following tables list the ACS800-104 inverter modules available.
Notes:
• The application program for the modules must be specified when ordering
• Control panel (CDP 312R) is not included
• Frame R7i modules are delivered with either a 115 or 230 V AC cooling fan
• The modules have coated circuit boards as standard equipment.
Frame sizes R2i to R5i

Option key:
+Q950: Prevention of unexpected start (for more information, see the document
ACS800 MultiDrive; Planning the Electrical Installation [3AFE 64783742, English]).
Inverter modules (R2i to R5i)

Pcont.max Order code
ACS800-104 type Frame size
(kW) (no options) +Q950
UN = 400 V (380/400/415 V)
ACS800-104-0003-3 R2i 1.5 64685724 64741730
ACS800-104-0004-3 R2i 2.2 64704338 64751972
ACS800-104-0005-3 R2i 3 64704346 64751999
ACS800-104-0006-3 R2i 4 64704354 64752162
ACS800-104-0009-3 R2i 5.5 64704362 64752243
ACS800-104-0011-3 R3i 7.5 64702262 64752464
ACS800-104-0016-3 R3i 11 64704478 64752529
ACS800-104-0020-3 R3i 15 64704486 64752723
ACS800-104-0025-3 R4i 22 64702271 64752812
ACS800-104-0030-3 R4i 30 64704524 64752855
ACS800-104-0040-3 R5i 37 64702246 64759833
ACS800-104-0050-3 R5i 45 64702254 64759922
ACS800-104-0060-3 R5i 55 64704320 64759965
UN = 500 V (380/400/415/440/460/480/500 V)
ACS800-104-0004-5 R2i 2.2 64704419 64752065
ACS800-104-0005-5 R2i 3 64704427 64752111

108
Inverter modules (R2i to R5i)

Pcont.max Order code
ACS800-104 type Frame size
(kW) (no options) +Q950
ACS800-104-0006-5 R2i 4 64704435 64752146
ACS800-104-0009-5 R2i 5.5 64704443 64752201
ACS800-104-0011-5 R2i 7.5 64704451 64752278
ACS800-104-0016-5 R3i 11 64704494 64752626
ACS800-104-0020-5 R3i 15 64704508 64752707
ACS800-104-0025-5 R3i 18.5 64704516 64752758
ACS800-104-0030-5 R4i 22 64704532 64752839
ACS800-104-0040-5 R4i 30 64704541 64752863
ACS800-104-0050-5 R5i 37 64704567 64759990
ACS800-104-0060-5 R5i 45 64704583 64760033
ACS800-104-0070-5 R5i 55 64704591 64760041
UN = 690 V (525/575/600/660/690 V)
ACS800-104-0011-7 R4i 11 64771116 64772473
ACS800-104-0016-7 R4i 15 64772074 64772481
ACS800-104-0020-7 R4i 18.5 64772082 64772490
ACS800-104-0025-7 R4i 22 64772091 64772503
ACS800-104-0030-7 R4i 30 64772104 64772511
ACS800-104-0040-7 R4i 30 64772171 64772520
ACS800-104-0050-7 R5i 45 64772325 64772538
ACS800-104-0060-7 R5i 55 64772376 64772546
PDM-256538

109
Frame size R7i

Option key:
+F272: Internal charging circuit. To be selected if the inverter module is connected to
the DC bus through a switching component such as a switch fuse.
+G304: Auxiliary voltage is 115 V AC (instead of 230 V AC).
+Q950: Prevention of unexpected start (for more information, see the document
ACS800 MultiDrive; Planning the Electrical Installation [3AFE 64783742, English]).
Inverter modules (R7i)

Order code
+F272
ACS800-104 type (no +F272 +F272 +G304
+F272 +G304 +Q950 +G304
options) +G304 +Q950 +Q950
+Q950
UN = 400 V (380/400/415 V)
ACS800-104-0105-3 68445396 68446368 68499224 68500257 68499411 68446589 68500729 68499623
ACS800-104-0125-3 68445400 68446384 68499232 68500290 68499437 68446597 68500737 68499631
ACS800-104-0145-3 68445418 68446392 68499241 68500338 68499453 68446601 68500745 68499640
ACS800-104-0175-3 68445426 68446406 68499259 68500346 68499470 68446619 68500753 68499658
UN = 500 V (380/400/415/440/460/480/500 V)
ACS800-104-0105-5 68445434 68446414 68499275 68500362 68499488 68446627 68500770 68499666
ACS800-104-0125-5 68445442 68446422 68499283 68500435 68499518 68446643 68500800 68499674
ACS800-104-0145-5 68445469 68446449 68499291 68500460 68499526 68446651 68500818 68499682
ACS800-104-0175-5 68445477 68446457 68499305 68500516 68499534 68446660 68500842 68499691
ACS800-104-0215-5 68445485 68446465 68499313 68500567 68499542 68446678 68500851 68499704
UN = 690 V (525/575/600/660/690 V)
ACS800-104-0075-7 68446295 68446473 68499321 68500583 68499551 68446686 68500869 68499712
ACS800-104-0105-7 68446309 68446481 68499330 68500672 68499577 68446694 68500877 68499721
ACS800-104-0125-7 68446317 68446490 68499348 68500681 68499585 68446708 68500885 68499739
ACS800-104-0145-7 68446325 68446511 68499364 68500699 68499593 68446716 68500893 68499747
ACS800-104-0175-7 68446333 68446538 68499381 68500702 68499607 68446724 68500907 68499755
ACS800-104-0215-7 68446341 68446546 68499399 68500711 68499615 68446732 68500923 68499763

110
Frame size R8i and multiples

Multiple R8i inverter modules can be connected in parallel to produce higher output
powers. The table below shows the quantity and order code of inverter modules
required for each inverter unit.
Option key:
+C126: Speed-controlled cooling fan supplied from the DC bus
+E205: du/dt filtering (required for 690 V modules, and parallel-connected modules)
+Q950: Prevention of unexpected start (factory-installed in parallel-connected
modules) (for more information, see the document ACS800 MultiDrive; Planning the
Electrical Installation [3AFE 64783742, English]).
Inverter modules (R8i and multiples)

Inverter unit Consists of
Order code
type modules of type…
+C126
(no +C126 +C126 +E205
ACS800-104… Qty +C126 +E205 +Q950 +E205 Qty ACS800-104-…
options) +E205 +Q950 +Q950
+Q950
UN = 400 V
0210-3 1 68262208 68260914 68262356 68262291 68260957 68260931 68262526 68260973 1 0210-3
0260-3 1 68262224 68259231 68262364 68262305 68259746 68259762 68262551 68259754 1 0260-3
0320-3 1 68262232 64766058 68262411 68262313 64766121 64766139 68262577 64766031 1 0320-3
0390-3 1 64694383 64793969 64694367 64694375 64793985 64794001 64694332 64793993 1 0390-3
0510-3 1 64694324 64794019 64694294 64694308 64792580 64794051 64694286 64792598 1 0510-3
0770-3 1 – – – – – – 68259410 68259436 2 0390-3
1030-3 1 – – – – – – 68259461 68259487 2 0510-3
1540-3 1 – – – – – – 68259941 68259975 3 0510-3
2050-3 1 – – – – – – 68260027 68260051 4 0510-3
UN = 500 V
0260-5 1 68263565 68260990 68263697 68263620 68261031 68261015 68263760 68261066 1 0260-5
0320-5 1 68263581 68259258 68263719 68263638 68259703 68259738 68263816 68259720 1 0320-5
0400-5 1 68263590 64766252 68263727 68263646 64766244 64766236 68263824 64766201 1 0400-5
0460-5 1 64694197 64794124 64650289 64694189 64794159 64794183 64650297 64794167 1 0460-5
0610-5 1 64694162 64794191 64650301 64694154 64794205 64794221 64650319 64794213 1 0610-5
0910-5 1 – – – – – – 68260116 68260132 2 0460-5
1210-5 1 – – – – – – 68260574 68260591 2 0610-5
1820-5 1 – – – – – – 68260612 68260647 3 0610-5
2430-5 1 – – – – – – 68260655 68260671 4 0610-5
UN = 690 V
0260-7 1 – – 68263859 – 68259665 – 68263930 68259681 1 0260-7
0320-7 1 – – 68263875 – 68261082 – 68263956 68261104 1 0320-7
0400-7 1 – – 68263883 – 64766406 – 68263972 64766309 1 0400-7
0440-7 1 – – 64650327 – 64793918 – 64650335 64793926 1 0440-7
0580-7 1 – – 64650343 – 64792571 – 64650351 64794086 1 0580-7
0870-7 1 – – – – – – 68260728 68261155 2 0440-7
1160-7 1 – – – – – – 68261163 68261198 2 0580-7
1740-7 1 – – – – – – 68261201 68261210 3 0580-7
2320-7 1 – – – – – – 68261228 68261236 4 0580-7

111
DC fuses and fuse bases; DC switch fuses

The inverter unit can be connected to the DC bus through either fuses only or a
switch fuse. See the chapter Circuit diagrams.
Fitting a switch fuse enables the isolation and reconnection of an inverter module
even when the DC bus is energised. On the other hand, an external circuit is
required for controlled charging of the capacitor bank of the module when the switch
fuse is closed. For frame R2i to R7i inverter modules, only the DC fuses are required
in addition to the switch fuse kit since the modules contain an internal charging
circuit (standard for R2i to R5i, option +G304 for R7i). Frame R8i (and multiples)
inverter units require the switch fuse kit, DC fuses, and fuses for the charging circuit.
The tables below specify the DC fuses, DC fuse bases, switch fuse parts, and
charging circuit fuses for the ACS800-104 inverter units.
DC fuses and fuse bases/Switch fuse parts for inverter modules

Module type
DC fuse DC fuse base Switch fuse parts
ACS800-104-…
Order Order
Qty Type Info Qty Type Info Qty Order code(s)
400 V 500 V 690 V code code
0003-3 0004-5
0004-3 0005-5
170M 25A 160A
0005-3 0006-5 2 10028566 2 SB00-D 68569613 1 64089650*
1561 660V 690V
0006-3 0009-5
0009-3 0011-5
0011-3 0016-5 170M 50A 160A
2 09838767 2 SB00-D 68569613 1 64089650*
0016-3 0020-5 1564 660V 690V
0020-3 0025-5 170M 80A 160A
2 09838791 2 SB00-D 68569613 1 64089650*
0025-3 0030-5 1566 660V 690V
0030-3 0040-5
170M 160A 160A
0040-3 0050-5 2 10003521 2 SB00-D 68569613 1 64089650*
1569 660V 690V
0050-3 0060-5
170M 200A 160A
0060-3 0070-5 2 10003539 2 SB00-D 68569613 1 64089650*
1570 660V 690V
170M 200A 160A 1 64285165 (Switch fuse OS160D02)
0105-5 2 10003539 2 SB00-D 68569613
1570 660V 690V 1 64078488 (Aux. contacts OA1G 10)
0105-3 0125-5 170M 350A 250A 1 68474515 (Switch fuse OS250D02P)
0125-3 0145-5 2 10028582 2 SB1-D 68569656
170M 400A 250A 1 68474515 (Switch fuse OS250D02P)
0145-3 0175-5 2 10003547 2 SB1-D 68569656
170M 630A 630A 1 35066888 (Switch fuse OESA630D2PL)
0175-3 0215-5 2 10030617 2 SB3-D 68380430
6810 690V 690V 1 10000432 (Aux. contacts OZXK 1)
0210-3 0260-5 170M 800A 630A
2 64786423 2 SB3-D 68380430 1 64808796*
0260-3 0320-5 8545 690V 690V
170M 1100A 630A
0320-3 0400-5 2 68301564 2 SB3-D 68380430 1 64808796*
8552 690V 690V
170M 1250A 630A
0390-3 0460-5 2 64786512 2 SB3-D 68380430 1 64808796*
8547 690V 690V
170M 1600A 630A
0510-3 0610-5 2 64673734 2 SB3-D 68380430 1 64808796*
8550 690V 690V
170M 1250A 630A
0770-3 0910-5 4 64786512 4 SB3-D 68380430 1 64808800*
8547 690V 690V
170M 1600A 630A
1030-3 1210-5 4 64673734 4 SB3-D 68380430 1 64808800*
8550 690V 690V
170M 1600A 630A
1540-3 1820-5 6 64673734 6 SB3-D 68380430 1 64808826*
8550 690V 690V
170M 1600A 630A
2050-3 2430-5 8 64673734 8 SB3-D 68380430 2 64808800*
8550 690V 690V
170M 25A 160A
0011-7 2 10032041 2 SB00-D 68569613 1 64089650*
2674 1000V 690V
0016-7 170M 35A 160A
2 10033250 2 SB00-D 68569613 1 64089650*
0020-7 2676 1000V 690V
0025-7 170M 63A 160A
2 10029791 2 SB00-D 68569613 1 64089650*
0030-7 2679 1000V 690V
0040-7 170M 80A 160A
2 10029805 2 SB00-D 68569613 1 64089650*
0050-7 2680 1000V 690V

112
DC fuses and fuse bases/Switch fuse parts for inverter modules

Module type
DC fuse DC fuse base Switch fuse parts
ACS800-104-…
Order Order
Qty Type Info Qty Type Info Qty Order code(s)
400 V 500 V 690 V code code
170M 125A 160A
0060-7 2 10029813 2 SB00-D 68569613 1 64089650*
2682 1000V 690V
170M 125A 160A 1 64285165 (Switch fuse OS160D02)
0075-7 2 10029813 2 SB00-D 68569613
0105-7 170M 200A 250A 1 68474515 (Switch fuse OS250D02P)
0125-7 2 10001731 2 SB1-D 68569656
0145-7 170M 315A 630A 1 35066888 (Switch fuse OESA630D2PL)
0175-7 2 10037158 2 SB3-D 68380430
170M 400A 630A 1 35066888 (Switch fuse OESA630D2PL)
0215-7 2 10037166 2 SB3-D 68380430
170M 630A 630A
0260-7 2 68265541 2 SB3-D 68380430 1 64808796*
8645 1000V 690V
0320-7 170M 630A 630A
2 68316006 2 SB3-D 68380430 1 64808796*
0400-7 8646 1000V 690V
170M 800A 630A
0440-7 2 68265568 2 SB3-D 68380430 1 64808842*
8647 1000V 690V
170M 1000A 630A
0580-7 2 64673769 2 SB3-D 68380430 1 64808842*
8650 1000V 690V
170M 800A 630A
0870-7 4 10029881 4 SB3-D 68380430 1 64808851*
6203 1250V 690V
170M 1000A 630A
1160-7 4 64673769 4 SB3-D 68380430 1 64808851*
8650 1000V 690V
170M 1000A 630A
1740-7 6 64673769 6 SB3-D 68380430 1 64808877*
8650 1000V 690V
170M 1000A 630A
2320-7 8 64673769 8 SB3-D 68380430 2 64808851*
8650 1000V 690V
*Switch fuse kit. For contents, see separate table below.
Switch fuse kit contents

Order
Kit contents
code
1–Switch Fuse (OESA00-160D2PL) • 1–Mounting Frame for 4 aux. contacts • 4–Aux. Contact (2–NO,
64089650
1–NO gold-plated, 1–NC)
64808796 1–Switch Fuse (OESL630/32D02) • 2–Resistor (ZRF 30×167,5) • 1–Switch fuse controller (ASFC-01C)
64808842 1–Switch Fuse (OESL630/32D02) • 2–Resistor (ZRF 30×165) • 1–Switch fuse controller (ASFC-01C)

113
Charging circuit fuses for inverter modules

Fuse Fuse base
Module type
Order Order
ACS800-104-… Qty Type Info Qty Type Info
code code
0210-3 0260-5 0260-7
0260-3 0320-5 0320-7
170M 20A
0320-3 0400-5 0400-7 2 68326435
2673 1000V
0390-3 0460-5 0440-7
0510-3 0610-5 0580-7
0770-3 0910-5 0870-7 170M 20A Fuses to be installed on switch fuse
4 68326435
1030-3 1210-5 1160-7 2673 1000V
170M 20A
1540-3 1820-5 1740-7 6 68326435
2673 1000V
170M 20A
2050-3 2430-5 2320-7 8 68326435
2673 1000V
Mounting plates for R2i to R5i modules
Inclined mounting
These are ready-made mounting plates for inclined mounting of frame R2i to R5i
inverter modules as exemplified in the chapter Cabinet construction.
Dimension drawings of the plates are available from ABB by request.
Inclined mounting plates for R2i to R5i modules

64739328
Frame size Order code
R2i 64739328
R3i 64739174
R4i 64739344
R5i 64739352
Vertical mounting
These are ready-made mounting plates for vertical mounting of frame R2i to R5i
inverter modules as exemplified in the chapter Cabinet construction.
Dimension drawings of the parts are available from ABB by request.
Vertical mounting plates and airflow guides for

R2i to R5i modules 64792261 64792881
Order codes
Frame size
Mounting plate Airflow guide
R2i 64792261 64792881
R3i 64792270 64792946
R4i 64792288 64792962
R5i 64792296 64792971

114
Mounting parts for R7i modules

The kits below include the necessary parts for mounting the module on either the left
or right side in a Rittal TS 8 cubicle. See also the mounting examples starting on
page 30.
Dimension drawings of the sheet metal parts are available from ABB by
request.
Rittal TS 8 mounting parts for R7i modules

Kit Contents Quantity Order code
LH 1 kit per inverter module 68646278
RH 1 kit per inverter module 68646294

115
Common mode filters for R7i modules

Common mode filtering reduces bearing currents and is required for electromagnetic
compatibility (EMC). The filtering is implemented by installing three toroidal cores
onto the DC input of the inverter module. A filter kit with mounting parts is available.
Common mode filters for R7i and R8i modules

Common mode
1 kit per inverter module 68625548
filter kit

116
Installation parts for R8i modules

The following tables list the R8i installation parts available from ABB.
Also refer to the drawings in the chapters Cabinet construction. Dimension drawings
of the sheet metal parts (such as module guides, crossmembers and mounting
plates) are available from ABB by request.
Quick connector chassis socket kits

The chassis socket part of the quick connector is to be mounted on the rear pillars of
the cubicle. The socket can also be mounted on the back plate.
Quick connector kits for R8i modules

Kit For… Contents of 1 kit Order code
Single R8i
Connector only 1 pc Quick connector 64698401
module
1 pc Quick connector
Single R8i 1 pc Mounting plate
68239427
module 3 pcs Output busbar
3 pcs Support insulator
Connector with 2 pcs Quick connector

Two R8i
mounting parts 1 pcs Mounting plate
modules side 68239435
and output 6 pcs Output busbar
by side
busbars 6 pcs Support insulator
3 pcs Quick connector

Three R8i
1 pcs Mounting plate
modules side 68242231
9 pcs Output busbar
by side
1 + 2 R8i
68239427 + 68239435 68260744
modules

117
DC busbar kits
These kits contain the parts needed to connect the DC busbars of the inverter
module and the DC switch fuse or DC fuses. The common mode filters (optionally
available) are to be installed on the DC busbars.
DC busbar kits for R8i modules

4 pcs Busbar
Connecting 2 pcs Holder for
busbars from Single R8i common mode filters
64806823
fuse bases to DC module 5 pcs Support insulator
input of module 1 pc Mounting plate for
fuse bases
Connecting
4 pcs Busbar
busbars from Single R8i
2 pcs Holder for
switch fuse module (2-pole 68256747
common mode filters
(OESL) to DC switch fuse)
input of module

118
DC busbar kits for R8i modules

Two R8i 8 pcs Busbar

modules side by 4 pcs Holder for
68256771
side (4-pole common mode filters
switch fuse) 8 pcs Support insulator
Connecting
busbars from
12 pcs Busbar
switch fuse Three R8i
6 pcs Holder for
(OESL) to DC modules side by
common mode filters 68256780
input of module side (6-pole
15 pcs Support
switch fuse)
insulator
1 + 2 R8i
12 pcs Busbar
modules in
6 pcs Holder for
adjacent Rittal
common mode filters 68260752
TS 8 cubicles
15 pcs Support
(6-pole switch
insulator
fuse)

119
Upper and lower guides

These parts guide the top and bottom of the module when it is being inserted into the
cubicle.
Guiding parts kits for R8i modules

For… Contents of 1 kit Order code
1 pc Lower guide
Single R8i 1 pc Upper guide
68256836
module 1 pc Upper guide, rear
2 pcs Crossmember
Kit #68256836 and

1 pc Floor plate
Single R8i 1 pc Mounting plate
module in Rittal 2 pcs Air baffle 68283027
TS 8 cubicle 1 pcs EMC sealing,
conductive (comes in 2
pieces)
2 pcs Lower guide

Two R8i
2 pcs Upper guide
modules side by 68259517
2 pcs Upper guide, rear
side
2 pcs Crossmember

120
Guiding parts kits for R8i modules

For… Contents of 1 kit Order code
Kit #68259517 and

2 pcs Floor plate
Two R8i
1 pc Mounting plate
modules in a
2 pcs Air baffle 68283035
Rittal TS 8
1 pcs EMC sealing,
cubicle
conductive (comes in 3
pieces)
3 pcs Lower guide

Three R8i 3 pcs Upper guide
modules side by 3 pcs Upper guide, rear 68259541
side 1 pcs Crossmember, front
1 pcs Crossmember, rear
1 + 2 R8i
modules in
68283027 + 68283035 68260833
adjacent Rittal
TS 8 cubicles
Common mode filters for R8i modules

Common mode filtering reduces bearing currents and is required for electromagnetic
compatibility (EMC). The filtering is implemented by installing three toroidal cores
onto the DC input of each module. The DC busbar sets listed later in this chapter
contain holders for the common mode filters.
Common mode filters for R7i and R8i modules

Common mode filter kit

1 kit per inverter module 64315811
(toroids only)

121
Cabinet ventilation kits

These kits contain air inlet and outlet gratings, filters and fans for different degrees of
protection.
Air inlet kits

400 mm wide
cubicle.
Aperture size:
274 × 522 mm
1 pc Grille (metallic) 68239478
(10.8” × 20.55”).
Effective area:
1150 cm 2
(180 in2) approx.
600 mm wide
cubicle.
Aperture size:
471 × 522 mm
(18.54” × 20.55”).
Effective area:
1920 cm2
IP20 inlet kit,
(295 in2) approx.
unfiltered
800 mm wide
cubicle.
Aperture size:
671 × 522 mm
(26.42“ × 20.55”).
Effective area:
2880 cm2
(445 in2) approx.
400 + 600 mm
68239478 + 68239460 68260817
wide cubicles
600 + 800 mm
68239460 + 68259827 68328691
wide cubicles
400 + 2×600 mm
68239478 + 2×68239460 68328705
wide cubicles

122
Air inlet kits

400 mm wide
1 pc Grille, inner
cubicle.
(metallic)
Aperture size:
1 pc Filter mat (Luftfilter
274 × 522 mm
airTex G150) 68239443
(10.8” × 20.55”).
1 pc Grille, outer
Effective area: (plastic)
1150 cm2 1 pc Fastener
(180 in2) approx.
600 mm wide
1 pc Grille, inner
cubicle.
(metallic)
Aperture size:
471 × 522 mm
airTex G150) 68239451
(18.54” × 20.55”).
1 pc Grille, outer
IP42 inlet kit, 1920 cm2 1 pc Fastener
filtered (295 in2) approx.
800 mm wide
1 pc Grille, inner
cubicle.
(metallic)
Aperture size:
671 × 522 mm
airTex G150) 68259797
(26.42“ × 20.55”).
1 pc Grille, outer
2880 cm2 2 pcs Fastener
(445 in2) approx.
400 + 600 mm
68239443 + 68239451 68260795
wide cubicles
600 + 800 mm
68239451 + 68259797 68328560
wide cubicles
400 + 2×600 mm
68239443 + 2×68239451 68328586
wide cubicles

123
Air inlet kits

400 mm wide
1 pc Grille, inner
cubicle.
(metallic)
Aperture size:
274 × 522 mm
airComp 300-50) 68327806
(10.8” × 20.55”).
1 pc Grille, outer
1150 cm 2 1 pc Fastener
(180 in2) approx.
600 mm wide
1 pc Grille, inner
cubicle.
(metallic)
Aperture size:
471 × 522 mm
airComp 300-50) 68327822
(18.54” × 20.55”).
1 pc Grille, outer
IP54 inlet kit, 1920 cm2 1 pc Fastener
filtered (295 in2) approx.
800 mm wide
1 pc Grille, inner
cubicle.
(metallic)
Aperture size:
671 × 522 mm
airComp 300-50) 68328462
(26.42“ × 20.55”).
1 pc Grille, outer
2880 cm2 2 pcs Fastener
(445 in2) approx.
400 + 600 mm
68327806 + 68327822 68327890
wide cubicles
600 + 800 mm
68327822 + 68328462 68328471
wide cubicles
400 + 2×600 mm
68327806 + 2×68327822 68327903
wide cubicles

124
Air outlet kits (Roof)

400 mm wide
generic cubicle.
Aperture size: 1 pc Roof plate
314 × 320 mm 2 pcs Side plate (L/R)
68328128
(12.36” × 12.60”). 2 pcs Side plate
Effective area: (Front/Rear)
920 cm2 (140 in 2)
approx.
600 mm wide
generic cubicle.
IP21/42 Aperture size: 1 pc Roof plate
generic roof 514 × 350 mm 2 pcs Side plate (L/R)
outlet kit 68328144
(20.24” × 13.78”). 2 pcs Side plate
1536 cm2
(240 in2) approx.
800 mm wide
generic cubicle.
Aperture size: 1 pc Roof plate
714 × 320 mm 2 pcs Side plate (L/R)
68328446
(28.11“ × 12.60”). 2 pcs Side plate
2304 cm2
(355 in2) approx.
600 + 800 mm
68328144 + 68328446 68328608
wide cubicles

125

400 mm wide
Rittal TS 8
1 pc Roof plate
cubicle.
2 pcs Side plate (L/R)
Aperture size:
2 pcs Side plate
314 × 320 mm 68328110
(Front/Rear)
(12.36” × 12.60”).
2 pcs Support plate
Effective area: (L/R)
920 cm2 (140 in2)
approx.
IP21/42 roof
outlet kit for
Rittal TS 8
cubicles
600 mm wide
Rittal TS 8
1 pc Roof plate
cubicle.
2 pcs Side plate (L/R)
Aperture size:
2 pcs Side plate
514 × 350 mm 68328136
(Front/Rear)
(20.24” × 13.78”).
2 pcs Support plate
Effective area: (L/R)
1536 cm2
(240 in2) approx.
400 + 600 mm
68328110 + 68328136 68328161
wide cubicles
400 + 2×600 mm
68328110 + 2×68328136 68328641
wide cubicles

126

1 pc Support plate
1 pc Bottom plate
1 pc Support frame
400 mm wide
1 pc Cooling fan
cubicle.
1 pc Fan housing
Aperture size: 68327831
2 pcs Grille (inner)
314 × 350 mm
2 pcs Filter mat
(12.36” × 13.78”)
(Luftfilter airTex
G150)
2 pcs Grille (outer)
IP54 roof
outlet kit with
fan
1 pc Support plate
1 pc Bottom plate
1 pc Support frame
600 mm wide
1 pc Cooling fan
cubicle.
1 pc Fan housing
Aperture size: 68327857
2 pcs Grille (inner)
514 × 350 mm
2 pcs Filter mat
(20.24” × 13.78”)
(Luftfilter airTex
G150)
2 pcs Grille (outer)
400 + 600 mm
68327831 + 68327857 68328519
wide cubicles
600 + 800 mm
68327857 + 2×68327831 68328489
wide cubicles

127
Air outlet kits (Door)

1 pc Cooling fan
One power 1 pc Support plate
IP42 door module. 1 pc Grille (inner)
outlet kit with Aperture size: 1 pc Filter mat (Luftfilter 68410711
fan 274 × 440 mm airTex G150)
(10.79” × 17.32”) 1 pc Grille (outer)
1 pc Fastener
1 pc Cooling fan
One power 1 pc Support plate
IP54 door module. 1 pc Grille (inner)
outlet kit with Aperture size: 1 pc Filter mat (Luftfilter 68330301
fan 274 × 440 mm airComp 300-50)
(10.79” × 17.32”) 1 pc Grille (outer)
1 pc Fastener

128
PPCS branching units for n×R8i inverter units

Inverter units consisting of parallel-connected frame R8i inverter modules require
PPCS branching units for distribution of control signals to the modules. One
branching unit can control up to four inverter modules.
There are two types available – the NPBU-42C is the basic unit; the APBU-44C also
incorporates a datalogger and supports redundancy, enabling, in case of removal of
one inverter module, continued operation using the remaining modules.
PPCS branching unit (Multiples of frame R8i)

Inverter unit type
Quantity Contents of 1 kit Order code
ACS800-104…
1 pc. APBU-44C branching unit & datalogger
1 2 pcs. 2000 mm fibre optic cables *68242355
0770-3 0910-5 0870-7 2 pcs. 3000 mm fibre optic cables
1030-3 1210-5 1160-7 1 pc. NPBU-42C branching unit
2 pcs. 3000 mm fibre optic cables
1 pc. APBU-44C branching unit & datalogger
1540-3 1820-5 1740-7 4 pcs. 5000 mm fibre optic cables
2050-3 2430-5 2320-7 1 pcs. NPBU-42C branching unit
4 pcs. 5000 mm fibre optic cables
*Check availability with ABB
Output (du/dt) filters for frame R2i to R7i inverter modules

For information on the usage of output (du/dt) filters, see the document ACS800
MultiDrive; Planning the Electrical Installation (3AFE 64783742, English).
Output (du/dt) filters for inverter modules

Module type Order IRMS L Power loss Cable size Connection
Qty Type
ACS800-104-… code (A) (µH) (W) (mm2) size
0003-3 0004-5 0011-7
0004-3 0005-5 0016-7
0005-3 0006-5 1 NOCH0016-60 58982784 15 150 110 0.2 … 10 M5
0006-3 0009-5
0009-3 0011-5
0011-3 0016-5 0020-7
0016-3 0020-5 0025-7 1 NOCH0030-60 58982792 28 140 167 0.5 … 16 M5
0030-7
0020-3 0025-5 0040-7
0025-3 0030-5 0050-7 1 NOCH0070-60 58982806 65 115 210 10 … 35 M6
0030-3 0040-5 0060-7
0050-5
0040-3 0060-5 0075-7
0050-3 0070-5 0105-7 1 NOCH0120-60 58982814 105 92 240 – M8
0060-3 0105-5 0125-7
0105-3 0125-5 0145-7
0125-3 0145-5 0175-7 M10 (in)
1 FOCH0260-70 68490308 289 35 370 –
0145-3 0175-5 0215-7 M12 (out)
0175-3 0215-5
Other options
See the ACS800 Multidrive Modules Product Reference (3AFE 64813340 [English])
for generic equipment for the ACS800 product family such as control panels, I/O
options, application programs and PC tools.

129
Technical data

This chapter contains the technical data for the ACS800-104 inverter modules and
associated optional equipment.
Ratings
Frame R2i to R7i
Nominal ratings No-overload use Light-overload use Heavy-duty use

Frame
Inverter module type Icont.max Imax Pcont.max I2N PN I2hd Phd
size
A A kW A kW A kW
UN = 400 V
ACS800-104-0003-3 R2i 5.1 6.5 1.5 4.7 1.5 3.4 1.1
ACS800-104-0004-3 R2i 6.5 8.2 2.2 5.9 2.2 4.3 1.5
ACS800-104-0005-3 R2i 8.5 10.8 3 7.7 3.0 5.7 2.2
ACS800-104-0006-3 R2i 10.9 13.8 4 10.2 4.0 7.5 3.0
ACS800-104-0009-3 R2i 13.9 17.6 5.5 12.7 5.5 9.3 4.0
ACS800-104-0011-3 R3i 19 24 7.5 18 7.5 14 5.5
ACS800-104-0016-3 R3i 25 32 11 24 11 19 7.5
ACS800-104-0020-3 R3i 34 46 15 31 15 23 11
ACS800-104-0025-3 R4i 44 62 22 41 18.5 32 15
ACS800-104-0030-3 R4i 55 72 30 50 22 37 18.5
ACS800-104-0040-3 R5i 72 86 37 69 30 49 22
ACS800-104-0050-3 R5i 86 112 45 80 37 60 30
ACS800-104-0060-3 R5i 103 138 55 94 45 69 37
ACS800-104-0105-3 R7i 147 220 75 141 75 110 55
ACS800-104-0125-3 R7i 178 252 90 171 90 133 55
ACS800-104-0145-3 R7i 208 311 110 200 110 156 75
ACS800-104-0175-3 R7i 250 374 132 240 132 187 90
UN = 500 V
ACS800-104-0004-5 R2i 4.9 6.5 2.2 4.5 2.2 3.4 1.5
ACS800-104-0005-5 R2i 6.2 8.2 3 5.6 3.0 4.2 2.2
ACS800-104-0006-5 R2i 8.1 10.8 4 7.7 4.0 5.6 3.0
ACS800-104-0009-5 R2i 10.5 13.8 5.5 10.0 5.5 7.5 4.0
ACS800-104-0011-5 R2i 13.2 17.6 7.5 12.0 7.5 9.2 5.5
ACS800-104-0016-5 R3i 19 24 11 18 11 13 7.5
ACS800-104-0020-5 R3i 25 32 15 23 15 18 11
ACS800-104-0025-5 R3i 34 46 18.5 31 18.5 23 15
ACS800-104-0030-5 R4i 42 62 22 39 22 32 18.5
ACS800-104-0040-5 R4i 48 72 30 44 30 36 22
ACS800-104-0050-5 R5i 65 86 37 61 37 50 30
ACS800-104-0060-5 R5i 79 112 45 75 45 60 37
ACS800-104-0070-5 R5i 96 138 55 88 55 69 45
ACS800-104-0105-5 R7i 115 172 75 110 55 86 55
ACS800-104-0125-5 R7i 135 202 90 130 90 101 55
ACS800-104-0145-5 R7i 166 248 110 159 110 124 75
Technical data
130
Nominal ratings No-overload use Light-overload use Heavy-duty use

Frame
Inverter module type Icont.max Imax Pcont.max I2N PN I2hd Phd
size
A A kW A kW A kW
ACS800-104-0175-5 R7i 208 311 132 200 132 156 90
ACS800-104-0215-5 R7i 250 374 160 240 160 187 110
UN = 690 V
ACS800-104-0011-7 R4i 13 14 11 11.5 7.5 8.5 5.5
ACS800-104-0016-7 R4i 17 19 15 15 11 11 7.5
ACS800-104-0020-7 R4i 22 28 18.5 20 15 15 11
ACS800-104-0025-7 R4i 25 38 22 23 18.5 19 15
ACS800-104-0030-7 R4i 33 44 30 30 22 22 18.5
ACS800-104-0040-7 R4i 36 54 30 34 30 27 22
ACS800-104-0050-7 R5i 51 68 45 46 37 34 30
ACS800-104-0060-7 R5i 57 84 55 52 45 42 37
ACS800-104-0075-7 R7i 69 103 55 66 55 52 45
ACS800-104-0105-7 R7i 88 132 75 84 75 66 55
ACS800-104-0125-7 R7i 105 157 90 101 90 79 75
ACS800-104-0145-7 R7i 132 197 110 127 110 99 90
ACS800-104-0175-7 R7i 150 224 132 144 132 112 90
ACS800-104-0215-7 R7i 170 254 160 163 160 127 110
No-overload Light-overload
Nominal ratings Heavy-duty use
Frame Inverter modules use use
Inverter unit type
size used Icont.max Imax P cont.max I2N PN I2hd Phd
A A kW A kW A kW
UN = 400 V
ACS800-104-0210-3 1×R8i ACS800-104-0210-3 292 400 160 280 132 218 110
ACS800-104-0260-3 1×R8i ACS800-104-0260-3 370 506 200 355 200 277 132
ACS800-104-0320-3 1×R8i ACS800-104-0320-3 469 642 250 450 250 351 200
ACS800-104-0390-3 1×R8i ACS800-104-0390-3 565 773 315 542 300 423 220
ACS800-104-0510-3 1×R8i ACS800-104-0510-3 741 1014 400 711 400 554 315
ACS800-104-0770-3 2×R8i ACS800-104-0390-3 1111 1521 630 1067 560 831 450
ACS800-104-1030-3 2×R8i ACS800-104-0510-3 1452 1988 900 1394 710 1086 560
ACS800-104-1540-3 3×R8i ACS800-104-0510-3 2156 2951 1250 2070 1120 1613 900
ACS800-104-2050-3 4×R8i ACS800-104-0510-3 2845 3894 1600 2731 1600 2128 1120
UN = 500 V
ACS800-104-0260-5 1×R8i ACS800-104-0260-5 315 457 200 302 200 236 132
ACS800-104-0320-5 1×R8i ACS800-104-0320-5 365 530 250 350 250 273 160
ACS800-104-0400-5 1×R8i ACS800-104-0400-5 455 660 315 437 315 340 200
ACS800-104-0460-5 1×R8i ACS800-104-0460-5 525 762 355 504 355 393 250
ACS800-104-0610-5 1×R8i ACS800-104-0610-5 700 1016 500 672 450 524 355
ACS800-104-0910-5 2×R8i ACS800-104-0460-5 1050 1524 710 1008 710 785 500
ACS800-104-1210-5 2×R8i ACS800-104-0610-5 1372 1991 900 1317 900 1026 710
ACS800-104-1820-5 3×R8i ACS800-104-0610-5 2037 2956 1400 1956 1400 1524 1120
ACS800-104-2430-5 4×R8i ACS800-104-0610-5 2688 3901 2000 2580 1800 2011 1400
UN = 690 V
ACS800-104-0260-7 1×R8i ACS800-104-0260-7 215 322 200 206 200 161 132
ACS800-104-0320-7 1×R8i ACS800-104-0320-7 289 432 250 277 250 216 160
ACS800-104-0400-7 1×R8i ACS800-104-0400-7 336 503 315 323 315 251 200
ACS800-104-0440-7 1×R8i ACS800-104-0440-7 382 571 355 367 355 286 250
ACS800-104-0580-7 1×R8i ACS800-104-0580-7 486 727 450 467 450 364 315
ACS800-104-0870-7 2×R8i ACS800-104-0440-7 729 1091 710 700 710 545 500
Technical data
131
No-overload Light-overload
Nominal ratings Heavy-duty use
Frame Inverter modules use use
Inverter unit type
size used Icont.max Imax Pcont.max I2N PN I2hd Phd
A A kW A kW A kW
ACS800-104-1160-7 2×R8i ACS800-104-0580-7 953 1425 900 914 900 713 630
ACS800-104-1740-7 3×R8i ACS800-104-0580-7 1414 2116 1400 1358 1400 1058 900
ACS800-104-2320-7 4×R8i ACS800-104-0580-7 1866 2792 1800 1792 1800 1396 1400
PDM-00184674
Symbols
Nominal ratings
Icont.max Continuous RMS output current. No overloadability at 40 °C.
Imax Maximum output current. Allowable for 10 seconds at start, otherwise as long as allowed
by drive temperature. Note: Maximum motor shaft power is 150% Phd .
Typical ratings for no-overload use
Pcont.max Typical motor power. The power ratings apply to most IEC 34 motors at nominal voltage
(400, 500 or 690 V).
Typical ratings for light-overload use (10% overloadability)
I2N Continuous rms current. 10% overload is allowed for 1 minute every 5 minutes.
PN Typical motor power. The power ratings apply to most IEC 34 motors at nominal voltage
(400, 500 or 690 V).
Typical ratings for heavy-duty use (50% overloadability)
I2hd Continuous rms current. 50% overload is allowed for 1 minute every 5 minutes.
Phd Typical motor power. The power ratings apply to most IEC 34 motors at nominal voltage
(400, 500 or 690 V).
Derating
The load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres
(3300 ft), or if the ambient temperature exceeds 40 °C (104 °F).
In the temperature range +40 °C (+104 °F) to +50 °C (+122 °F) the rated output current is decreased
1 % for every additional 1 °C (1.8 °F). The output current is calculated by multiplying the current given
in the rating table by the derating factor.
Example If the ambient temperature is +50 °C (+122 °F) the derating factor is 100% - 1 % · 10 °C =
90 % or 0.90. The output current is then 0.90 · I or 0.90 · I . °C
2N 2hd
Note: Icont.max rating is not allowed above 40 °C (104 °F).
Altitude derating
In altitudes from 1000 to 4000 m (3300 to 13123 ft) above sea level, the derating is 1% for every 100 m
(328 ft). For a more accurate derating, use the DriveSize PC tool. If the installation site is higher than
2000 m (6600 ft) above sea level, please contact your local ABB distributor or office for further
information.
Technical data
132
Dimensions, noise, DC capacitance

Noise DC
Inverter module/unit Frame Height Width Depth Weight
level capacitance
type size
mm (in.) mm (in.) mm (in.) kg (lbs) dBA µF
UN = 400 V
ACS800-104-0003-3 R2i 401 (15.79) 165 (6.50) *193 (7.60) 9 (20) 62 350
ACS800-104-0004-3 R2i 401 (15.79) 165 (6.50) *193 (7.60) 9 (20) 62 350
ACS800-104-0005-3 R2i 401 (15.79) 165 (6.50) *193 (7.60) 9 (20) 62 350
ACS800-104-0006-3 R2i 401 (15.79) 165 (6.50) *193 (7.60) 9 (20) 62 350
ACS800-104-0009-3 R2i 401 (15.79) 165 (6.50) *193 (7.60) 9 (20) 62 350
ACS800-104-0011-3 R3i 466 (18.35) 173 (6.81) *232 (9.13) 12 (26) 62 820
ACS800-104-0016-3 R3i 466 (18.35) 173 (6.81) *232 (9.13) 12 (26) 62 820
ACS800-104-0020-3 R3i 466 (18.35) 173 (6.81) *232 (9.13) 12 (26) 62 820
ACS800-104-0025-3 R4i 525 (20.67) 240 (9.45) *252 (9.92) 15 (33) 62 1000
ACS800-104-0030-3 R4i 525 (20.67) 240 (9.45) *252 (9.92) 15 (33) 62 1000
ACS800-104-0040-3 R5i 673 (26.50) 265 (10.43) *276 (10.87) 23 (51) 65 2000
ACS800-104-0050-3 R5i 673 (26.50) 265 (10.43) *276 (10.87) 23 (51) 65 2000
ACS800-104-0060-3 R5i 673 (26.50) 265 (10.43) *276 (10.87) 23 (51) 65 2400
ACS800-104-0105-3 R7i 966 (38.03) 170 (6.69) 408 (16.06) 38 (84) 72 4100
ACS800-104-0125-3 R7i 966 (38.03) 170 (6.69) 408 (16.06) 38 (84) 72 6150
ACS800-104-0145-3 R7i 966 (38.03) 170 (6.69) 408 (16.06) 38 (84) 72 6150
ACS800-104-0175-3 R7i 966 (38.03) 170 (6.69) 408 (16.06) 38 (84) 72 6150
ACS800-104-0210-3 1×R8i 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 72 8200
ACS800-104-0260-3 1×R8i 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 72 8200
ACS800-104-0320-3 1×R8i 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 72 10250
ACS800-104-0390-3 1×R8i 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 72 12300
ACS800-104-0510-3 1×R8i 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 72 14350
ACS800-104-0770-3 2×R8i **1397 (55.00) **245 (9.65) **596 (23.46) **150 (330) 74 24600
ACS800-104-1030-3 2×R8i **1397 (55.00) **245 (9.65) **596 (23.46) **150 (330) 74 28700
ACS800-104-1540-3 3×R8i **1397 (55.00) **245 (9.65) **596 (23.46) **150 (330) 76 43050
ACS800-104-2050-3 4×R8i **1397 (55.00) **245 (9.65) **596 (23.46) **150 (330) 76 57400
UN = 500 V
ACS800-104-0004-5 R2i 401 (15.79) 165 (6.50) *193 (7.60) 9 (20) 62 350
ACS800-104-0005-5 R2i 401 (15.79) 165 (6.50) *193 (7.60) 9 (20) 62 350
ACS800-104-0006-5 R2i 401 (15.79) 165 (6.50) *193 (7.60) 9 (20) 62 350
ACS800-104-0009-5 R2i 401 (15.79) 165 (6.50) *193 (7.60) 9 (20) 62 350
ACS800-104-0011-5 R2i 401 (15.79) 165 (6.50) *193 (7.60) 9 (20) 62 350
ACS800-104-0016-5 R3i 466 (18.35) 173 (6.81) *232 (9.13) 12 (26) 62 820
ACS800-104-0020-5 R3i 466 (18.35) 173 (6.81) *232 (9.13) 12 (26) 62 820
ACS800-104-0025-5 R3i 466 (18.35) 173 (6.81) *232 (9.13) 12 (26) 62 820
ACS800-104-0030-5 R4i 525 (20.67) 240 (9.45) *252 (9.92) 15 (33) 62 1000
ACS800-104-0040-5 R4i 525 (20.67) 240 (9.45) *252 (9.92) 15 (33) 62 1000
ACS800-104-0050-5 R5i 673 (26.50) 265 (10.43) *276 (10.87) 23 (51) 65 2000
ACS800-104-0060-5 R5i 673 (26.50) 265 (10.43) *276 (10.87) 23 (51) 65 2000
ACS800-104-0070-5 R5i 673 (26.50) 265 (10.43) *276 (10.87) 23 (51) 65 2400
ACS800-104-0105-5 R7i 966 (38.03) 170 (6.69) 408 (16.06) 38 (84) 72 4100
ACS800-104-0125-5 R7i 966 (38.03) 170 (6.69) 408 (16.06) 38 (84) 72 6150
ACS800-104-0145-5 R7i 966 (38.03) 170 (6.69) 408 (16.06) 38 (84) 72 6150
ACS800-104-0175-5 R7i 966 (38.03) 170 (6.69) 408 (16.06) 38 (84) 72 6150
ACS800-104-0215-5 R7i 966 (38.03) 170 (6.69) 408 (16.06) 38 (84) 72 6150
ACS800-104-0260-5 1×R8i 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 72 8200
ACS800-104-0320-5 1×R8i 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 72 8200
Technical data
133
Noise DC
Inverter module/unit Frame Height Width Depth Weight
level capacitance
type size
mm (in.) mm (in.) mm (in.) kg (lbs) dBA µF
ACS800-104-0400-5 1×R8i 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 72 10250
ACS800-104-0460-5 1×R8i 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 72 12300
ACS800-104-0610-5 1×R8i 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 72 14350
ACS800-104-0910-5 2×R8i **1397 (55.00) **245 (9.65) **596 (23.46) **150 (330) 74 24600
ACS800-104-1210-5 2×R8i **1397 (55.00) **245 (9.65) **596 (23.46) **150 (330) 74 28700
ACS800-104-1820-5 3×R8i **1397 (55.00) **245 (9.65) **596 (23.46) **150 (330) 76 43050
ACS800-104-2430-5 4×R8i **1397 (55.00) **245 (9.65) **596 (23.46) **150 (330) 76 57400
UN = 690 V
ACS800-104-0011-7 R4i 525 (20.67) 240 (9.45) *252 (9.92) 15 (33) 62 670
ACS800-104-0016-7 R4i 525 (20.67) 240 (9.45) *252 (9.92) 15 (33) 62 670
ACS800-104-0020-7 R4i 525 (20.67) 240 (9.45) *252 (9.92) 15 (33) 62 670
ACS800-104-0025-7 R4i 525 (20.67) 240 (9.45) *252 (9.92) 15 (33) 62 670
ACS800-104-0030-7 R4i 525 (20.67) 240 (9.45) *252 (9.92) 15 (33) 62 670
ACS800-104-0040-7 R4i 525 (20.67) 240 (9.45) *252 (9.92) 15 (33) 62 670
ACS800-104-0050-7 R5i 673 (26.50) 265 (10.43) *276 (10.87) 23 (51) 65 1330
ACS800-104-0060-7 R5i 673 (26.50) 265 (10.43) *276 (10.87) 23 (51) 65 1330
ACS800-104-0075-7 R7i 966 (38.03) 170 (6.69) 408 (16.06) 38 (84) 72 1530
ACS800-104-0105-7 R7i 966 (38.03) 170 (6.69) 408 (16.06) 38 (84) 72 3070
ACS800-104-0125-7 R7i 966 (38.03) 170 (6.69) 408 (16.06) 38 (84) 72 3070
ACS800-104-0145-7 R7i 966 (38.03) 170 (6.69) 408 (16.06) 38 (84) 72 3070
ACS800-104-0175-7 R7i 966 (38.03) 170 (6.69) 408 (16.06) 38 (84) 72 3070
ACS800-104-0215-7 R7i 966 (38.03) 170 (6.69) 408 (16.06) 38 (84) 72 3070
ACS800-104-0260-7 1×R8i 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 72 4600
ACS800-104-0320-7 1×R8i 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 72 6130
ACS800-104-0400-7 1×R8i 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 72 6130
ACS800-104-0440-7 1×R8i 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 72 7670
ACS800-104-0580-7 1×R8i 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 72 9200
ACS800-104-0870-7 2×R8i **1397 (55.00) **245 (9.65) **596 (23.46) **150 (330) 74 15330
ACS800-104-1160-7 2×R8i **1397 (55.00) **245 (9.65) **596 (23.46) **150 (330) 74 18400
ACS800-104-1740-7 3×R8i **1397 (55.00) **245 (9.65) **596 (23.46) **150 (330) 76 27600
ACS800-104-2320-7 4×R8i **1397 (55.00) **245 (9.65) **596 (23.46) **150 (330) 76 36800
*Excluding control panel (optional)
**Single module only
Technical data
134
Power loss and cooling characteristics

See the dimensional drawings for free space requirements.
Minimum effective area Minimum effective area Max. pressure

of air inlet of air outlet drop of
Nominal air
Inverter module/ Frame Power loss with with cabinet at
flow
unit type size unfiltered Luftfilter/ unfiltered Luftfilter/ nominal air
airTex G150 airTex G150 flow
W (Btu/h) m3/h (ft3/min) cm2 (in2) cm 2 (in2) cm 2 (in2) cm 2 (in2) Pa
UN = 400 V
ACS800-104-0003-3 R2i 80 (280) 35 (21) 100 (16) 200 (31) 160 (25) 320 (50) 12
ACS800-104-0004-3 R2i 100 (340) 35 (21) 100 (16) 200 (31) 160 (25) 320 (50) 12
ACS800-104-0005-3 R2i 110 (380) 35 (21) 100 (16) 200 (31) 160 (25) 320 (50) 12
ACS800-104-0006-3 R2i 130 (450) 35 (21) 100 (16) 200 (31) 160 (25) 320 (50) 12
ACS800-104-0009-3 R2i 160 (550) 35 (21) 100 (16) 200 (31) 160 (25) 320 (50) 12
ACS800-104-0011-3 R3i 200 (680) 69 (41) 200 (31) 400 (62) 320 (50) 640 (99) 12
ACS800-104-0016-3 R3i 270 (920) 69 (41) 200 (31) 400 (62) 320 (50) 640 (99) 12
ACS800-104-0020-3 R3i 350 (1200) 69 (41) 200 (31) 400 (62) 320 (50) 640 (99) 12
ACS800-104-0025-3 R4i 420 (1440) 103 (61) 300 (47) 600 (93) 480 (74) 960 (149) 12
ACS800-104-0030-3 R4i 490 (1680) 103 (61) 300 (47) 600 (93) 480 (74) 960 (149) 12
ACS800-104-0040-3 R5i 650 (2220) 250 (147) 400 (62) 800 (124) 640 (99) 1280 (198) 17
ACS800-104-0050-3 R5i 790 (2700) 250 (147) 400 (62) 800 (124) 640 (99) 1280 (198) 17
ACS800-104-0060-3 R5i 950 (3250) 250 (147) 400 (62) 800 (124) 640 (99) 1280 (198) 17
ACS800-104-0105-3 R7i 1400 (4780) 800 (470) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0125-3 R7i 1700 (5810) 800 (470) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0145-3 R7i 1900 (6490) 800 (470) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0175-3 R7i 2100 (7170) 800 (470) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0210-3 1×R8i 2700 (9220) 1280 (750) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0260-3 1×R8i 3700 (12700) 1280 (750) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0320-3 1×R8i 4900 (16700) 1280 (750) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0390-3 1×R8i 6100 (20800) 1280 (750) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0510-3 1×R8i 8000 (27300) 1280 (750) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0770-3 2×R8i 12000 (41000) 2560 (1510) 960 (150) 1920 (295) 1536 (240) 3072 (475) 180
ACS800-104-1030-3 2×R8i 15000 (51200) 2560 (1510) 960 (150) 1920 (295) 1536 (240) 3072 (475) 180
ACS800-104-1540-3 3×R8i 23000 (78600) 3840 (2260) 1440 (225) 2880 (445) 2304 (355) 4608 (715) 180
ACS800-104-2050-3 4×R8i 30000 (102500) 5120 (3010) 1920 (295) 3840 (595) 3072 (475) 6144 (950) 180
UN = 500 V
ACS800-104-0004-5 R2i 100 (340) 35 (21) 100 (16) 200 (31) 160 (25) 320 (50) 12
ACS800-104-0005-5 R2i 110 (380) 35 (21) 100 (16) 200 (31) 160 (25) 320 (50) 12
ACS800-104-0006-5 R2i 130 (450) 35 (21) 100 (16) 200 (31) 160 (25) 320 (50) 12
ACS800-104-0009-5 R2i 160 (550) 35 (21) 100 (16) 200 (31) 160 (25) 320 (50) 12
ACS800-104-0011-5 R2i 200 (680) 35 (21) 100 (16) 200 (31) 160 (25) 320 (50) 12
ACS800-104-0016-5 R3i 270 (920) 69 (41) 200 (31) 400 (62) 320 (50) 640 (99) 12
ACS800-104-0020-5 R3i 350 (1200) 69 (41) 200 (31) 400 (62) 320 (50) 640 (99) 12
ACS800-104-0025-5 R3i 420 (1440) 69 (41) 200 (31) 400 (62) 320 (50) 640 (99) 12
ACS800-104-0030-5 R4i 490 (1680) 103 (61) 300 (47) 600 (93) 480 (74) 960 (149) 12
ACS800-104-0040-5 R4i 650 (2220) 103 (61) 300 (47) 600 (93) 480 (74) 960 (149) 12
ACS800-104-0050-5 R5i 790 (2700) 250 (147) 400 (62) 800 (124) 640 (99) 1280 (198) 17
ACS800-104-0060-5 R5i 950 (3250) 250 (147) 400 (62) 800 (124) 640 (99) 1280 (198) 17
ACS800-104-0070-5 R5i 1150 (3930) 250 (147) 400 (62) 800 (124) 640 (99) 1280 (198) 17
ACS800-104-0105-5 R7i 1100 (3760) 800 (470) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0125-5 R7i 1300 (4440) 800 (470) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0145-5 R7i 1700 (5810) 800 (470) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
Technical data
135
Minimum effective area Minimum effective area Max. pressure

of air inlet of air outlet drop of
Nominal air
Inverter module/ Frame Power loss with with cabinet at
flow
unit type size unfiltered Luftfilter/ unfiltered Luftfilter/ nominal air
airTex G150 airTex G150 flow
W (Btu/h) m3/h (ft3/min) cm 2 (in2) cm2 (in 2) cm2 (in2) cm2 (in2) Pa
ACS800-104-0175-5 R7i 2000 (6830) 800 (470) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0215-5 R7i 2200 (7510) 800 (470) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0260-5 1×R8i 3200 (10900) 1280 (750) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0320-5 1×R8i 4000 (13700) 1280 (750) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0400-5 1×R8i 5400 (18400) 1280 (750) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0460-5 1×R8i 5900 (20100) 1280 (750) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0610-5 1×R8i 7800 (26600) 1280 (750) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0910-5 2×R8i 12000 (41000) 2560 (1510) 960 (150) 1920 (295) 1536 (240) 3072 (475) 180
ACS800-104-1210-5 2×R8i 15000 (51200) 2560 (1510) 960 (150) 1920 (295) 1536 (240) 3072 (475) 180
ACS800-104-1820-5 3×R8i 22000 (75100) 3840 (2260) 1440 (225) 2880 (445) 2304 (355) 4608 (715) 180
ACS800-104-2430-5 4×R8i 29000 (99000) 5120 (3010) 1920 (295) 3840 (595) 3072 (475) 6144 (950) 180
UN = 690 V
ACS800-104-0011-7 R4i 300 (1030) 103 (61) 300 (47) 600 (93) 480 (74) 960 (149) 12
ACS800-104-0016-7 R4i 340 (1160) 103 (61) 300 (47) 600 (93) 480 (74) 960 (149) 12
ACS800-104-0020-7 R4i 440 (1500) 103 (61) 300 (47) 600 (93) 480 (74) 960 (149) 12
ACS800-104-0025-7 R4i 530 (1810) 103 (61) 300 (47) 600 (93) 480 (74) 960 (149) 12
ACS800-104-0030-7 R4i 610 (2080) 103 (61) 300 (47) 600 (93) 480 (74) 960 (149) 12
ACS800-104-0040-7 R4i 690 (2360) 103 (61) 300 (47) 600 (93) 480 (74) 960 (149) 12
ACS800-104-0050-7 R5i 840 (2870) 250 (147) 400 (62) 800 (124) 640 (99) 1280 (198) 17
ACS800-104-0060-7 R5i 1010 (3450) 250 (147) 400 (62) 800 (124) 640 (99) 1280 (198) 17
ACS800-104-0075-7 R7i 1100 (3760) 800 (470) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0105-7 R7i 1300 (4440) 800 (470) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0125-7 R7i 1600 (5460) 800 (470) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0145-7 R7i 2000 (6830) 800 (470) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0175-7 R7i 2300 (7850) 800 (470) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0215-7 R7i 2600 (8880) 800 (470) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0260-7 1×R8i 3600 (12300) 1280 (750) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0320-7 1×R8i 4800 (16400) 1280 (750) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0400-7 1×R8i 6100 (20800) 1280 (750) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0440-7 1×R8i 7000 (23900) 1280 (750) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0580-7 1×R8i 7500 (25600) 1280 (750) 575 (90) 1150 (180) 920 (140) 1840 (290) 150
ACS800-104-0870-7 2×R8i 13000 (44400) 2560 (1510) 960 (150) 1920 (295) 1536 (240) 3072 (475) 180
ACS800-104-1160-7 2×R8i 15000 (51200) 2560 (1510) 960 (150) 1920 (295) 1536 (240) 3072 (475) 180
ACS800-104-1740-7 3×R8i 22000 (75100) 3840 (2260) 1440 (225) 2880 (445) 2304 (355) 4608 (715) 180
ACS800-104-2320-7 4×R8i 29000 (99000) 5120 (3010) 1920 (295) 3840 (595) 3072 (475) 6144 (950) 180
Technical data
136
Cable terminals
DC input and motor cable terminal sizes, accepted cable diameters and tightening
torques are given below.
UDC+, UDC–, U2, V2, W2 Earthing PE
Frame Maximum Tightening
Max. wire size Cable Ø Tightening torque
size wire size torque
mm 2 AWG mm in. Nm lbf.ft mm2 AWG Nm lbf.ft
R2i 16* 6 AWG 21 0.83 1.2...1.5 0.9…1.1 10 8 1.5 1.1
R3i 16* 6 AWG 29 1.14 1.2...1.5 0.9...1.1 10 8 1.5 1.1
R4i 25 4 AWG 35 1.38 2…4 1.5…3.0 16 5 3.0 2.2
R5i 70 2/0 AWG 35 1.38 15 11.1 70 2/0 15 11.1
Frame
DC terminals Motor output terminals
size
R7i
Busbars to quick connector: M12. Tightening

torque: 50 Nm (37 lbf.ft)
M12
Busbars to support insulators: M8. Tightening
R8i Tightening torque: 50 Nm (37 lbf.ft)
torque: 9 Nm (6.5 lbf.ft)
Max. intrusion into module: 20 mm (0.8”).
Cables to busbars: M12. Tightening torque:
70 Nm (52 lbf.ft)
* 16 mm2 rigid solid cable, 10 mm2 flexible stranded cable
Technical data
137
Input power connection

Voltage 510…560 V DC for 400 V units
510…675 V DC for 500 V units
710…930 V DC for 690 V units
Motor connection
Voltage (U2) 0 to U1, 3-phase symmetrical, Umax at the field weakening point
Frequency DTC mode: 0 to 3.2 × fFWP. Maximum frequency 300 Hz.
UNmains
fFWP = × fNmotor
UNmotor
fFWP: frequency at field weakening point; UNmains: mains (input power) voltage;
UNmotor: rated motor voltage; fNmotor: rated motor frequency
Frequency resolution 0.01 Hz
Current See Ratings starting on page 129.
Power limit 1.5 × Phd
Field weakening point 8 to 300 Hz
Switching frequency 3 kHz (average). In 690 V units 2 kHz (average).
Maximum recommended Sizing method Max. motor cable length
motor cable length Motor control mode: DTC Motor control mode: Scalar
according to I2N and I2hd
according to Icont.max in R2i to R3: 100 m (328 ft) R2i: 150 m (492 ft)
ambient temperatures below R4i to R5i: 300 m (984 ft) R3i to R5i: 300 m (984 ft)
30 °C (86 °F)
according to Icont.max in R2i: 50 m (164 ft)
ambient temperatures above R3i and R4i: 100 m (328 ft)
30 °C (86 °F) R5i: 150 m (492 ft)
R7i: 300 m (984 ft)
–
R8i: 500 m (1640 ft)
Note: With cables longer than 100 m, the EMC Directive requirements may not be fulfilled.
Efficiency
Approximately 98% at nominal power level
Degree of protection
IP00
Technical data
138
Ambient conditions
Environmental limits for the drive are given below. The drive is to be used in a heated,
indoor, controlled environment.
Operation Storage Transportation
installed for stationary use in the protective package in the protective package
Installation site altitude 0 to 4000 m (13123 ft) above - -
sea level [above 1000 m
(3281 ft), see Derating on
page 131].
Air temperature 0 to +50 °C (32 to 122 °F). -40 to +70 °C (-40 to -40 to +70 °C (-40 to
No frost allowed. See +158 °F) +158 °F)
Derating on page 131.
Relative humidity 5 to 95% Max. 95% Max. 95%
No condensation allowed. Maximum allowed relative humidity is 60% in the presence of
corrosive gases.
Contamination levels No conductive dust allowed.
(IEC 60721-3-3, IEC 60721-3- Boards without coating: Boards without coating: Boards without coating:
2, IEC 60721-3-1) Chemical gases: Class 3C1 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Boards with coating: Boards with coating: Boards with coating:
Chemical gases: Class 3C2 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Atmospheric pressure 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa
0.7 to 1.05 atmospheres 0.7 to 1.05 atmospheres 0.6 to 1.05 atmospheres
Vibration (IEC 60068-2) Max. 1 mm (0.04 in.) Max. 1 mm (0.04 in.) Max. 3.5 mm (0.14 in.)
(5 to 13.2 Hz), (5 to 13.2 Hz), (2 to 9 Hz),
max. 7 m/s2 (23 ft/s 2) max. 7 m/s2 (23 ft/s2) max. 15 m/s2 (49 ft/s 2)
(13.2 to 100 Hz) sinusoidal (13.2 to 100 Hz) sinusoidal (9 to 200 Hz) sinusoidal
Shock (IEC 60068-2-29) Not allowed Max. 100 m/s2 (330 ft./s 2), Max. 100 m/s2 (330 ft./s 2),
11 ms 11 ms
Free fall Not allowed 250 mm (10 in.) for weight 250 mm (10 in.) for weight
under 100 kg (220 lb) under 100 kg (220 lb)
100 mm (4 in.) for weight 100 mm (4 in.) for weight
over 100 kg (220 lb) over 100 kg (220 lb)
Materials
Module • PC/ABS 2.5 mm, colour NCS 1502-Y (RAL 90021 / PMS 420 C)
• hot-dip zinc coated steel sheet 1.5 to 2 mm, thickness of coating 100 micrometres
• cast aluminium AlSi (R2i and R3i)
• extruded aluminium AlSi (R4i and R5i)
Packaging Corrugated cardboard (frames R2i to R5i and option modules), expanded polystyrene.
Plastic covering of the package: PE-LD, bands PP or steel.
Disposal The drive contains raw materials that should be recycled to preserve energy and natural
resources. The package materials are environmentally compatible and recyclable. All
metal parts can be recycled. The plastic parts can either be recycled or burned under
controlled circumstances, according to local regulations. Most recyclable parts are marked
with recycling marks.
If recycling is not feasible, all parts excluding electrolytic capacitors and printed circuit
boards can be landfilled. The DC capacitors (C1-1 to C1-x) contain electrolyte and the
printed circuit boards contain lead, both of which are classified as hazardous waste within
the EU. They must be removed and handled according to local regulations.
For further information on environmental aspects and more detailed recycling instructions,
please contact your local ABB distributor.
Technical data
139
Auxiliary power consumptions
Circuit boards
Un Un f In Imax
Type
V DC V AC Hz A A
– 230 50 0.1 –
AGPS-11C
– 115 60 0.2 –
230 50 0.3 –
AGPS-21C –
115 60 0.6 –
APBU-44 24 – – 0.2 –
– 230 50 0.04 –
ASFC-01C
– 115 60 0.08 –
NPBU-42 24 – – 0.2 0.235
RDCU-02 24 – – 0.25 1.2
Cooling fans
Frame Un f In Istart
Type
size V AC Hz A A
50 0.7 1.4
R2E225-BD92-12 230
R7i 60 0.7 1.4
R2E225-BD40-21 115 60 1.8 3.6
400 50 1.3 2.6
R8i D2D160-BE02-11
320 60 1.9 3.8
Technical data
140
Technical data
141
Circuit diagrams

This chapter contains the block diagrams of the ACS800-104 inverter modules, as
well as example connection diagrams for the whole inverter unit.
Circuit diagrams
142
Frame R2i to R5i
R2i/R3i – Block diagram
Circuit diagrams
143
R4i – Block diagram
Circuit diagrams
144
R5i – Block diagram
Circuit diagrams
145
Example – Three frame R2i to R5i inverter units
Circuit diagrams
146
Frame R7i
Connection diagram (400/500 V)
Circuit diagrams
147
Circuit diagrams
148
Connection diagram (690 V)
Circuit diagrams
149
Circuit diagrams
150
R8i – Internal diagram

The diagram depicts an R8i module with optional speed-controlled fan.
Circuit diagrams
151
Charging circuit
R8i
Circuit diagrams
152
2×R8i
Circuit diagrams
153
3×R8i
Circuit diagrams
154
I/O and control

R8i
Circuit diagrams
155
2×R8i
Circuit diagrams
156
Cooling fan control (inverter modules without optional speed-controlled fan)

Auxiliary voltage distribution
Circuit diagrams
157
R8i
Circuit diagrams
158
2×R8i
Circuit diagrams
159
Example – Emergency stop (Category 1)
Circuit diagrams
160
Example – Prevention of unexpected start
Circuit diagrams
161
Dimension drawings

This chapter contains dimension drawings of the ACS800-104 inverter modules as
well as auxiliary components. Dimensional drawings of most mounting accessories
are available from ABB by request.
Dimension drawings
162
Frame R2i
Module dimensions
Dimension drawings
163
Frame R3i
Module dimensions
Dimension drawings
164
Frame R4i
Module dimensions
Dimension drawings
165
Frame R5i
Module dimensions
Dimension drawings
166
Frame R7i
Module dimensions
Dimension drawings
167
Dimension drawings
168
Dimension drawings
169
Frame R8i
Module dimensions
Dimension drawings
170
Dimension drawings
171
Quick connector chassis socket kits

Kit #68239427
Dimension drawings
172
Kit #68239435
Dimension drawings
173
Kit #68242231
Dimension drawings
174
Module extraction/insertion ramp

This example design of a module extraction/insertion ramp is for a lifting height of
50 mm, and should be redesigned for other heights.
Dimension drawings
175
Dimension drawings
176
Control electronics
RDCU-02(C) control unit
Dimension drawings
177
NPBU-42C branching unit
1 0 8 4
N P B U -4 2 4 4
N P B U -4 2
P P C S
B R A N C H IN G
U N IT , 4 C H
V 1 3 5
C H 4
V 1 3 4
R X D
V 1 3 1
C H 3
V 1 3 0
R X D
V 1 2 7 2 6 5
C H 2
V 1 2 6
R X D
V 1 2 3
C H 1
V 1 2 2
R X D
T X D
V 1 2 1
A M C
V 1 2 0
R X D
+ 5 V O K
1 2 4 V D C
X 1
2 0 V
6 3 9 8 6 3 1 3
64009249-A
Dimension drawings
178
APBU-44C branching unit
1 2 3 4 5 6 7 8
6 9 6
5 9
B A P B U -4 4 C B O A R D
V 1 V 2 1
C H 1 C H 5
V 2 V 2 2
D
V 3 V 2 3
C H 2 C H 6
V 4 V 2 4
E
V 5 V 2 5
C H 3 C H 7
V 6 V 2 6
V 7 V 2 7
C H 4 C H 8
F V 8 V 2 8
V 9 V 2 9
C N T L 1 C H 9
V 1 0 V 3 0
G
V 1 1 C N T L 2 V 3 1 2 7 5
O R C H 1 0
V 1 2 D D C S (P C ) V 3 2
H V 3 3
V 1 3
T R IG G E R C H 1 1
V 1 4 V 3 4
V 3 5
0 1
C H 1 2 E F 2
S 1
3 4 5
B C D
D D C S V 3 6 8 9 A
6
J N O D E 0 1
E F 2
S 2 A D D R
3 4 5
A P E B -8 4 C
B C D
6
8 9 A
D IP
1 2
1 O P
T E
T P W
S T 1
R (V 1 1 )
X A P B U -4 4 C
3
S 3 T E S T 2 (4 C H )
4
M O D E 1
5
M O D E 2
A P B U -4 4 C E
O N
6
6 B A T T E R Y
K O N O F F (1 2 C H )
B A R C O D E L A B E L
L O G IC V E R S IO N
R X D T X D S W IT C H B A T T E R Y
B A T P W R O N W H E N B R IN G IN G
U N IT IN T O U S E
1 2 4 V A
2 G N D 2 4 V D C
X 1
3 2 4 V B IN
L 4 G N D
6 4 6 8 8 3 9 1
D R A W N 0 5 .1 1 .2 0 0 2 T .F . R E F E R S A C S 8 0 0 M D
A B B O y C H E C K 0 6 .0 9 .2 0 0 4 M .T
A P B U -4 4 C F IL E 0 0 2 1 9 0 1 8 .D S F
M D r iv e s , S y s te m A C
A P P R O V 0 6 .0 9 .2 0 0 4 P P C S B R A N C H IN G & D A T A L O G G E R U N IT , 4 C H S H E E T 1 / 2
I.T . R E V
H e ls in k i, F in la n d D IM E N S IO N D R A W IN G
R E V IS E D D R A W IN G 3 A F E 6 4 6 9 6 9 4 7 B 64696947-B
Dimension drawings
179
Fuse bases
SB series
Dimension drawings
180
Switch fuses, charging components
OESA00-160D2PL
Dimension drawings
181
OS160D02
Dimension drawings
182
OS250D02P
Dimension drawings
183
OESA630D2PL
Dimension drawings
184
OESL630/32D02
Dimension drawings
185
OESL630/32D04
Dimension drawings
186
OESL630/32D06
Dimension drawings
187
ASFC-01C switch fuse controller
7 7
6 5 .5
F 1
1
X 7 X 8
2
3
1 L 2 3 0 V 1 1 5 V
4
2 N
5
3 P E
X 5
6
4
5 L S O L
6 N S O L
A S F C -0 1 C R E L A Y
S W IT C H F U S E C O N T R O L L E R
T O B E U S E D W IT H
A B B D R IV E S O N L Y .
M A X IM U M R A T E D
S Y S T E M V O L T A G E
U L : 6 0 0 V A C
IE C : 6 9 0 V A C
1 1 5 V
1
2 A U X 2
X 4
2
3 G N D
4
3
G N D
4
P W R
R A T IN G S
S U P P L Y V O L T A G E (X 5 ) D IS 2 4 7
2 3 0 V , 5 0 /6 0 H z , 4 0 m A S 1
1 1 5 V , 5 0 /6 0 H z , 8 0 m A E N
S O L E N O ID C O N T R O L U D C
B A R C O D E L A B E L
O U T P U T (X 5 ) 1 1 5 /2 3 0
V A C , M A X 2 A / 3 ,5 s
S T A T
E X C IT A T IO N V O L T A G E V 1
O U T P U T (X 4 )
1 5 V D C , M A X 1 0 m A IN V 1
C H A R G IN G C U R R E N T V 2
M O N IT O R IN G IN P U T S
(X 1 - X 3 ) M A X 1 6 A D C
O P E R . T E M P E R A T U R E D IS
M A X + 7 0 ºC S 2
E N
IN V 1
U D C
1
1 IR 1 +
S T A T V 3
X 1
2
2
IN V 2
3
3 IR 1 -
V 4
IN V 2
1 IR 2 +
1
D IS
X 2 2 S 3
2
E N
3 IR 2 -
3
U D C
IN V 3
S T A T V 5
1 IR 3 +
IN V 3
1
X 3 2
V 6
2
3 IR 3 -
3
6 4 7 3 9 6 1 1
68222966-B
Dimension drawings
188
ZRF charging resistors
Type L LB fxi D MAX k e
ZRF 30×165 165 ±3 183 5.5 × 8 34 6 (min.) 4.2
ZRF 30×167,5 167.5 ±3 185.5 5.5 × 8 34 6 (min.) 4.2
Dimension drawings
189
Diverse
Output (du/dt) filters
Common mode filter toroids
PDM-58368-B
Dimension drawings
190
Dimension drawings
3AFE64809032 REV E / EN
ABB Oy
AC Drives
P.O. Box 184
FI-00381 HELSINKI
FINLAND
Telephone +358 10 22 211
Telefax +358 10 22 22681
Internet http://www.abb.com
NOV PART NO.:
601933/616
Ritardatore elettronico
Electronic Delay
Elektroniscer verzögerungsvorrichtung
Temporisateur électronique
Retardador electrónico
55/2,16" 110/4,33"
70/2,75"
Guida EN 50022 sec. norme DIN 43880

EN 50022 guide according to DIN 43880 STANDARD
Profilschiene EN 50022 gemäß DIN 43880
Glissière EN 50022 selon normes DIN 43880
A Guía EN 50022 según normas DIN 43880
Alimentazione Power supply

Stromversorgung Alimentation
Alimentación
d.c. (*) a.c. (**)
24
48
60
110÷127
220÷250
(*) Senza cavallotto (*) No yumper
(*) Ohne Drahtbrücke (*) Sans cavalier
(*) Sin conexión
(**) Cavallotto 3÷4 presente (**) Yumper 3÷4 present
(**) Drahtbrücke 3÷4 vorhanden (**) Cavalier 3÷4 présent
(**)Conexión 3÷4 presente
Tempo di apertura regolabile

Adjustable opening time
Ausschaltzeit einstellbar
Temps d'ouverture réglable
Tiempo de apertura regulable
Cavallotto tra i morsetti Yumper between camps
Drahtbrücke zwischen den Klemmen
Cavalier entre les bornes Conexión entre bornes
6-7 = 0.5s
6-8 = 1s
6-9 = 1.5s
6-10 = 2s
senza cavallotti = 3s
no yumpers = 3s
ohne Drahtbrücken = 3s
sans cavaliers = 3s
B sin conexiones = 3s
ABB SACE S.p.a. SACE Emax E1 ÷ E6 601933/616 L0139 1/1

Head Office: Via Baioni, 35 - 24123 Bergamo - Italy - Tel.: +39 035 395111 - Telex: 301627 ABBSAC I - Telefax: +39 035 395306-395433
NOV PART NO.:
B201581
NOTES:
B201581
-PROVISION FOR FORKLIFTING
-PROVISION FOR FANS
(FOR FRESH AIR AUGMENTATION ONLY)
-PROVISION FOR HEATERS
-PROVISION FOR THERMOSTATS / RTD'S
-HV & LV CABLE SUPPORTS
-ENCLOSURE TIE DOWNS
HAMMOND POWER SOLUTIONS INC., AND IS NOT FOR GENERAL DISTRIBUTION

TERMINAL BLOCK
THIS DRAWING CONTAINS PROPRIETARY INFORMATION BELONGING TO

FOR THERMOSTAT CABLE SUPPORT
4.00
X1 X2 X3
1.88 1.07
.75
18.00 18.00 0.56"x1.00" 1.75
CL
SLOT (4)
64.0
CL 44.43
12.38 12.38
14.50
HV TERMINAL
CABLE SUPPORT 4.58 0.25 x 4.0 PLATED AL
H1 H2 H3
HV
4.00
1.88 1.06
.63
0.56"x1.00"
SLOT(4) 1.75
68.00
57.93 18.70
X1 X2 X3
46.82 LV
PROVISION LV TERMINAL
FOR FANS
CONFIDENTIAL
0.25 x 4.0 PLATED AL
24.51 2.00(4)
TIE DOWN
8.00 5.50 HOLES
PROVISION
FOR HEATERS
8.00 26.57
FORKLIFT 1.38 42.00 0.69 (4)
11.89 40.00 PROVISIONS 44.75
TOLERANCES STD. ± 0.25 [6] REVISION DATE DES'D BY: KJV

CAD REV.NO. TITLE: DWG.NO.
GENERATED DATE: 01/11/2011
OTHER
DRAWING CHK'D BY: -- 1000kVA TRANSFORMER OUTLINE
ALL DIMENSIONS IN INCHES
MM IN BRACKETS
DO NOT
MANUALLY
DATE: -- Ref: 10618396-001 B201581
UPDATE APP'D BY: --
--
SHEET 1 OF 1 REV 0
DATE:
NOV PART NO.:
D25T&B RESISTOR-CAL-001
DOCUMENT ID: D25T&B RESISTOR-CAL-001 REV.01
August 12, 2008
Attn: Biren Desai
Reference: Dynamic Braking Resistor Calculations
Below are power calculations based upon 1100V DC and resistance values given for your
braking resistor application. Please note that we have based our design on 1200 KW
continuous with 2 sections of 2.0 ohms at 600 KW each; which can be connection
together in parallel to equal 1.0 ohms at 1200 KW.
Please confirm the following:
Maximum DC bus Voltage: 1100VDC
Equivalent Hot Operating Resistance = (2) 2.0 Ohms resistors in parallel = 1.0 Ohms
Hot Operating Amps = 1100 Volts/ 1.0 Ohms = 1100 Amps (550 amps per resistor
section)
**Hot Operating Power = 1100 Volt x 1100 amps = 1210 KW (maximum power)
Equivalent Cold Resistance = 2 x 1.7 ohm resistors in parallel = 0.85 ohms
**Peak Amps = 1100 volts / 0.85 amps = 1294 Amps pk (Peak current on the Chopper)
NOV PART NO.:
D25T&B RESISTOR-DAS-001
August 24, 2009

1530 W. Sam Houston Pkwy
Houston, TX 77043
Document ID: T&B RESISTOR-DAS-001 REV. 03
Resistor Bank Data Sheet-Drawing LB0036
 Resistor bank material- Stainless Steel

 .00036 material resistivity
 Cold Ohms: 1.9 Ohms at 20°C per section
 Hot Ohms: 2.15 Ohms at 375°C per section
 600 KW per section
 Cold Amps: 562 amps at 20°C per section
 Hot Amps: 528 amps at 375°C per section
 1000VDC insulation per bank
NOV PART NO.:
D25T&B RESISTOR-REP-001
Test report
Test report
Water test report for load bank resistor
1200KW

VFD T&B RESISTOR
which belongs to National Oilwell Varco; it is loaned for limited Rig Solution Group
purposes only and remains the property of National Oilwell.
Reproduction, in whole or in part; or use of this design or 1530 W. Sam Houston Pky N
distribution of this information to others is not permitted without the Houston, Texas 77043 (USA)
express written consent of National Oilwell Varco. This document is Phone + 713-935-8000
event upon completion of the use for which it was loaned. Fax + 713-346-7426
DOCUMENT NUMBER REV
D25T&B RESISTOR-REP-001 01
www.nov.com
Document number D25T&B RESISTOR-REP-001
Revision 01
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REVISION HISTORY
01 20.03.2008 First Release BD GA BD

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TABLE OF CONTENTS
1 WATER TEST PROCRDURE ........................................................................................... 4

2 WATER TEST RESULT FROM 01/18/2008 ..................................................................... 4
3 WATER TEST RESULT FROM 02/08/2008 ................................................................... 10
4 WATER TEST RESULT FROM 02/28/08 ....................................................................... 15
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1 WATER TEST PROCRDURE
1. Ensure that the unit is complete with all covers in place prior to test.
2. Place unit under rain apparatus.
3. Connect a meg-ohm meter between the cable termination point and the grounded
enclosure.
4. Turn on water supply and the unit’s fan motor. Adjust the flow of the water until the flow
meter indicates a rate of approximately 6” of rainfall per hour.
5. Water should be left on for the complete 8 hour test and continuous monitoring of the
meg-ohm meter should be recorded.
6. After one hour, turn off the unit’s fan and record the readings for the next 30 minutes.
7. After the 30 minute off period, turn fan back on and continue to monitor reading for the
remainder of the 8 hour period.
8. At end of 8 hour period, turn off water supply.
9. Remove terminal compartment cover and inspect the inside of unit to make note of any
water ingress.
10. Record meg-ohm reading from the resistor terminal to the enclosure frame (1000 V).
11. Using an ohm-meter, record the ohms across the resistor.
12. Write up report of all test results.
2 WATER TEST RESULT FROM 01/18/2008
Readings were observed every 5 minutes and the unit was inspected every 15 minutes.
The temperature throughout the day was at 33 degrees F and at sunset drop quickly to
approximately 25 degrees F. The temperature made it to a low of 10 degree F.
Unit was inspected at 5:45PM and showed no signs of ice. At 5:55pm units was coated with
ice on the outside. Upon removal of covers the inside of unit also was coated with ice.
Time Results
12:00-12:30PM >2 Giga Ohms
12:35PM 1,512 Mega Ohms
12:40PM 1,200 Mega Ohms
12:45PM 950 Mega Ohms
12:55Pm 705 Mega Ohms
1:05-5:50PM > 2 Giga Ohms
5:55PM 0 Ohms
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We began our water test at exactly 10:00am. The first two hours of the morning were spent
setting the machine up outside the building to do the water test. The temperature at the
start of the water test was approximately 40° F. The test ended at 6:00pm with the
temperature at approximately 45° F. The high for the day was 49° F.
The flow of water was adjusted to 6” per hour and readings were taken every five minutes.
A visual observation of the unit was done on a random basis. The unit’s fan motor was run
for an hour with readings staying above 2 Giga Ohms. The unit was then shut off for half an
hour and a low reading of 816 Mega Ohms occurred. The unit’s fan motor was turned back
on and the Mega Ohm reading again measured over 2 Giga Ohms. The unit’s fan motor
was left on until the end of the test and the readings continued to be greater than 2 Giga
Ohms.
After the test the unit was inspected for water egress and a small amount was found at the
top of the unit in a drip pan. No water was found to be in the unit or the terminal enclosure.
Time Reading Status

10:00am-10:55am > 2 Giga Ohms ON
11:00am >2 Giga Ohms OFF
11:15am 1530 Mega Ohms OFF
11:30am 816 Mega Ohms ON
11:35am- 6:00pm >2 Giga Ohms ON
Readings were taken every five minutes. The temperature range for the day was between
40° F and 49° F. An inspection of the interior of the unit and the terminal enclosure after
completion of the test showed no sign of water egress.
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We began our water test at exactly 10:20am. The Side Water Test was ran for exactly one
hour and ended at 11:20am. The temperature was 75°F and was done inside of our facility.
It was easier to control the run-off water, which allowed for the indoor test. Water from two
hoses was directed at each side of the unit. This allowed for a large flow of water directly
over the air inlet. Water also pooled under the unit. The fan was in the on position
throughout the entire test.
Readings were taken every five minutes on a 2 Giga-Ohm Megger Meter. All readings were
greater than 2 Giga-Ohms. Visually no water was sucked into the unit. All water stayed at
the bottom of the unit.
Time Reading Status

10:20am-11:20am > 2 Giga Ohms ON
Readings were taken every five minutes. The range for this water test was approximately
75° F and was done in our facility.
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Right Side View
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NOV PART NO.:
EDB201581
NOV PART NO.:
EDB201586
NOV PART NO.:
EXANE-125
®
Exane 125
Drilling Rig and
Commercial Marine Cable
Over 20 Years
of Superior
Perfomance On
Oil Rigs Around
The World
• Certified as Type “P” per

IEEE-45 STD 1998
• Listed by UL for Marine
Applications to STD UL 1309
• Meets IEC 332-3 Category A
Flame Test
• Approved by ABS, DNV,
Lloyds, USCG and Canadian
Coast Guard
• CSA listed to C22.2 No. 245
• ITS listed to the performance
requirements of IEC 92-3
Innovative Engineered Cable Solutions • ITS listed to the performance
requirements of IEC 60092-353
EXANE® 125
The Ideal Solution for

Harsh Oil Rig Environments Found
Anywhere in the World
• Wide Size Range (#18 AWG-1111 MCM) • Excellent Electrical Properties
(1.0 mm2-560 mm2) • Highly Flame Retardant (VW-1, IEEE-383,
• Single and Multiconductor — Up to 91 Conductors IEEE1202, FT-4, IEC 332-3 Cat. A)
• Flexible Stranding — Tinned Copper • Excellent Moisture Resistance
Conductors — ASTM B33, B8 and B172 • Superior Oil and Chemical Resistance
• Irradiation Crosslinked Polyolefin (Exane®) • Superior Abrasion, Crush & High Temperature
Insulation Cut Thru Resistance
• Free Stripping without Separator over Strand • Easy to Handle During Installation
• High Energy Irradiation Process. Produces Thermoset • Resistant to Oilfield Drilling Muds
Insulation Able to Withstand Thermal Overloads
• Heavy Duty Arctic Grade Neoprene Jacket per Note: Special wire and cable constructions avail-
ICEA S-95-658 able — check with factory. Product available with
blue jackets to indicate intrinsically safe circuit.
• Wide Temperature Range -55°C to 125°C
• Passes Cold Bend at -55°C, and Cold Impact at
-40°C
1
EXANE® 125
EXANE® Product Line

A Unique Combination of Features.
Wire and Cable with Wide Range of World Wide Approvals.
• ITS Listed to IEEE-45-1998 & IEEE 1580-2001, • Approved by ABS
Type P • Approved by DNV
• Listed — UL 1309 Marine Shipboard Cable • Approved by Lloyd’s U.K., Register of Shipping
• Listed — CSA • Approved by NVE
C22.2 No. 245 Marine Shipboard Cable
• Approved by Korean Register of Shipping
• ITS Type Approved in accordance with IEC 92-3
and IEC 60092-353 • Meets IEC 332-3 Cat. A Flame Test
• Accepted by U.S. Coast Guard • Meets IEEE 1202 Vertical Cable Tray Flame Test
• Meets requirements of 46 CFR Parts 110 & 111 • Listed by UL as Type CWCMC for cables with
continuously welded and corrugated aluminum
• Accepted by Canadian Coast Guard
armor in accordance with UL 1309.
Engineering Information
Ampacity Ratings Based on the Electrical Values
Following* #18 AWG Pairs and Triads
• 95°C IEC 92-3 Ampacity @ 45°C Ambient in • Capacitance — pf/ft = 36
Free Air
• Inductance — milli-henries/1000 ft = .126
• 100°C IEEE-45 STD 1998 @ 45°C Ambient in
Free Air • Resistance — Ohms/1000 ft @ 20°C = 6.22
• 125°C ICEA Pub. P-46-426 @ 45°C Ambient in #16 AWG Pairs and Triads
Free Air • Capacitance — pf/ft = 39
*Contact factory for specific installation conditions
• Inductance — milli-henries/1000 ft = .117
Recommended Minimum Dynamic Bend • Resistance — Ohms/1000 ft @ 20°C = 4.82
Radius
• Unarmored 6X Finished Cable Diameter #14 AWG Pairs
• Armored and Armored and Sheathed Cable 8X • Capacitance — pf/ft = 28
Finished Cable Diameter • Inductance — milli-henries/1000 ft = .104
*Contact factory for specific installation conditions
• Resistance — Ohms/1000 ft @ 20°C = 3.05
Standard O.D. Tolerances ± 10%
Soft Metric Diameter Conversion Factor — * Contact factory for special electrical requirements.
Inches to Millimeters: Multiply by 25.4
2
EXANE® 125
Oil Rig/Commercial Marine Cable

Single Conductor Power Multi-Conductor Power
RSCC DAA 1048B RSCC DAC 1048C
Conductor
Flexible stranded, Conductor
tin-coated copper Flexible stranded,
(various strandings) tin-coated copper
(various strandings)
Insulation
Insulation Crosslinked
Crosslinked Polyolefin
Polyolefin Inner Jacket
Neoprene
Armor
Armor
Outer Sheath
Neoprene
Sheath
Neoprene
600 & 2000 Volt 600 Volt

Single Conductor Power, Unarmored or Armored and Multi-Conductor Power Cable, Unarmored or Armored
Sheathed. and Sheathed.
Conductor: Conductors:
Flexible, Annealed, Tinned Copper per ASTM B33, B8 Flexible, Annealed, Tinned Copper per ASTM B33, B8
and B172 and B172
Insulation: Exane®-125 Insulation: Exane®-125
Crosslinked Polyolefin 125°C Crosslinked Polyolefin 125°C
(Colors as Required)
Color Code:
Armor: IEEE-45, UL1309 or as Specified by Customer
Bronze, Tinned Copper or Aluminum Braid
Fillers:
Sheath: When Required, Flame Retardant and Non-Hygroscopic
Heavy Duty Arctic Neoprene
Binder Tape:
Non-Hygroscopic and Non-Wicking
Inner Jacket:
Armor:
Outer Sheath:
3
EXANE® 125
Oil Rig/Commercial Marine Cable

Multi-Conductor Control Multi-Conductor Instrumentation
RSCC DAC 1048C RSCC DAC 1048C
Conductor Conductor
Flexible stranded, Flexible stranded,
tin-coated copper Insulation
Insulation tin-coated copper Crosslinked
Crosslinked (various strandings) (various strandings) Polyolefin
Polyolefin
Binder Tape
Drain Wires
Inner Jacket
Tin-coated copper
Neoprene
Shield Tapes
Armor
Inner Jacket
Neoprene
Outer Sheath Armor

Neoprene
Outer Sheath
Neoprene
600 Volt 600 Volt

Multi-Conductor Control Cable, Unarmored or Multi-Shielded Pairs or Triples with Overall Shield,
Armored and Sheathed Unarmored or Armored and Sheathed
Conductors: Conductors:
Annealed, Tinned Copper per ASTM B33, B8 and Annealed, Tinned Copper per ASTM B33, B8 and B172
B172 Insulation: Exane®-125
Insulation: Exane®-125 Crosslinked Polyolefin 125°C
Crosslinked Polyolefin 125°C Pair or Triple Assembly:
Two or Three Conductors Twisted with a Tin-Coated
Color Code:
Copper Drain Wire, a Helically Applied Aluminum/
IEEE-45, UL1309 or as Specified by Customer
Ployester Laminated Tape Shield
Fillers: Cabling:
When Required, Flame Retardant and Non-Hygroscopic Required Number of Pairs or Triples Cabled Together
Binder Tape: Color Code:
Non-Hygroscopic and Non-Wicking IEEE-45, UL1309 or as Specified by Customer
Inner Jacket: Fillers:
Heavy Duty Arctic Neoprene When Required, Flame Retardant and Non-Hygroscopic
Armor: Overall Shield System:
Bronze, Tinned Copper or Aluminum Braid Helically Applied Aluminum/Polyester Laminated Tape
Shield in Continuous Contact with Tin-Coated Copper
Outer Sheath: Drain Wire
Inner Jacket:
Armor:
Outer Sheath:
4
EXANE® 125
One Conductor Wire: 600 Volt

Armored and
Unarmored Armored – “B”* Sheathed “BN”*
Nominal Nominal
Conductor Overall Weight Nominal Weight Nominal Weight Ampacity**
Product Diameter Diameter Lbs per Diameter Lbs per Diameter Lbs per ICEA IEEE-45 IEC
Size Number* Inches Inches M FT Inches M FT Inches M FT 125°C 100°C 95°C
22 01C22-600V 0.030 0.090 6 14 N/A 11
20 01C20-600V 0.038 0.098 8 17 12 15
18 01C18-600V 0.047 0.107 11 22 16 20
16 01C16-600V 0.054 0.114 13 25 23 23
14 01C14-600V 0.067 0.127 18 39 37 30
12 01C12-600V 0.086 0.146 27 49 45 36
10 01C10-600V 0.123 0.183 45 68 58 52
8 01C8-600V 0.138 0.231 65 0.286 107 0.410 156 90 72 64
6 01C6-600V 0.190 0.280 101 0.335 150 0.459 208 126 96 87
5 01C5-600V 0.240 0.330 149 0.385 197 0.513 263 158 109 112
4 01C4-600V 0.260 0.350 170 0.405 225 0.533 290 176 128 122
3 01C3-600V 0.285 0.375 195 0.434 270 0.550 337 195 146 137
2 01C2-600V 0.320 0.410 233 0.465 305 0.593 380 217 169 153
1 01C1-600V 0.390 0.500 343 0.550 426 0.678 525 281 194 197
1/0 01C1/0-600V 0.435 0.545 408 0.600 498 0.728 603 319 227 224
2/0 01C2/0-600V 0.480 0.590 481 0.645 502 0.773 675 354 262 248
3/0 01C3/0-600V 0.550 0.660 653 0.715 705 0.883 930 437 300 304
Note: #18 AWG through #3/0 AWG also available in 2000V rated thicknesses when required.
*Exane-125® Ordering Part Number **Ampacity Ratings Based on the Following

• Unarmored – use product number. Example: 01C262-600V. • 95°C IEC 92-3 Ampacity in Free Air @ 45°C Ambient
• Armored only – add the letter B. Example: 01C262-600VB. • 100°C IEEE-45 STD 1998 in Free Air @ 45°C Ambient
• Armored and Sheathed – add the letters BN. • 125°C ICEA Pub. P-46-426 in Free Air @ 45°C Ambient
Example: 01C262-600V BN. **Contact Factory for sizes 4/0 AWG to 1111KCMIL.
One Conductor Power Cable: 2000 Volts (Heavy Duty)

Armored and
Nominal Nominal
4/0 01C4/0-HD 0.580 0.790 852 0.845 995 1.013 1139 495 351 345
262 01C262-HD 0.652 0.862 982 0.917 1115 1.085 1303 550 407 383
313 01C313-HD 0.720 0.930 1152 0.985 1296 1.163 1507 617 455 427
373 01C373-HD 0.770 0.980 1354 1.035 1520 1.203 1718 692 516 477
444 01C444-HD 0.845 1.055 1597 1.110 1785 1.280 1995 772 588 532
535 01C535-HD 0.915 1.165 1935 1.220 2194 1.428 2432 871 662 597
646 01C646-HD 1.030 1.270 2264 1.325 2525 1.533 2788 979 731 672
777 01C777-HD 1.120 1.360 2734 1.415 2960 1.643 3304 1101 822 754
1111 01C1111-HD 1.340 1.580 3807 1.635 4005 1.893 4553 1374 1025 943

• Unarmored – use product number. Example: 01C262-HD. • 95°C IEC 92-3 Ampacity in Free Air @ 45°C Ambient
• Armored only – add the letter B. Example: 01C262-HDB. • 100°C IEEE-45 STD 1998 in Free Air @ 45°C Ambient
Example: 01C262-HD BN. Contact factory for specific environmental conditions.
5
EXANE® 125
One Conductor Wire: 2000 Volt (Standard)

Armored and
Nominal Nominal
18 01C18-2KV 0.047 0.137 22 16 20
16 01C16-2KV 0.054 0.144 25 23 23
14 01C14-2KV 0.067 0.157 39 37 30
12 01C12-2KV 0.086 0.176 49 45 36
10 01C10-2KV 0.123 0.213 68 58 52
8 01C8-2KV 0.138 0.248 70 0.303 111 0.406 150 90 72 64
6 01C6-2KV 0.190 0.300 110 0.355 159 0.459 205 126 96 87
5 01C5-2KV 0.240 0.350 157 0.405 214 0.509 265 158 109 112
4 01C4-2KV 0.260 0.370 178 0.425 239 0.529 292 176 128 122
3 01C3-2KV 0.285 0.395 204 0.450 268 0.578 338 195 146 137
2 01C2-2KV 0.320 0.430 242 0.485 316 0.609 388 217 169 153
1 01C1-2KV 0.390 0.520 355 0.575 440 0.703 528 281 194 197
1/0 01C1/0-2KV 0.435 0.565 428 0.620 525 0.748 619 319 227 224
2/0 01C2/0-2KV 0.480 0.610 496 0.665 595 0.793 695 354 262 248
3/0 01C3/0-2KV 0.550 0.680 668 0.735 780 0.901 925 437 300 304
4/0 01C4/0-2KV 0.580 0.710 785 0.765 902 0.931 1053 495 351 345
262 01C262-2KV 0.652 0.802 946 0.857 1075 1.025 1244 550 407 383
313 01C313-2KV 0.720 0.870 1117 0.925 1256 1.095 1438 617 455 427
373 01C373-2KV 0.770 0.920 1319 0.975 1470 1.145 1661 692 516 477
444 01C444-2KV 0.845 0.995 1554 1.050 1715 1.220 1919 772 588 532
535 01C535-2KV 0.915 1.095 1882 1.150 2057 1.320 2258 871 662 597
646 01C646-2KV 1.030 1.210 2199 1.265 2392 1.435 2635 979 731 672
777 01C777-2KV 1.120 1.300 2686 1.355 2894 1.525 3154 1101 822 754
1111 01C1111-2KV 1.340 1.560 3781 1.615 4031 1.845 4455 1374 1025 943

• Unarmored – use product number. Example: 01C262-2KV. • 95°C IEC 92-3 Ampacity in Free Air @ 45°C Ambient
• Armored only – add the letter B. Example: 01C262-2KVB. • 100°C IEEE-45 STD 1998 in Free Air @ 45°C Ambient
Example: 01C262-2KV BN. Contact factory for specific environmental conditions.
*** 4/0 AWG and larger are per UL1309/CSA C22.2 No. 245
18 AWG to 3/0 AWG are in accordance with IEEE 45 and
UL 1309/CSA C22.2 No. 245.
6
EXANE® 125
Two Conductor Power Cable: 600 Volt

Armored and
Nominal Weight Nominal Weight Nominal Weight Ampacity**
Product Diameter Lbs per Diameter Lbs per Diameter Lbs per ICEA IEEE-45 IEC
Size Number* Inches M FT Inches M FT Inches M FT 125°C 100°C 95°C
16 02C16 0.352 70 0.407 132 0.535 190 22 19 19
14 02C14 0.380 80 0.435 148 0.560 214 33 31 26
12 02C12 0.416 111 0.480 173 0.605 252 44 40 31
10 02C10 0.490 156 0.575 204 0.670 320 64 49 44
8 02C8 0.590 217 0.645 320 0.775 440 77 64 54
6 02C6 0.688 316 0.743 430 0.911 573 111 85 74
5 02C5 0.785 409 0.840 515 1.020 687 146 101 95
4 02C4 0.868 550 0.943 655 1.090 828 153 110 104
3 02C3 0.918 583 0.973 740 1.140 921 180 132 114
2 02C2 0.988 682 1.043 845 1.215 1059 196 149 130
1 02C1 1.153 923 1.208 1115 1.425 1392 245 174 167
1/0 02C1/0 1.258 1087 1.313 1295 1.525 1598 278 199 190
2/0 02C2/0 1.348 1271 1.403 1490 1.635 1850 309 242 211
3/0 02C3/0 1.560 1870 1.615 2130 1.820 2600 382 265 258
4/0 02C4/0 1.695 2220 1.750 2506 1.985 2932 432 307 293
262 02C262 1.792 2600 1.847 2896 2.145 3269 481 358 325
313 02C313 1.968 3100 2.023 3430 2.305 4000 539 391 363
373 02C373 2.110 3605 2.165 3960 2.410 4650 599 442 405
444 02C444 2.250 4135 2.305 4520 2.570 5250 669 504 452
535 02C535 2.490 4950 2.545 5360 2.840 6150 741 566 508
646 02C646 2.698 5860 2.753 6330 3.065 7175 860 632 571
777 02C777 2.905 7010 2.960 7505 3.195 8400 968 684 641
Three Conductor Power Cable: 600 Volt

Armored and
16 03C16 0.370 84 0.425 142 0.550 212 18 16 16
14 03C14 0.398 103 0.453 165 0.580 245 28 25 21
12 03C12 0.440 135 0.495 202 0.620 285 37 31 25
10 03C10 0.520 202 0.575 280 0.700 375 49 41 37
8 03C8 0.625 280 0.680 390 0.849 536 63 52 45
6 03C6 0.735 405 0.790 539 0.955 697 91 70 61
5 03C5 0.880 570 0.935 753 1.105 913 120 82 78
4 03C4 0.925 700 0.976 853 1.144 1043 126 92 86
3 03C3 0.975 761 1.030 949 1.200 1125 148 108 96
2 03C2 1.050 919 1.105 1006 1.275 1314 161 122 107
1 03C1 1.246 1333 1.300 1495 1.500 1769 202 143 138
1/0 03C1/0 1.340 1552 1.395 1857 1.625 2138 229 164 156
2/0 03C2/0 1.480 1867 1.535 2141 1.765 2500 254 188 173
3/0 03C3/0 1.650 2487 1.705 2741 1.965 3205 313 218 213
4/0 03C4/0 1.810 3020 1.865 3282 2.123 3801 451 252 241
262 03C262 1.940 3499 1.995 3824 2.285 4452 395 294 268
313 03C313 2.090 4103 2.145 4385 2.435 5077 442 321 299
373 03C373 2.195 4743 2.250 5081 2.540 5734 492 361 334
444 03C444 2.395 5552 2.450 6050 2.745 6758 549 411 372
535 03C535 2.660 6824 2.715 7410 3.005 8190 608 465 418
646 03C646 2.905 8016 2.960 8486 3.250 9353 714 516 470
777 03C777 3.040 9382 3.095 9883 3.850 10790 803 562 528

• Unarmored – use product number. Example: 03C4. • 95°C IEC Ampacity Regulations in Free Air @ 45°C Ambient
• Armored only – add the letter B. Example: 03C4B. • 100°C IEEE-45 STD 1998 in Free Air @ 45°C Ambient
Example: 03C4BN. Contact factory for specific environmental conditions.
7
EXANE® 125
Four Conductor Power Cable: 600 Volt

Armored and
16 04C16 0.400 102 0.455 162 0.575 235 15 13 13
14 04C14 0.430 127 0.485 198 0.613 271 22 20 17
12 04C12 0.475 158 0.530 238 0.659 329 29 25 20
10 04C10 0.565 260 0.620 334 0.750 445 39 33 29
8 04C8 0.681 355 0.736 475 0.904 623 50 42 36
6 04C6 0.805 540 0.860 672 1.030 856 73 56 49
5 04C5 0.965 750 1.020 915 1.090 1115 96 66 63
4 04C4 1.020 927 1.067 1060 1.235 1277 101 74 68
3 04C3 1.080 1080 1.135 1162 1.300 1389 118 86 76
2 04C2 1.160 1155 1.215 1345 1.425 1683 128 98 86
1 04C1 1.376 1722 1.431 1875 1.659 2325 161 114 110
1/0 04C1/0 1.482 2058 1.537 2200 1.765 2739 182 131 125
2/0 04C2/0 1.650 2471 1.705 2643 1.935 3245 203 150 139
3/0 04C3/0 1.820 3238 1.875 3515 2.135 4096 250 174 170
4/0 04C4/0 1.995 3973 2.050 4115 2.335 4977 283 202 193
262 04C262 2.145 4418 2.200 4795 2.490 5450 315 235 214
313 04C313 2.340 5433 2.395 5680 2.685 6485 353 257 239
373 04C373 2.460 6276 2.515 6680 2.810 7417 393 289 267
444 04C444 2.650 7503 2.705 7820 2.995 8622 438 329 298
535 04C535 2.940 9159 2.995 9660 3.285 10484 504 372 334
646 04C646 3.220 10654 3.275 11193 3.565 12270 567 412 376
777 04C777 3.375 12730 3.430 13290 3.720 14490 638 450 423
Five Conductor Power Cable: 600 Volt

Armored and
16 05C16 0.440 118 0.495 192 0.620 265 15 13 13
14 05C14 0.467 145 0.522 225 0.650 315 22 20 17
12 05C12 0.525 190 0.580 278 0.710 367 29 25 20
10 05C10 0.620 308 0.675 393 0.805 538 39 33 29
8 05C8 0.748 451 0.815 550 0.980 713 50 42 36
6 05C6 0.925 698 0.980 830 1.150 1011 73 56 49
5 05C5 1.060 960 1.115 1140 1.285 1350 73 66 63
4 05C4 1.115 1116 1.170 1240 1.340 1505 101 74 68
3 05C3 1.185 1270 1.240 1470 1.450 1775 118 86 76
2 05C2 1.275 1477 1.335 1630 1.545 1984 128 98 86
1 05C1 1.545 2148 1.605 2425 1.835 2806 161 114 110
1/0 05C1/0 1.700 2514 1.755 2800 2.015 3266 182 131 125
2/0 05C2/0 1.825 3005 1.880 3305 2.140 3898 203 150 139
3/0 05C3/0 2.040 4046 1.095 4386 2.385 5013 250 174 170
4/0 05C4/0 2.210 4682 2.265 5085 2.550 5899 283 202 193

8
EXANE® 125
#16 AWG Multi-Conductor Control Cable: 600 Volt

Armored and
Number Nominal Weight Nominal Weight Nominal Weight Ampacity**
of Product Diameter Lbs per Diameter Lbs per Diameter Lbs per ICEA IEEE-45 IEC
Cond. Number* Inches M FT Inches M FT Inches M FT 125°C 100°C 95°C
4 04C16 0.400 95 0.455 162 0.590 235 15 13 13
5 05C16 0.440 115 0.495 192 0.620 265 15 13 13
7 07C16 0.475 145 0.530 225 0.655 300 15 11 11
8 08C16 0.550 181 0.605 245 0.733 371 13 11 11
10 10C16 0.585 213 0.640 300 0.770 406 9 8 8
16 16C16 0.670 307 0.725 395 0.855 545 9 8 8
20 20C16 0.735 350 0.790 475 0.960 635 9 8 8
24 24C16 0.812 443 0.875 575 1.045 755 8 7 7
37 37C16 0.970 668 1.025 785 1.195 1033 7 6 6
44 44C16 1.085 735 1.140 915 1.315 1125 6 6 6
60 60C16 1.194 1042 1.249 1160 1.457 1514 6 6 6
91 91C16 1.460 1470 1.515 1750 1.745 2119 6 6 6

Armored and
4 04C14 0.430 115 0.485 191 0.620 275 22 20 17
5 05C14 0.475 158 0.522 225 0.650 315 22 20 17
6 06C14 0.515 179 0.560 250 0.688 340 22 20 17
7 07C14 0.515 199 0.560 265 0.688 366 20 18 15
10 10C14 0.636 2840 0.691 370 0.819 500 14 13 11
12 12C14 0.660 290 0.715 400 0.885 550 14 13 11
14 14C14 0.695 364 0.750 445 0.920 600 14 13 11
20 20C14 0.810 495 0.865 630 1.025 791 14 13 11
24 24C14 0.930 627 0.985 745 1.155 930 13 11 10
30 30C14 0.990 695 1.045 865 1.215 1060 13 11 10
37 37C14 1.060 877 1.115 1025 1.280 1336 11 10 9
44 44C14 1.190 990 1.245 1190 1.455 1510 10 9 7
91 91C14 1.630 1980 1.685 2250 1.915 2750 10 9 7

Armored and
Unarmored Armored – “B” Sheathed “BN”
4 04C12 0.475 155 0.530 138 0.665 325 30 25 20
5 05C12 0.525 190 0.580 278 0.710 370 30 25 20
6 06C12 0.570 220 0.625 320 0.750 415 30 25 20
10 10C12 0.712 389 0.767 475 0.935 649 19 16 13
20 20C12 0.950 714 1.005 840 1.175 1071 19 16 13
24 24C12 1.050 795 1.105 970 1.275 1180 17 14 11
37 37C12 1.190 1140 1.245 1340 1.453 1743 15 12 10

9
EXANE® 125
#18 AWG Instrumentation Cable – Shielded Pairs, Overall Shield: 600 Volts
Armored and
Number Nominal Weight Nominal Weight Nominal Weight
of Product Diameter Lbs per Diameter Lbs per Diameter Lbs per
Pairs Number* Inches M FT Inches M FT Inches M FT
1 01P18I/S-OS 0.340 68 0.405 126 0.530 270
2 02P18I/S-OS 0.565 177 0.625 282 0.795 376
3 03P18I/S-OS 0.641 225 0.696 335 0.864 454
4 04P18I/S-OS 0.694 268 0.749 370 0.917 536
5 05P18I/S-OS 0.715 285 0.770 395 0.928 560
7 07P18I/S-OS 0.811 364 0.866 500 1.034 656
8 08P18I/S-OS 0.950 444 1.010 645 1.173 814
10 10P18I/S-OS 1.010 576 1.065 705 1.233 929
12 12P18I/S-OS 1.071 655 1.126 798 1.294 998
16 16P18I/S-OS 1.179 767 1.234 960 1.442 1194
18 18P18I/S-OS 1.225 890 1.280 1110 1.495 1285
24 24P18I/S-OS 1.438 1089 1.493 1340 1.721 1688
Armored and
1 01P16I/S-OS 0.360 70 0.415 130 0.545 201
2 02P16I/S-OS 0.609 188 0.664 296 0.792 394
3 03P16I/S-OS 0.668 243 0.723 353 0.891 487
4 04P16I/S-OS 0.685 285 0.740 395 0.908 538
5 05P16I/S-OS 0.751 342 0.797 420 0.968 548
7 07P16I/S-OS 0.835 385 0.890 540 1.025 695
8 08P16I/S-OS 0.972 543 1.027 702 1.205 943
10 10P16I/S-OS 1.070 562 1.183 730 1.238 945
12 12P16I/S-OS 1.091 714 1.146 820 1.313 1118
16 16P16I/S-OS 1.206 895 1.261 1097 1.460 1250
18 18P16I/S-OS 1.260 925 1.315 1170 1.515 1370
24 24P16I/S-OS 1.485 1288 1.541 1410 1.769 1916
Armored and
1 01P14I/S-OS 0.390 83 0.445 148 0.578 222
2 02P14I/S-OS 0.658 241 0.691 335 0.830 425
3 03P14I/S-OS 0.685 250 0.740 375 0.905 520
4 04P14I/S-OS 0.755 295 0.810 425 0.970 570
5 05P14I/S-OS 0.815 350 0.870 580 1.032 649
7 07P14I/S-OS 0.930 480 0.985 645 1.143 812
8 08P14I/S-OS 1.040 550 1.095 750 1.265 930
10 10P14I/S-OS 1.090 690 1.145 805 1.285 1026
12 12P14I/S-OS 1.140 755 1.195 955 1.395 1253
*Exane-125® Ordering Part Number

• Unarmored – use product number. Example: 04P14I/S-OS.
• Armored only – add the letter B. Example: 04P14I/S-OS-B.
• Armored and Sheathed – add the letters BN. Example: 04P14I/S-OS-BN.
10
EXANE® 125
#18 AWG Instrumentation Cable –

Shielded Triads, Overall Shield: 600 Volts
Armored and
Triads Number* Inches M FT Inches M FT Inches M FT
1 01T18I/S-OS 0.360 79 0.415 144 0.542 201
2 02T18I/S-OS 0.602 160 0.657 270 0.780 355
3 03T18I/S-OS 0.641 205 0.696 315 0.858 439
4 04T18I/S-OS 0.708 267 0.763 390 0.932 520
5 05T18I/S-OS 0.771 304 0.826 435 0.988 586
7 07T18I/S-OS 0.882 423 0.937 575 1.099 740
8 08T18I/S-OS 0.998 566 1.015 660 1.175 830
12 12T18I/S-OS 1.150 710 1.206 900 1.435 1175

• Unarmored – use product number. Example: 04T18I/S-OS.
• Armored only – add the letter B. Example: 04T18I/S-OS-B.
• Armored and Sheathed – add the letters BN. Example: 04T18I/S-OS-BN.
#16 AWG Instrumentation Cable –

Shielded Triads, Overall Shield: 600 Volts
Armored and
Triads Number* Inches M FT Inches M FT Inches M FT
1 01T16I/S-OS 0.376 129 0.431 146 0.554 207
3 03T16I/S-OS 0.674 241 0.849 335 0.891 483
4 04T16I/S-OS 0.739 303 0.794 425 0.956 565
6 06T16I/S-OS 0.967 538 0.976 585 1.149 810
7 07T16I/S-OS 0.967 480 0.976 635 1.149 810
8 08T16I/S-OS 1.103 600 1.158 685 1.230 983
12 12T16I/S-OS 1.215 817 1.270 1018 1.472 1284

• Unarmored – use product number. Example: 06T16I/S-OS.
• Armored only – add the letter B. Example: 06T16I/S-OS-B.
• Armored and Sheathed – add the letters BN. Example: 06T16I/S-OS-BN.
11
NOV PART NO.:
IB8926-1A
NOV PART NO.:
IOMGDD1
INSTALLATION, OPERATION AND MAINTENANCE GUIDE
FOR INDOOR/OUTDOOR DRY-TYPE TRANSFORMERS

WHICH UTILIZE NH SERIES, NJ1, NJ2, NJ3 OR NJ4 ENCLOSURES
*Note: This guide is Trilingual Literature No.: IOMGDDI

(English, French and Spanish)* Issue Date: May 2011
Safety Precautions
(1) Do not lift or move a transformer without proper equipment and experienced personnel. On some
larger kVA distribution transformers, lifting provisions are provided on the inside of the enclosure
on the core & coil.
(2) Do not off-load the transformer until a full inspection has been completed.
(3) Use terminals only for electrical connections. Flexible connectors are recommended for bus
connections. The transformer terminals are not designed to support the weight of supply or load
cables. Uni-strut supports can be added in the field providing proper clearances are maintained.
(4) Connections should only be in accordance with the nameplate diagram or connection drawings.
(5) Make sure all power is disconnected before attempting any work on a transformer or inside of
control box and ground all windings.
(6) Make certain all ground connections, line terminals and selected taps are complete and tightened
before energizing the transformer.
(7) Do not attempt to change any taps - primary or secondary, while the transformer is energized.
(8) Do not change connections when the transformer is energized.
(9) Do not tamper with control panels, alarms, interlocks or control circuits.
(10) Do not adjust or remove any accessories or cover plates while the transformer is energized.
No supply cables should come in contact with the core or any live part except the terminal that it is
intended for.
CONTENTS
General 3
Handling 3
Receiving & Inspection 3
Storage 3
Installation 3
Ventilation 4
Accessibility 4
Transformer Sound Levels 4
Cable Connections 4
Grounding 5
Inspection Before Energization 5
Operation 5
Maintenance 6
Dry-out of Transformers 6
Accessories 6
Appendix A 7
Appendix B 8
Appendix C 8
Appendix D 9
Figure 1 10
Figure 2 11
Figure 3 12
-2-
INSTALLATION, OPERATION AND MAINTENANCE
OF DRY-TYPE TRANSFORMERS
GENERAL pertinent information relative to the order and the

circumstances should be filed with the local sales
office.
Dry-type transformers are manufactured to If this examination of the unit takes place
provide optimum performance for a lifetime of outdoors, caution should be exercised such that
uninterrupted service. Careful attention to the following inclement weather would not present further hazard.
instructions is recommended for safe and reliable
operation.
Installation, operation and maintenance of STORAGE
transformers should be performed by authorized
persons, familiar with electrical apparatus and the
Transformers that will not be immediately
potential hazards involved.
installed and energized, should be stored in a clean
dry environment away from any environmental
Warning: Danger! There is the potential of airborne contaminants.
electric shock whenever working in or It is recommended that transformers be stored in
a heated building with the protective plastic wrap still
around electrical equipment such as installed.
transformers. Power must be shut off
before any work is conducted on a
transformer. INSTALLATION
As with any electrical device, transformers must

be installed according to the requirements of the Enclosures are designed and approved
national and local electrical codes. Refer to ANSI/IEEE in accordance with specifications
C57-94 may also be referred to for recommended CSA 22.2 No. 47 (General Purpose),
installation, application, operation and maintenance of CSA 22.2 No. 94 (Specialty Enclosures),
dry-type transformers.
NEMA 250 and UL 50.
For IEC enclosure equivalents please see
HANDLING IEC 60529 (Enclosure Classifications
Designations).
Transformers are palletized and can either be
lifted via a forklift truck or hoisted by the lifting lugs
provided. a) Indoor/Outdoor Dry-Type Transformers with
Appropriate lifting equipment should be used Enclosures
relative to the size of each transformer. For safety
purposes and to protect the transformer, spreader bars Most dry-type transformers are supplied with
are recommended. either a type 3R, 4 or 12 enclosure. Units may be
No attempt should be made to lift or move a installed indoors, or outdoors where applicable. If
transformer from any points on the unit other than equipped with a type 1 enclosure, these units are for
those indicated. Refer to Figures 1 and 2 (pages 10 indoor use only.
and 11). Ventilated enclosures are recommended for
indoor installation but may also be installed outdoors
where weather conditions allow a type 3R ventilated
RECEIVING & INSPECTION enclosure to be installed.
For any outdoor location, the appropriate
applicable codes must be followed including cable
Immediately after receiving the transformer, it
installation and hardware suitable for outdoor service.
should be inspected for any transit damage and for
Water tight couplings must be used at the
correctness against the shipping documents.
knockouts and any holes in the enclosure must be
The unit should be examined for any breaks in its
drilled below any un-insulated live parts, (below LV
packaging, dented or damaged enclosures or missing
terminals).
parts from the packing list.
Dry-type transformers may be located in an
If any damage is noted, a claim should be filed
upright position on walls, floors, posts, beams or other
immediately with the carrier and a second copy of all
-3-
locations capable of supporting their weight with the However, transformers should not be located in
proper accessories attached. Refer to Appendix B and areas where stored items are likely to interfere with
C (page 8) for wall mounting kits. either natural air convection or the capability to have
Conventional open ventilated dry-type them inspected. Passage ways or other areas where
transformers have a bottom screen for air convection. people could be exposed to live parts during
When transformers are mounted above the ground inspection should also be avoided.
surface a catcher plate should be installed under each Adequate protection should be provided under
transformer as a safety precaution against any hot any circumstances.
particles that may fall through the screen in the event
of a faulted condition. Refer to Appendix B and C
(page 8).
TRANSFORMER SOUND LEVELS
It is important that ventilated transformers be
installed in a dry area where the ambient air is clean Transformers are an electrically energized
and free of dust, dirt, corrosive fumes, moisture, heat apparatus and by their nature emit sound due to their
or other adverse conditions. Transformers should not component materials.
be installed in such a place having the possibility of Transformers are required to meet NEMA
water logging inside the enclosure. standards for the maximum sound levels permissible.
In the event that a transformer has been These sound level standards vary from 40 to 60 DB
subjected to moisture or dampness before installation, and hence, can be an annoyance if located in close
ensure that it is completely cleaned and dried before proximity to where people work or reside.
energization. The blowing of warmed air through the Care should therefore be exercised in selecting
transformer is recommended to dry internal sites for transformers particularly to avoid sensitive
components. Refer to the section on dry-out of areas like hospitals, classrooms, medical or office
transformers. facilities.
b) Indoor/Outdoor Transformers with The following guidelines may be helpful:

Non-Ventilated Type 4, 4X or 12 Enclosures.
Units should be mounted away from corners or

Transformers equipped with non-ventilated type reflecting walls or ceilings.
4, 4X or 12 enclosures maybe located either indoors or
outdoors in any similar location noted above. Non-  Cable or other flexible conduit should be
ventilated enclosed transformers, although slightly considered to make connections.
larger, offer much greater protection against a variety
of elements such as dust, dirt, snow, moisture, rain All dry-type transformers are provided with

etc. isolation rubber mounts between the core and
For any outdoor location, the appropriate coil assembly and the enclosure. However,
applicable codes must be followed including cable sound absorbing vibration isolators may also be
installation and hardware suitable for outdoor service. installed between the transformer and its
mounting surface.
VENTILATION  Acoustically absorbing materials could be

considered for walls and ceilings around the
Transformers are required to be installed in an unit.
area where they can be cooled by means of the free
circulation of air where the average ambient The location of the unit should be located as

temperature is 30°C (86°F) and should not exceed far as practical from areas where sound levels
40°C (104°F) at any time. could be considered undesirable.
Adequate ventilation is essential for transformers
to meet their nameplate kVA capability. The distance a
transformer should be located away from any wall or
CABLE CONNECTIONS
any other obstruction is stated on the nameplate.
To allow free, clean circulation of air through the The connecting cable size is determined from the
ventilation openings or around a non-ventilated unit. line current rating of the transformers primary and
secondary windings and may be selected from the
information in Appendix A (page 7). Cables rated for at
ACCESSIBILITY least 90°C (194°F) is recommended as are ALC9CU
lugs.
NEC standards require that transformers be Convenient pre-punched knockouts are provided
accessible for inspection and located accordingly. on all ventilated transformer enclosures up to 150 kVA
three phase and 100 kVA single phase, to facilitate
-4-
cable entry. INSPECTION BEFORE ENERGIZATION
For non-ventilated transformers, pre-punched
knockouts are not provided and the appropriate cable
connector suitable for the application must be used. For the safe and proper operation of the
Please refer to figures 1 and 2 (pages 10 and 11) transformer, please check and verify the following:
for cable entry locations.
a) The insulation resistance, core to primary, core to
secondary and primary to secondary, should be
Warning: Never attempt to change con- greater than 10k ohms.
nections or taps unless the transformer is
b) Before energizing and connecting any loads,
de-energized and all windings grounded. please measure and verify the output voltage
matches nameplate specifications.
Side entry of cables is recommended as it leaves
the ventilated areas unobstructed. c) Ensure correct phase connections. Refer to the
Cable connection lugs of plated copper or nameplate vector diagram.
aluminum may be used to connect to the transformer
terminals. Terminals should be cleaned and electrical d) The load on a delta secondary winding with a 120
joint compounds are recommended for use on all volt center tap should not exceed the normal
electrical connections. current rating of the winding. This center tap is
Refer to the transformer nameplate for primary designed for a max. of 5% of the nameplate kVA.
and secondary voltage connection combinations and
primary and/or secondary tap positions as applicable. e) When windings are connected in parallel (as in
Transformers received from the factory will have the case of dual voltage primaries), the primary
tap leads installed on the nominal, or 100%, voltage taps for all coils must be connected to the
position. The balance of the tap positions will still be identical percentage tap positions to avoid the
coated with impregnation material and insulation. shorting of turns. For tap positions, refer to the
To change taps, it is necessary to gently remove nameplate on the transformer.
all contaminants and insulation from the surface of the
top and bottom of the taps (eye-loop or lugs) by f) The enclosure should be grounded with the
sanding the lugs clean. appropriately sized conductor.
The surface of the tap lead should be clean and
coated subsequently with electrical compound to all g) The total load among all the phases should be
non-plated contacts between the jumper terminal and balanced as much as possible for optimum
the tap. Assemble jumpers to taps as per Appendix D performance of the transformers windings.
(Drawing 1 for single conductor eye-loops and tap lugs Any three phase or single phase load may be
or Drawing 2 for double conductor eye-loop taps). connected to the transformer but the kVA loading
on each phase must not exceed 1/3 of the
nameplate kVA rating.
NOTE: After installation of cables and
connectors, a minimum of 1” clearance h) The clearance and tightness of all electrical
must be maintained from energized parts connections should be checked.

to all case parts.
i) If there is any reason to suspect that the
transformer has been exposed to moisture during
GROUNDING transit or storage, it should be checked for
dryness before energization. This can be done by
making an insulation resistance test. Dry-out
All core and coil assemblies are solidly grounded procedures are on page 6.
to the enclosure internally to ensure that all conductive
metal parts have the same potential.
The transformer enclosure in turn should also be OPERATION
securely and effectively grounded as a safety
precaution.
For all relatively normal and clean installations,
This grounding should be in accordance with
dry-type transformers will operate satisfactorily under
national electrical code standards.
normal conditions of energization and load.
For your reference, fully loaded dry-type
transformers may appear warm to the touch,
particularly on the cover of the unit.
Standards permit the temperatures of the cover
-5-
to be 65°C (149°F) over ambient. This represents Internal maintenance must be performed
normal loading and should not be of concern.
Dry-type transformers are designed to operate
with a transformer de-energized, isolated
continuously at their full nameplate kVA rating. and with the terminals grounded.
ANSI C57.96 provides guidance for loading Maintenance would include internal cleaning,
transformers under different conditions including: tightening of links and bolted connections, servicing
and inspection of auxiliary devices.
Ambient temperatures that are varied from the

Air ducts should be free of any accumulation of
ambient temperatures required for transformer
dust and debris and any bolted connections of
operation.
terminals must be in good condition.
Vacuuming or blowing of compressed air from
Short time overload as it relates to time and

the top down is an accepted practice for removing dust
temperature and the corresponding loss of life of
from the ducts of a transformer coil. Low pressure, dry
the transformer.
air should be used to avoid further contamination of
the windings by foreign material.
Overload that results in a reduction of life

The ground connection should also be checked
expectancy of the transformer.
to ensure a low impedance connection. The
accumulation of ice, snow or any other object blocking
If the transformer is experiencing increased
the ventilation should be cleaned up immediately
temperatures, the following load characteristics
during the operation of the transformer.
should be considered immediately:
On outdoor units where filters have been
Rigorous motor starting loads or other impact
 installed, being exposed to the outside atmosphere
type loading for which a specific transformer for can cause the filters to get dirty quickly. A periodic
that application is required. check of the filters will help avoid filter clogging and
thus transformer overheating. Also, never run the
Over-excitation of unit due to excess supply line
 transformer without the filters properly in place.
voltage or current.
DRY-OUT OF TRANSFORMERS
Ambient temperatures above standard.

Overload beyond ANSI C57.96 guidelines.

 In the event that transformers have been
exposed to moisture such as condensation or rain, it is
Harmonic distortions of the supply line voltage
 advisable to dry-out any unit prior to energization.
and currents. Drying may be accomplished by using any hot or
warmed air, radiant heat or internal heat that is
If overheating is noted, any attempt to add directed through the windings. Heated air should be
supplemental fan cooling must be in accordance with allowed to rise up through the windings for a minimum
factory installation guidelines. Incorrectly installed fans of twenty four (24) hours after the evidence of
can misdirect the airflow and cause serious condensation is no longer visible.
deterioration of the insulation life in a transformer coil. Transformers that have been exposed to flood
Dry-type transformers can be shut down and conditions, direct rain or sprinklers, may not be able to
stored for extended periods of time without any be dried out appropriately. Contact the transformer
deterioration. Care must be exercised to clean and dry manufacturer for appropriate action.
units prior to energization, as previously outlined.
ACCESSORIES
MAINTENANCE
Dry-type distribution transformers are available
Under normal operating conditions and with a number of accessories to facilitate installation.
environments, dry-type transformers do not require Consult your local dealer or distributor for the
maintenance. However, periodic care and inspection is purchase of any of the items which may be carried in
a good practice particularly dependent on the inventory.
environmental conditions in which the unit is installed.
Peripheral inspection and external dust removal 1) Wall Mounting Brackets
may be carried out while the transformer is in
operation. However, access covers must not be Encapsulated transformers have integral wall
opened under energized conditions. mounting capabilities for units up to 285 lbs. Units over
285 lbs. must be floor mounted only.
-6-
Ventilated dry-type transformers are normally APPENDIX A
designed to be floor mounted only. However, some
ventilated units up to 51kVA are supplied in enclosures
that have integral wall mounting capabilities. These AMPACITY RATINGS FOR CONNECTIONS
units can be conveniently mounted on walls, beams or
poles. A. For a single phase transformer
Conventional open ventilated dry-type
Line Amperes = volt-amperes
transformers have a bottom screen for air convection.
line volts
When transformers are mounted above the ground
B. For a three phase transformer
surface a catcher plate should be installed under each
transformer as a safety precaution against any hot
Line Amperes = volt amperes
particles that may fall through the screen in the event
3 X line Volts
of a faulted condition. Refer to Appendix B and C
(page 8).
Full Load Current Table
2) Sound Isolation Pads Single Phase Transformer
All dry-type transformers have rubberized sound kVA Current in Amperes
absorbing pads mounted internally between the core Rating 120V 240V 416V 480V 600V
and coil assembly and the enclosure.
For maximum absorption of vibration and 3 25.0 12.5 7.21 6.25 5.00
emission of sound, additional sound isolation pads are 5 41.6 20.8 12.0 10.4 8.33
recommended for installation between the transformer 7.5 62.5 31.2 18.0 15.6 12.5
and the mounting surface. 10 83.3 41.6 24.0 20.8 16.6
These molded neoprene and steel plate 15 125 62.5 36.0 31.2 25.0
assemblies virtually eliminate vibration noise between 25 208 104 60.0 52.0 41.6
the transformer and the mounting surface.
37.5 312 156 90.1 78.1 62.5
Consult the manufacture’s catalog for the part
50 416 208 120 104 83.3
number of the correct isolation pad required
75 625 312 180 156 125
100 833 416 240 208 166
3) Connectors 150 1250 625 360 312 250
167 1391 695 401 347 278
Connectors for the installation of dry-type 250 2083 1041 600 520 416
transformers are readily available. These connectors
333 2775 1387 800 693 555
are suitable for either copper or aluminum cable.
Connectors should be sized and installed in
accordance with your local electrical code Full Load Current Table
requirements using the best practices to ensure safe Three Phase Transformer
and reliable operation. Cable surfaces should be
kVA Current in Amperes
cleaned and electrical compound should be used for
all joints. Rating 208 240V 380V 416V 480V 600V
2 5.55 4.81 3.03 2.77 2.40 1.92
Selecting Connectors
3 8.32 7.21 4.55 4.16 3.60 2.88
a) Determine the primary current for the required 6 16.6 14.4 9.11 8.32 7.21 5.77
transformer from the Appendix A. 9 24.9 21.6 13.6 12.4 10.8 8.66
15 41.6 36.0 22.7 20.8 18.0 14.4
b) Similarly, determine the secondary current rating 30 83.2 72.1 45.5 41.6 36.0 28.8
for the transformer from Appendix A. 45 124 108 68.3 62.4 54.1 43.3
75 208 180 113 104 90.2 72.1
c) For 120/240 voltage connections the current
112.5 312 270 170 156 135 108
should be based on 240 volts.
150 416 360 227 208 180 144
d) For 240/480 volt connections, the current should 225 624 541 341 312 270 216
be based on 480 volts. 300 832 721 455 416 360 288
450 1249 1082 683 624 541 433
500 1387 1202 759 693 601 481
600 1665 1443 911 832 721 577
750 2081 1804 1139 1040 902 721
-7-
APPENDIX B
LOCATION OF WALL MOUNTING BRACKETS AND CATCHER PLATES
FOR NH3 SERIES TYPE 3R ENCLOSURES
Optional Wall
Mounting Bracket
Catcher Plate Optional Ceiling

Catcher Plate Where Local Code Requires Mounting Bracket
Where Local Code Requires
APPENDIX C
LOCATION OF WALL MOUNTING BRACKETS AND CATCHER PLATES
FOR NH5 & NH6 SERIES TYPE 3R ENCLOSURES
Wall Mounting
Hole Locations
Catcher Plate
Floor/Ceiling Mounting
Where Local Code Requires
Hole Locations
-8-
APPENDIX D
Jumper Assembly Drawings
DRAWING 1 :
DRAWING
SINGLE CONDUCTOR 1 TAP LUGS
EYELOOP
Single Conductor Eyeloop Tap Lugs
Top View
Steel
STEELFlat
FLATWasher
WASHER
CONNECTOR
Connector
TINNED
Tinned BRASSWasher
Brass WASHER
Side View Tap LoopON

TAP LOOP onCOIL
Coil
STEELFlat
Steel FLAT Washer
WASHER
STEELLock
Steel LOCK Washer
WASHER
DRAWING 2 :
DRAWING 2
DOUBLE CONDUCTOR EYELOOP TAP LUGS
Double Conductor Eyeloop Tap Lugs
Top View
STEEL FLAT
Steel FlatWASHER
Washer
TapLOOP
TAP LoopONon Coil
COIL
TINNEDBrass
Tinned BRASS WASHER
Washer
Side View
Steel FlatWASHER
STEEL FLAT Washer
STEEL Lock
Steel LOCK WASHER
Washer
-9-
FIGURE 1
Typical Type 3R, NH Series Ventilated Enclosure Assembly for Three Phase and Single
Phase Transformers.
Notes:
1. Handling - units are designed to be raised by a fork lift from underneath the pallet. Final positioning of the unit
with the pallet removed can be via a fork lift under the transformer with the forks between the channels.
2. Shipping - units are shipped on pallets which are to be removed at installation.
3. Installation - This transformer can be installed indoor or outdoor providing a degree of protection against falling
rain, sleet and external ice formation.
4. All general purpose/drive isolation transformers should be located away from walls or any other obstructions at
least 6 inches when floor mounted and 4 inches when wall mounted.
5. DO NOT block bottom ventilation area.
Removable front
access panel
Cable entrance
knockouts (2 per side)
Position fork For final positioning

lift under pallet with pallet removed,
fork lift points are under
the transformer
- 10 -
FIGURE 2
Typical Type 3R, NJ Series Ventilated Enclosure Assembly for Three Phase or Single Phase
Transformers.
Notes:
with the pallet removed can be via a fork lift under the transformer with the forks between the channels. (Note:
for transformers weighing greater than 2350 lbs should be lifted by removing the top panel and
accessing the lifting provisions on top of the top of the core and coil.)
3. Installation - This transformer can be installed indoor or outdoor providing a degree of protection against falling
rain, sleet and external ice formation.
least 6 inches when floor mounted and 4 inches when wall mounted. (Note: These enclosures are not intended
to be wall mounted. They may be mounted on a customer supplied platform.)
5. DO NOT block bottom ventilation area.
Recommended cable
Removable front entry location (both
access panel sides). Refer to
outline drawing for
exact dimensions.
Position fork For final positioning with pallet

lift under pallet removed, fork lift points are
under the transformer. Forks
must be inserted all the way
through the depth.
- 11 -
FIGURE 3
Typical Type 4 & 12, NH Series Non-Ventilated Enclosure Assembly for Three Phase or
Single Phase Transformers.
Notes:
with the pallet removed can be via a fork lift under the transformer with the forks between the channels.
3. Installation - This is a non-ventilated indoor or outdoor enclosure designed primarily to provide a degree of
protection against falling dirt, rain, sleet, snow, windblown dust, splashing water, hose-directed water and that will
be undamaged by the external formation of ice on the enclosure. It is suitable in areas where exposure to large
amounts water from any direction is possible. (Note: not submersible)
least 6 inches when floor mounted and 4 inches when wall mounted.
Lifting Hook
Removable front
access panel
Recommended cable entry location

(either side). Refer to outline
Position fork drawing for exact dimensions.
lift under pallet
- 12 -
GUIDE D'INSTALLATION, DE FONCTIONNEMENT ET
D'ENTRETIEN
POUR LES TRANSFORMATEURS À SEC INTÉRIEUR/EXTÉRIEUR
UTILISANT UN BOÎTIER DE LA SÉRIE NH, NJ1, NJ2, NJ3 OU NJ4
N° de document: IOMGDDI
Date de publication: Mai 2011
Consignes de sécurité
(1) Ne levez pas et ne déplacez pas un transformateur sans disposer de l'équipement approprié et du personnel
expérimenté. Sur certaines unités de grandes dimensions, les dispositifs de levage sont situés à l'intérieur du
boîtier sur le noyau-bobines.
(2) Ne déchargez pas le transformateur tant qu'une inspection complète n'a pas été exécutée.
(3) N'utilisez les bornes que pour les branchements électriques. Il est recommandé d'utiliser des connecteurs
flexibles pour les connexions sur barre. Les bornes du transformateur ne sont pas conçues pour supporter
le poids des câbles d'entrée ou de sortie. Des supports de type "Uni-Strut" peuvent être ajoutés au site en
s'assurant de rencontrer les distances électriques.
(4) Les branchements doivent respecter le schéma de la plaque signalétique ou les diagrammes de connexion.
(5) Vérifiez que la source d'alimentation est coupée avant de commencer à travailler sur un transformateur ou à
l'intérieur de la boite de jomction Mettre tous les enroulements à la terre.
(6) Vérifiez que toutes les liaisons à la terre, les bornes d'entrée et de sortie et les prises sélectionnées sont
complètes et sont bien serrées avant de mettre le transformateur sous tension.
(7) Ne tentez pas de changer des prises (primaires ou secondaires), alors que le transformateur est sous tension.
(8) Ne changez pas les branchements lorsque le transformateur est sous excitation.
(9) N'altérez pas les panneaux de commande, les alarmes, les verrouillages ni les circuits de commande.
(10) Ne réglez pas et ne retirez pas les accessoires ou les plaques de recouvrement lorsque le transformateur est
sous tension. Les câbles d'entrée et de sortie ne doivent pas venir en contact avec le noyau ou toutes autres
parties vivantes sauf les bornes conçues à cette fin.
TABLE DES MATIÈRES

Informations générales 15
Manutention 15
Contrôle et inspection 15
Entreposage 15
Installation 15
Ventilation 16
Accessibilité 16
Niveaux de bruit du transformateur 16
Branchement des câbles 16
Mise à la terre 17
Inspection avant la mise sous tension 17
Fonctionnement 17
Entretien 18
Séchage des transformateurs 18
Accessoires 18
Appendice A 19
Appendice B 20
Appendice C 20
Appendice D 21
Figure 1 22
Figure 2 23
Figure 3 24
- 14 -
INSTALLATION, FONCTIONNEMENT ET ENTRETIEN
DES TRANSFORMATEURS DE TYPE SEC
INFORMATIONS GÉNÉRALES conservée au bureau de vente local.

Si l'examen de l'appareil a lieu à l'extérieur, il faut
prendre les précautions nécessaires afin que des
Les transformateurs de type sec sont fabriqués
conditions météorologiques inclémentes ne présentent
pour fournir un rendement optimal pendant une durée de
pas davantage de risques.
vie utile sans interruption. Il est recommandé de porter
une attention particulière aux consignes suivantes afin
d'obtenir un fonctionnement fiable et sûr. ENTREPOSAGE
L'installation, le fonctionnement et l'entretien des
transformateurs doivent être effectués par du personnel Les transformateurs qui ne sont pas immédiatement
autorisé, familier avec l'appareillage électrique utilisé et installés et mis sous tension doivent être entreposés
des dangers potentiels qu'il représente. dans un endroit propre et sec, à l'abri des contaminants
atmosphériques environnants.
Avertissement : Danger! Travailler sur un Il est recommandé d'entreposer les transformateurs
transformateur ou autour d'un équipement dans un immeuble chauffé muni de l'emballage plastique
d'origine.
électrique similaire présente un risque de choc
électrique. Il est indispensable de mettre hors
tension la source d'alimentation électrique INSTALLATION
avant d'entreprendre des travaux sous tension.
Comme pour tout appareil électrique, les Les boîtiers sont conçus et approuvés
transformateurs doivent être installés en conformité avec selon les normes CSA C22.2 No 47(usage
les codes nationaux et locaux de l'électricité. Veuillez
également vous reporter à la norme ANSI/IEEE C57-94
général), CSA22.2 No 94 (usage spécial),
pour les recommandations portant sur l'installation, NEMA 250 et UL50.
l'utilisation, le fonctionnement et l'entretien des Pour un boîtier équivalent sous CEI, voir
transformateurs de type sec. la norme IEC60259 (Classification des
boîtiers).
MANUTENTION
Les transformateurs sont posés sur palettes

pouvant être soulevées à l'aide d'un chariot élévateur à a) Transformateurs de type sec pour intérieur et
fourche ou levées par les anneaux de levage fournis. extérieur avec boîtiers
L'équipement de levage doit être adapté à la taille
de chaque transformateur. Il est recommandé d'utiliser La plupart des transformateurs de type sec sont
des barres d'écartement pour les besoins de sécurité et munis d'un boîtier type 3R, 4 ou 12. Les appareils
de protection du transformateur. peuvent être installés à l'intérieur ou à l'extérieur, le cas
En aucun cas, un transformateur ne doit être échéant. S'ils sont munis d'un boîtier type 1, ils doivent
soulevé ou déplacé en utilisant d'autres points d'ancrage être utilisés seulement à l'intérieur.
que ceux indiqués sur l'appareil. Veuillez vous reporter Les boîtiers ventilés sont recommandés pour être
aux figures 1 et 2 (page 22-23). installés à l'intérieur, mais ils peuvent également être
installés à l'extérieur lorsque les conditions
atmosphériques permettent l'installation d'un boîtier avec
CONTRÔLE ET INSPECTION aération de type 3R.
Pour les installations à l'extérieur, les codes en
Immédiatement après avoir reçu le transformateur, vigueur qui s'appliquent à l'installation doivent être
une inspection doit être effectuée pour vérifier la respectés, notamment ceux concernant l'installation des
présence de dommages éventuels survenus durant le câbles et le matériel convenant à une utilisation
transport ainsi que l'exactitude des documents extérieure.
d'expédition. Des connecteurs de conduits étanches doivent être
L'emballage sera examiné afin d'y détecter des bris, utilisés aux endroits prévus (disques défonçables) et pour
de voir si les boîtiers sont bosselés ou abîmés et si des toutes autres ouvertures. Si des trous sont percés sur les
pièces inscrites sur le bordereau de marchandises sont parois du boîtier, ils doivent être faits en dessous des
manquantes. parties sous tension non isolées (sous les bornes B.T.).
Si des dommages sont constatés, une réclamation Il est possible de poser les transformateurs de type
doit immédiatement être effectuée avec le transporteur et sec debout contre un mur, un plancher, un poteau, une
une deuxième copie des renseignements concernant la poutre ou un autre endroit pouvant supporter leur poids
commande et les problèmes survenus devrait être avec les accessoires adéquats fixés. Veuillez vous
- 15 -
reporter à l'appendice B et C (page 20) pour les jeux de obstacle à la circulation de l’air et aux inspections. Les
montage mural. passages et les endroits dans lesquels des personnes
Les transformateurs de type sec ventilés conven- risquent d’être exposées à des pièces sous tension au
tionnels sont dotés d'une grille inférieure pour la convec- cours de l’inspection doivent également être évités.
tion de l'air. Lorsque les transformateurs sont installés Une protection adéquate doit être assurée en toutes
au-dessus du sol, une plaque de captage devrait être circonstances.
installée sous chaque transformateur par mesure de
sécurité contre les particules chaudes risquant de passer NIVEAUX DE BRUIT DU
à travers la grille dans le cas d'une défaillance. Veuillez
vous reporter à l'appendice B et C (page 20). TRANSFORMATEUR
Il est important d'installer les transformateurs
ventilés dans un endroit sec où l'air ambiant est propre et Les transformateurs sont des appareils alimentés
exempt de poussières, saletés, émissions corrosives, par l’électricité, et lorsqu′ils sont en fonction, les maté-
humidité, chaleur ou autres conditions nocives. Les riaux qui sont nécessaires à leur construction émettent un
transformateurs ne doivent pas être installés dans un lieu certain bruit.
où il y a un risque de pénétration d'eau dans le boîtier. Les transformateurs doivent respecter les normes
Dans le cas où un transformateur aurait été soumis NEMA en matière de niveau sonore. Ces normes varient
à de l’humidité avant son installation, assurez-vous de de 40 à 60 dB, ce qui peut constituer une source de gêne
bien le nettoyer et de le sécher avant de le mettre sous pour les personnes qui travaillent ou résident à proximité.
tension. Il est recommandé de souffler de l’air chaud Il faut donc choisir avec soin leur emplacement
dans le transformateur afin de sécher les composants d’installation et éviter tout particulièrement les zones
internes. Veuillez vous reporter à la rubrique de séchage sensibles comme les hôpitaux, les écoles, les établisse-
des transformateurs. ments médicaux et les bureaux.
b) Transformateurs pour intérieur et extérieur Les lignes directrices suivantes pourront se
avec boîtiers Type 4, 4X ou 12 sans aération. révéler utiles pour déterminer le bon emplacement
Les transformateurs équipés de boîtiers type 4, d’installation.
4X ou 12 sans aération peuvent être installés à l’intérieur
comme à l’extérieur à l’un des endroits indiqués ci-des-  Les unités doivent être installées loin des angles et
sus. Les transformateurs à boîtier sans aération, bien que des murs ou plafonds réfléchissants.
légèrement plus grands, procurent une protection bien
plus grande contre une variété d’éléments, notamment la  Pour les branchements, pensez à utiliser des
poussière, la saleté, la neige, l’humidité, la pluie, etc. câbles ou autres conduits flexibles.
Pour les installations à l’extérieur, les codes en
vigueur qui s’appliquent à l’installation doivent être  Tous les transformateurs de type sec sont munis
respectés, notamment ceux concernant l’installation des de coussinets d′insonorisation caoutchoutés
câbles et le matériel convenant à une utilisation installés entre le noyau-bobines et le boîtier.
extérieure. Cependant, il est aussi possible d′installer d′autres
coussinets d′insonorisation entre le transformateur
et sa surface de montage.
VENTILATION
 Pensez à installer des matériaux acoustiques
Les transformateurs doivent être installés dans un absorbants sur les murs et les plafonds se trouvant
endroit où ils pourront être refroidis par la circulation de autour du transformateur.
l’air. La température ambiante moyenne doit être de 30  Le transformateur doit se trouver aussi loin que
°C (86 °F) et ne jamais excéder 40 °C (104 °F). possible des zones pour lesquelles le bruit pourrait
Une bonne ventilation est indispensable pour que constituer une gêne.
les transformateurs atteignent la capacité en kVA indi-
quée sur leur plaque signalétique. La distance d'un
transformateur doit être située loin de tout mur ou tout BRANCHEMENT DES CÂBLES
autre obstacle qui est indiqué sur la plaque signalétique.
Pour permettre la circulation d'air propre à travers les Le calibre des câbles de branchement dépend du
ouvertures de ventilation ou autour d'une unité non courant nominal des enroulements primaires et secondai-
ventilée. res du transformateur. Les informations pertinentes se
trouvent à l’appendice A (page 19). Il est recommandé
d’utiliser des câbles supportant une température d’au
ACCESSIBILITÉ moins 90 °C (194 °F) ainsi que des cosses ALC9CU.
Des disques défonçables sont fournies sur tous les
Il est prévu par les normes du Code national de transformateurs à boîtier ventilé jusqu’à 150 kVA tripha-
l’électricité que les transformateurs soient accessibles sés et 100 kVA monophasés afin de faciliter le passage
pour l’inspection et que l’emplacement de l’installation du câble.
soit choisi dans cette optique. Les transformateurs non ventilés ne sont pas munis
Ils ne doivent donc pas être installés dans des de disques défonçables; vous devez utiliser un connec-
locaux renfermant des objets entreposés risquant de faire teur de câble approprié pour l’utilisation.
- 16 -
Veuillez vous reporter aux figures 1 et 2 (page
INSPECTION AVANT LA MISE
22-23) pour l’emplacement du passage de câble.
SOUS TENSION
Avertissement : Ne remplacez jamais des Pour un fonctionnement adéquat et sans danger du
branchements ni des prises, sauf si le trans- transformateur, veuillez vérifier ce qui suit :
formateur est débranché et que toutes les a) La résistance d’isolation, de la bobine à l’enroule-
bobines sont mises à la terre. ment primaire, de la bobine à l’enroulement secon-
daire et de l’enroulement primaire au secondaire doit
être supérieure à 10 k ohms.
Il est recommandé de passer les câbles sur le côté b) Avant de brancher et de mettre la charge sous
afin d’éviter d’obstruer les aires de ventilation. tension, mesurez la tension de sortie pour vérifier si
Des prises de connexion de câble plaquées cuivre elle correspond aux spécifications de la plaque
ou aluminium peuvent être utilisées pour brancher les signalétique.
bornes des transformateurs. Les bornes doivent être
nettoyées et il est recommandé d’utiliser de la pâte à c) Assurez-vous de brancher les phases conformément
joints pour application électrique sur tous les au diagramme vectoriel de la plaque signalétique.
branchements. d) La charge de l’enroulement delta secondaire
Veuillez vous reporter à la plaque signalétique du comportant une prise centrale de 120 volts ne doit
transformateur pour connaître les combinaisons de pas dépasser le courant nominal normal de l’enrou-
tension primaire et secondaire ainsi que l’emplacement lement. Cette prise centrale est conçue pour recevoir
des prises primaires et/ou secondaire si applicable. un maximum de 5 % des kVA indiqués.
Les fils de prise des transformateurs livrés d’usine
e) Lorsque les enroulements sont branchés en paral-
seront positionnés sur la tension nominale ou 100 %. Les
lèle (comme dans le cas d’enroulements primaires à
autres emplacements des prises seront recouverts d’un
bitension), les prises primaires de toutes les bobines
matériel d’imprégnation et d’un isolant.
doivent être branchées au même pourcentage de
Pour effectuer un changement de prise, il est
positions de prises pour éviter que les spires ne
nécessaire d’en retirer avec soin les contaminants et
soient court-circuitées. Pour connaître les positions
autres isolants sur les surfaces du connecteur en sablant
des prises, consultez la plaque signalétique du
doucement le haut et le dessous de ce dernier, (œillet
transformateur.
ou cosse) doivent être mis à nu.
La surface de la prise doit-être propre et par la f) Le boîtier doit être mis à la terre à l’aide d’un
suite enduite d’un composé électrique sur toutes les conducteur de calibre approprié.
surfaces non-plaquées entre la borne du cavalier et la g) Dans la mesure du possible, la charge doit être
prise. Assembler les cavaliers à la prise tel que à répartie également entre les phases pour assurer le
l'appendice D ( Dessin 1 pour conducteur unique sur bon fonctionnement des enroulements du
œillets ou cosses et dessin 2 pour double conducteur à transformateur.
prise œillet.)
Toute charge triphasée ou monophasée peut être
branchée au transformateur; toutefois, la charge en
kVA de chaque phase ne doit pas excéder 1/3 du
REMARQUE : Après l’installation des câbles régime nominal en kVA indiqué sur la plaque
et des connecteurs, il faut maintenir un écar- signalétique.
tement d’au moins 2,5 cm (1 po) entre les h) Il faut vérifier que chaque branchement électrique
parties sous tension et toutes les parties du est bien serré et que le dégagement autour de
boîtier. chaque partie vivante est suffisant.
i) S’il existe un risque quelconque que le transforma-
teur a été soumis à de l’humidité pendant le trans-
port ou l’entreposage, assurez-vous qu’il est bien
MISE À LA TERRE sec avant de le mettre sous tension. Ceci peut être
exécuté en faisant un test d’induction de résistance.
Toutes les piéces métalliques du noyau-bobines Les procédures de séchage se trouvent à la page
non-porteuses de courant, sont reliées à la terre, via le 18.
connecteur de mise à la terre. L′intégrité équipotentielle y
est maintenue.
Pour des raisons de sécurité, le boîtier du transfor- FONCTIONNEMENT
mateur doit lui aussi être adéquatement relié à la terre.
La mise à la terre doit être effectuée en conformité Dans tous les cas d’installation normale et bien
avec les normes du Code national électrique. réalisée, les transformateurs de type sec fonctionnent
normalement dans des conditions normales de mise sous
tension et de charge.
Pour votre information, un transformateur de type
- 17 -
sec à pleine charge peut s’avérer très chaud au toucher,
particulièrement la partie supérieure de l’appareil. peuvent être effectués lorsque le transformateur fonc-
Les normes permettent que les boîtiers de ce type tionne. Cependant, les couvercles d’accès ne doivent pas
d’appareil puissent atteindre jusqu’à 65 °C (149 °F) de être ouverts lorsque l’appareil est sous tension.
plus que la température ambiante. Ceci représente une
charge normale et ne doit pas vous inquiéter.
Les transformateurs de type sec sont conçus pour L′entretien interne doit être effectué sur un
fonctionner en permanence selon la pleine capacité de transformateur éteint, isolé et dont les bornes
kVA indiquée sur la plaque signalétique.
sont mises à la terre.
Les normes C57.96 de l′ANSI donnent des directives
pour le chargement des transformateurs dans
différentes conditions, notamment : La maintenance comprend le nettoyage interne, le
serrage des barrettes et des connexions boulonnées,
les températures ambiantes différentes des tempé-
 l’entretien et l’inspection des dispositifs auxiliaires.
ratures à respecter pour un bon fonctionnement du Les conduits d’air doivent être exempts de toute
transformateur; accumulation de poussières et de saleté. Les connexions
la surcharge brève en fonction du temps et de la
 boulonnées des bornes doivent être en bon état.
température, ainsi que la perte de vie utile du Une pratique acceptée consiste à aspirer ou à
transformateur; souffler de l’air comprimé de haut en bas afin d’enlever la
poussière dans les conduits d’une bobine de transforma-
la surcharge entraînant une réduction de la vie utile
 teur. Il faut souffler de l’air sec à basse pression afin
du transformateur. d’éviter de contaminer davantage les enroulements avec
des matériaux étrangers.
Si le transformateur subit une augmentation de la
Il est nécessaire de vérifier également la liaison à la
température, les éléments de charge suivants doivent
terre pour garantir que le branchement est de faible
être immédiatement examinés :
impédance. Il faut enlever immédiatement toute accumu-
démarrage de moteur brusque ou autre type de
 lation de glace, de neige ou toute autre matière pouvant
charge brusque pour lequel un transformateur obstruer l’aération pendant le fonctionnement du
spécifique pour ce type d'application est requis; transformateur.
Les filtres des appareils pour l’extérieur exposés
sur-excitation de l′unité à la suite d′une surtension
 aux conditions climatiques peuvent rapidement se salir.
de l′alimentation ou d′une surcharge; Une vérification régulière des filtres permettra d’éviter
températures ambiantes supérieures à la normale;
 que le filtre se bouche et, par conséquent, que le trans-
formateur surchauffe. D’autre part, il ne faut jamais faire
surcharge supérieure aux directives C57.96 de

fonctionner le transformateur sans que les filtres soient
l’ANSI;
bien en place.
distorsions harmoniques de la tension de la ligne

d’alimentation et du courant.
SÉCHAGE DES
En cas de surchauffe, l’ajout de ventilateur de TRANSFORMATEURS
refroidissement complémentaire doit respecter les
directives d’installation de l’usine. Une mauvaise installa- Dans le cas où un transformateur a été exposé à de
tion de ventilateurs peut mal diriger la circulation de l’air l’humidité, condensation ou pluie, il est conseillé de
et entraîner une détérioration réduisant la durée de sécher l’appareil avant de le mettre sous tension.
l’isolant dans la bobine du transformateur. Il est possible d’exécuter le séchage en utilisant de
l’air chaud ou réchauffé, de la chaleur rayonnante ou un
Les transformateurs de type sec peuvent être
chauffage interne dirigé à travers les enroulements. Il faut
arrêtés et entreposés pour des périodes prolongées sans
continuer à envoyer de l’air chauffé dans les enroule-
subir de détérioration. Il faut soigneusement nettoyer et
ments pendant au moins vingt-quatre (24) heures après
sécher les appareils avant de les mettre sous tension,
avoir constaté qu’il n’y a plus de condensation visible.
comme indiqué préalablement.
Il peut être difficile de sécher correctement des
transformateurs ayant été soumis à une inondation, de la
ENTRETIEN pluie directe ou des gicleurs. Veuillez communiquer avec
l′usine afin de connaître la marche à suivre.
Dans des conditions de fonctionnement et des
environnements normaux, les transformateurs de type
sec ne nécessitent aucun entretien. Il est cependant ACCESSOIRES
recommandé de procéder à un entretien et à une inspec-
tion de routine en fonction des conditions climatiques Les transformateurs de type sec sont offerts avec
sous lesquelles l’appareil sera installé. plusieurs accessoires afin de faciliter l’installation.
Une inspection des éléments externes et un Veuillez consulter votre détaillant ou distributeur pour
nettoyage de la poussière accumulée sur le boîtier l’achat de ces articles pouvant être en magasin.
- 18 -
1) Supports de montage mural APPENDICE A
Les transformateurs encapsulés sont équipés de COURANT ADMISSIBLE POUR
montage mural intégré pour des appareils pesant jusqu’à BRANCHEMENTS
123,3 kg (285 lb). Les appareils pesant plus de 123,3 kg
(285 lb) doivent uniquement être montés au sol. A. Pour un transformateur monophasé
Les transformateurs de type sec ventilés sont, Volt-ampères
Courant de ligne = Tension de ligne
généralement, conçus pour un montage au sol unique-

ment. Cependant, certains appareils ventilés jusqu’à 51
kVA sont pourvus de boîtiers dotés de supports de B. Pour un transformateur triphasé
montage mural intégrés. Ces appareils peuvent être Volts-ampères
montés sur des murs, des poutres ou des poteaux. Courant de ligne =
3 X Tension de ligne
Les transformateurs de type sec ventilés conven-
tionnrls sont dotés d’une grille inférieure pour la convec-
tion de l’air. Lorsque les transformateurs sont installés Tableau de courant en pleine charge du
au-dessus du sol, une plaque de captage devrait être
transformateur monophasé
installée sous chaque transformateur par mesure de
sécurité contre les particules chaudes risquant de passer Courant en ampères
kVA
à travers la grille dans le cas d’une défaillance. Veuillez
Nominal 120 V 240 V 416 V 480 V 600 V
vous reporter à l’appendice B et C (page 20).
3 25,0 12,5 7,21 6,25 5,00
2) Coussinets d’insonorisation
5 41,6 20,8 12,0 10,4 8,33
Tous les transformateurs de type sec sont équipés
de coussinets d’insonorisation caoutchoutés installés 7,5 62,5 31,2 18,0 15,6 12,5
entre le noyau-bobines et le boîtier. 10 83,3 41,6 24,0 20,8 16,6
Afin d’assurer une absorption maximale des 15 125 62,5 36,0 31,2 25,0
vibrations et du bruit, il est recommandé d’installer 25 208 104 60,0 52,0 41,6
d’autres coussinets d’insonorisation entre le transforma- 37,5 312 156 90,1 78,1 62,5
teur et la surface de montage. 50 416 208 120 104 83,3
Ces plaques moulées en néoprène et acier élimi-
75 625 312 180 156 125
nent virtuellement le bruit de vibration entre le transfor-
mateur et la surface de montage. 100 833 416 240 208 166
Veuillez consulter le catalogue du fabricant pour 150 1 250 625 360 312 250
obtenir le numéro de pièce du coussinets requis. 167 1 391 695 401 347 278
250 2 083 1 041 600 520 416
3) Connecteurs
333 2 775 1 387 800 693 555
Les connecteurs pour l’installation de transforma-
teurs de type sec sont facilement utilisables. Ces connec- Tableau de courant en pleine charge du
teurs conviennent autant pour les câbles en aluminium transformateur triphasé
que ceux en cuivre.
La taille et l’installation des connecteurs doivent kVA Courant en ampères
respecter les exigences du code de l’électricité en Nominal 208 V 240 V 380 V 416 V 480 V 600 V
appliquant les meilleures pratiques afin d’assurer un
fonctionnement fiable et sûr. Les surfaces des câbles 2 5,55 4,81 3,03 2,77 2,40 1,92
doivent être nettoyées et il faut utiliser une pâte à joints 3 8,32 7,21 4,55 4,16 3,60 2,88
pour application électrique sur tous les branchements.
6 16,6 14,4 9,11 8,32 7,21 5,77
Choix des connecteurs 9 24,9 21,6 13,6 12,4 10,8 8,66
a) Déterminez le courant primaire pour le transforma- 15 41,6 36,0 22,7 20,8 18,0 14,4
teur requis à l’appendice A. 30 83,2 72,1 45,5 41,6 36,0 28,8
45 124 108 68,3 62,4 54,1 43,3
b) D’autre part, déterminez le courant secondaire pour 75 208 180 113 104 90,2 72,1
le transformateur requis à l’appendice A.
112,5 312 270 170 156 135 108
c) Le courant pour les branchements à 120/240 de 150 416 360 227 208 180 144
tension doit être basé sur 240 volts. 225 624 541 311 312 270 216
300 832 721 455 416 360 288
d) Le courant pour les branchements à 240/480 volts
doit être basé sur 480 volts. 450 1 249 1 082 683 624 541 433
500 1 387 1 202 759 693 601 481
600 1 665 1 443 911 832 721 577
750 2 081 1 804 1 139 1 040 902 721
- 19 -
APPENDICE B
EMPLACEMENT DES SUPPORTS DE MONTAGE MURAL ET PLAQUES DE CAPTAGE
POUR LES BOÎTIERS TYPE 3R DE LA SÉRIE NH3
Support de montage
mural en option
Plaque de captage
lorsque requis par le Support de montage
Plaque de captage code local au plafond en option
lorsque requis par le code local
APPENDICE C
EMPLACEMENT DES SUPPORTS DE MONTAGE MURAL ET PLAQUES DE CAPTAGE
POUR LES BOÎTIERS TYPE 3R DES SÉRIES NH5 et NH6
Points de fixation mural
Plaque de captage
Points de fixation pour
lorsque requis par le code local
montage au sol ou au plafond
- 20 -
APPENDICE D
Dessin de Barrette de Liaison
DRAWING 1 :
DESSIN
EYELOOP
Conducteur Unique à Prise Oeillet
Vue du Dessus
Rondelle
STEEL Acier Plat
FLAT WASHER
CONNECTOR
Connecteur
Rondelle
TINNED Laiton
BRASS Étamé
WASHER
Vue Latérale Prise Oeillet

TAP LOOP Sur Bobine
ON COIL
Rondelle
STEEL Acier Plat
FLAT WASHER
STEEL LOCK
Rondelle WASHER
Autobloquante Acier
DRAWING 2 :
Dessin 2
Double Conducteurs à Prise Oeillet
Vue du Dessus
STEELRondelle
FLAT WASHER
Acier Plat
Prise
TAP LOOPOeillet
ON COILSur Bobine
Rondelle
TINNED Laiton Étamé
BRASS WASHER
Vue Latérale
STEELRondelle Acier Plat
FLAT WASHER
STEEL LOCK
Rondelle WASHER
Autobloquante Acier
- 21 -
FIGURE 1
TYPE 3R typique, boîtier avec aération série NH pour les transformateurs triphasés et monophasés.
Notes :
1. Manutention - les appareils sont construits de manière à pouvoir être soulevés par la palette au moyen d'un
chariot à fourche. Le positionnement final de l'appareil lorsque la palette est retirée peut se faire avec le chariot à
fourche dont les fourches sont glissées entre les canaux du transformateur.
2. Expédition - les appareils sont transportés sur palettes qui seront retirées au moment de l'installation.
3. Installation - ce transformateur peut être installé à l'intérieur ou à l'extérieur avec une certaine protection contre la
pluie, la fonte des neiges et la formation de glace externe.
4. Les transformateurs doivent être éloignés des murs et de toutes autres obstructions au moins de 15,24 cm (6 po)
lorsqu'ils sont installés au plancher et de 10,16 cm (4 po) lorsqu'ils sont installés au mur.
5. NE BLOQUEZ PAS l'aération inférieure.
Panneau d'accès
avant
Passage de câble
avec disques
défonçables (2 par côté)
Placez le chariot à fourche Les points pour les fourches

sous la palette sont sous le transformateur
pour le positionnement final
sans la palette
- 22 -
FIGURE 2
TYPE 3R typique, boîtier avec aération série NJ pour les transformateurs triphasés ou monophasés.
Notes :
fourche dont les fourches sont glissées entre les canaux du transformateur. (Note: Pour les transformateurs
ayant un poids supdérieur à 2350 lbs, ceux-ci doivent être levés en utilisant les dispositifs de levage
situés sur le dessus du noyau-bobines. Vous devez d’abord soulever le panneau de dessus du boîtier.)
3. Installation - ce transformateur peut être installé à l'intérieur ou à l'extérieur avec une certaine protection contre la
pluie, la fonte des neiges et la formation de glace externe.
4. Les transformateurs doivent être éloignés des murs et de toutes autres obstructions au moins de 15,24 cm
(6 po) lorsqu'ils sont installés au plancher et de 10,16 cm (4 po) lorsqu'ils sont installés au mur. (Note: Ces boîtiers
ne sont pas conçus pour etre ancrés directement à un mur. Ils peuvent cependant être installés sur une
plateforme fournie par le client.)
5. NE BLOQUEZ PAS l'aération inférieure.
Emplacement
Panneau d'accès recommandé pour le
avant passage des câble
(deux côtés).
Reportez-vous au
diagramme pour les
dimensions exactes.
Placez le chariot à Les points pour les fourches sont sous

fourche sous la palette le transformateur pour le
positionnement final avec la palette
retirée. Les fourches doivent être
insérées la pleine profondeur du boîtier.
- 23 -
FIGURE 3
TYPE 4 et 12 typique, boîtier sans aération série NH pour les transformateurs triphasés ou
monophasés.
Notes :
fourche dont les fourches sont glissées entre les canaux du transformateur.
3. Installation - ceci est un boîtier sans aération pour intérieur ou extérieur conçu principalement pour offrir une
certaine protection contre les chutes de saletés, pluie, neige fondante, neige, poussières soufflées, éclaboussures
ou arrosage d'eau pouvant être endommagé par la formation externe de glace sur le boîtier. Convient aux
endroits particulièrement exposés à de grandes quantités d'eau provenant de toutes directions. (Remarque : n'est
pas submersible)
4. Les transformateurs doivent être éloignés des murs et de toutes autres obstructions au moins de 15,24 cm
(6 po) lorsqu'ils sont installés au plancher et de 10,16 cm (4 po) lorsqu'ils sont installés au mur.
Crochet de levage
Panneau d'accès
avant
Emplacement recommandé pour le

passage du câble (un des deux côtés).
Reportez-vous au diagramme pour les
Placez le chariot à dimensions exactes.
fourche sous la palette
- 24 -
GUÍA DE INSTALACIÓN, OPERACIÓN Y
MANTENIMIENTO
PARA TRANSFORMADORES TIPO SECO DE USO EN
INTERIORES/EXTERIORES QUE UTILIZEN GABINETES SERIE
NH, NJ1, NJ2, NJ3 O NJ4
N.º de folleto: IOMGDDI

Fecha de emisión: Mayo 2011
Precauciones de seguridad
(1) No levante ni traslade un transformador sin equipo apropiado ni personal experimentado. En algunos
transformador de distribución mayor capacidad. see proveen dispositivos de elevación en el conjunto de núcleo
y bobinas
(2) No instale el transformador hasta que se haya realizado una inspección completa.
(3) Utilice únicamente terminales para conexiones eléctricas. Se recomiendan conectores flexibles para las
conexiones en barras colectoras. Las terminals del transformador no estan diseñadas para soportar el peso del
cableado de alimentación o de carge. Largueros de soporte pueden ser agregados en el campo cuidando de que
se mantengan las distancias de separación adecuadas.
(4) Las conexiones solo deben realizarse siguiendo el diagrama de la placa de identificación o los diagramas de
conexión.
(5) Asegúrese de que toda la energía esté desconectada y de que todos los embobinados esten conectados a tierra,
antes de iniciar cualquier trabajo en un transformador o adentro del panel de control.
(6) Asegúrese de que todas las conexiones a tierra estén completas y ajustadas antes de energizar el
transformador.
(7) No intente cambiar una derivación primaria o secundaria mientras el transformador está energizado.
(8) No cambie las conexiones cuando el transformador esté energizado.
(9) No altere los paneles de control, las alarmas, los interruptores de seguridad ni los circuitos de control.
(10) No ajuste ni retire accesorios ni cubiertas protectoras mientras el transformador esté energizado. Ningun cable
de alimentación debe tener contacto con el núcleo o cualquier parte viva, excepto con la terminal que se debe
conectar.
CONTENIDO
General 27
Manipulación 27
Recepción e inspección 27
Almacenamiento 27
Instalación 27
Ventilación 28
Accesibilidad 28
Niveles de ruido del transformador 28
Cables de conexión 28
Conexión a tierra 29
Inspección antes de la energización 29
Operación 29
Mantenimiento 30
Secado de los transformadores 30
Accesorios 30
Apéndice A 31
Apéndice B 32
Apéndice C 32
Apéndice D 33
Figura 1 34
Figura 2 35
Figura 3 36
- 26 -
INSTALACIÓN, OPERACIÓN Y MANTENIMIENTO
DE LOS TRANSFORMADORES DE TIPO SECO
GENERAL Si este examen de la unidad se realiza en

exteriores, hay que tener precaución para que las
Los transformadores de tipo seco se fabrican para inclemencias del tiempo no presenten mayor peligro.
brindar un rendimiento óptimo para un servicio in
interrompido de provida. Se recomienda seguir al pie de Almacenamiento
la letra las siguientes instrucciones para lograr una
operación segura y confiable. Los transformadores que no se instalarán ni
La instalación, la operación y el mantenimiento de energizarán de inmediato se deben guardar en un
los transformadores deben ser realizados por personas ambiente limpio y seco, alejados de todo contaminante
autorizadas, que tengan conocimiento sobre aparatos ambiental en suspensión.
eléctricos y los posibles riesgos que conllevan. Se recomienda guardar los transformadores en un
lugar con calefacción, con el envoltorio de plástico
Advertencia: ¡Peligro! Existe el riesgo de protector todavía colocado.
descarga eléctrica cuando trabaja con o
cerca de equipos eléctricos como los INSTALACIÓN
transformadores. Se debe desconectar la
energía antes de realizar cualquier trabajo
en un transformador. Los gabinetes están diseñados y
Al igual que con cualquier dispositivo eléctrico, los
aprobados de acuerdo con las
transformadores se deben instalar de acuerdo con los eapecificaciones CSA 22.2 No. 47
requisitos de los códigos eléctricos nacionales y locales. (Propósitos Generales), CSA 22.2 No. 94
También puede consultar la norma ANSI/IEEE C57-94 (Gabinetes Especiales), NEMA 250 y
para conocer las pautas recomendadas de instalación,
aplicación, operación y mantenimiento de
UL 50.
transformadores de tipo seco. Para IEC gabineles equivalentes por favor
refiérase a IEC60529 (Designación y
MANIPULACIÓN clasificación de Gabinetes).
Los transformadores se envían en tarimas y se a) Transformadores de tipo seco para interior/exterior

pueden elevar con un montacargas o se pueden levantar con gabinete
por las argollas de elevación provistas.
La mayoría de los transformadores de tipo seco
Se debe utilizar equipo de elevación apropiado para
vienen provistos de un gabinete tipo 3R, 4 ó 12. Las
el tamaño de cada transformador. Con fines de seguridad
unidades se pueden instalar en interiores, exteriores o
y para proteger el transformador, se recomienda el uso
segón aplique. Si están equipadas con un gabinete tipo
de barras separadoras.
1, estas unidades son para uso interior únicamente.
No se debe intentar levantar ni trasladar un
Se recomiendan los gabinetes con ventilación para
transformador desde ningun punto en la unidad distinto
instalación en interiores, pero también se pueden instalar
de los puntos indicados. Consulte las Figuras 1 y 2
en exteriores en lugares en que las condiciones
(pag.34-35).
climáticas permiten que se instale un gabinete con
ventilación de tipo 3R.
Recepción e inspección Para una ubicación en exteriores, se deben seguir
los códigos aplicables adecuados, que incluyen la
Inmediatamente después de recibir el instalación de los cables y el equipo apropiado para el
transformador, debe ser inspeccionado para detectar servicio exterior.
cualquier daño de traslado y para verificar la exactitud de Se deben de usar acoplamientos herméticos y
los datos en comparación con los documentos de envío. cualquier orificio en el gabinete debe perforapse por
Se debe examinar la unidad para detectar cualquier debajo de cualquier parte viva sin aislamiento (debajo de
rotura en el embalaje, abolladura o daño en los las termina les de bajo voltaje).
gabinetes, o piezas faltantes de la lista de empaquetado. Los transformadores de tipo seco pueden ubicarse
Si se observa algún daño, se debe presentar un en posición vertical apoyados en paredes, pisos, postes,
reclamo de inmediato ante la empresa de transporte y vigas u otros lugares que puedan soportar el peso con
una segunda copia ante la oficina local de ventas con los accesorios apropiados colocados. Consulte el
toda la información pertinente con respecto al pedido y Apéndice B y C (página 32) para ver los equipos de
las circunstancias. montaje de paredes.
- 27 -
Los transformadores de tipo seco convencionales ubicar en áreas donde es probable que los elementos
con ventilación abierta tienen una pantalla inferior para la almacenados interfieran con la convección natural del
entrada del aire. Cuando los transformadores se montan aire o con la facilidad de inspeccionarlos. También se
por encima de la superficie de la tierra, debe instalarse deben evitar los pasillos u otras áreas donde la gente
una placa receptora debajo de cada transformador como pueda estar expuesta a piezas energizadas durante la
precaución de seguridad contra cualquier partícula inspección.
caliente que pueda caer por la pantalla en caso de Se debe proporcionar protección adecuada bajo
alguna condición defectuosa. Consulte el Apéndice B y C cualquier circunstancia.
(página 32).
Es importante que los transformadores ventilados
NIVELES DE RUIDO DEL
se instalen en un área seca donde el aire del ambiente
sea limpio y sin polvo, suciedad, gases corrosivos, TRANSFORMADOR
humedad, calor u otras condiciones adversas. Los
transformadores no deben instalarse en lugares que Los transformadores son aparatos energizados
tengan la posibilidad de ingreso de agua en el caja. eléctricamente que, por su naturaleza y debido a los
En caso de que un transformador haya estado materiales que los componen, emiten ruidos.
expuesto a la humedad antes de la instalación, Los transformadores deben cumplir con las normas
asegúrese de que esté totalmente limpio y seco antes de NEMA para los niveles máximos de ruido permitidos.
la energización. Se recomienda el soplo de aire caliente Estos niveles de ruido varían de 40 a 60 DB y, por lo
por el transformador para secar los componentes tanto, pueden ser molestos si se encuentran en las
internos. Consulte la sección que habla del secado de los inmediaciones de los lugares donde residen o trabajan
transformadores. personas.
Por consiguiente, se debe tener cuidado al elegir
b) Transformadores para interior/exterior con los sitios de ubicación para los transformadores,
gabinetes TIPO 4, 4X o 12 sin ventilación. especialmente para evitar áreas sensibles como
hospitales, escuelas, centros médicos u oficinas.
Los transformadores equipados con gabinetes tipo
4, 4X o 12 sin ventilación pueden colocarse en interiores Las siguientes pautas pueden ser útiles:
o exteriores en cualquier ubicación similar a la
mencionada anteriormente. Los transformadores con  Las unidades deben montarse alejadas de
gabinetes sin ventilación, si bien son ligeramente más esquinas o de paredes reflectantes o cielorrasos.
grandes, ofrecen una protección mucho mayor contra
varios elementos, entre ellos polvo, suciedad, nieve,  Los cables u otros conductos flexibles deben
humedad, lluvia, etc. tenerse en cuenta para realizar conexiones.
Para una ubicación en exteriores, se deben seguir
los códigos aplicables adecuados, que incluyen la  Todos los transformadores de tipo seco vienen
instalación de los cables y el equipo apropiado para el con montajes de goma para aislamiento entre el
servicio exterior. conjunto de núcleo y bobina y el gabinete. Sin
embargo, aisladores de vibración que absorben el
ruido también pueden instalarse entre el
VENTILACIÓN transformador y su superficie de montaje.
Los transformadores se deben instalar en una área  Se pueden tomar en cuenta materiales
donde se puedan enfriar mediante la libre circulación de abosorbentes acusticamente, para ser instalados
aire y donde la temperatura ambiente promedio sea de en paredes y cielosrasos alrededor de la unidad.
30 °C (86 °F) y no supere los 40 °C (104 °F) en ningún
momento.  La unidad debe ubicarse lo más alejada posible de
La ventilación adecuada es esencial para que los las áreas donde los niveles de ruido podrían
transformadores cumplan con la capacidad de kVA que considerarse indeseables.
figura en la placa de identificación. En la placa de
identificación del transformador se establece a que
distancia de la pared o de otra obstrucción se debe CONEXIÓN DE LOS CABLES
localizar el transformador. Esto es para permitir la
circulación limpia y libre de aire por las aberturas de El tamaño del cable de conexión se determina con
ventilación o alrededor de la unidad para las unidades sin la corriente de línea de los embobinados primario y
ventilación. secundario del transformador y puede seleccionarse con
la información que aparece en el Apéndice A (página
31). Se recomiendan que los cables sean para al menos
ACCESIBILIDAD 90 °C (194° F), ya que los conectores son ALC9CU.
Se suministran prácticas perforaciones
Las normas NEC exigen que los transformadores premarcadas para tubería en todos los gabinetes para
sean accesibles para la inspección y que se ubiquen los transformadores ventilados trifásicos de hasta 150
adecuadamente para tal fin. kVA y monofásicos de 100 kVA para facilitar la entrada de
Sin embargo, los transformadores no se deben los cables.
- 28 -
Para los transformadores sin ventilación, no se
suministran perforaciones premarcadas para tubería y se INSPECCIÓN ANTES DE LA
debe utilizar el cable conector apropiado para la ENERGIZACIÓN
aplicación.
Consulte las figuras 1 y 2 (páginas 34-35) para ver Para la operación segura y apropiada del
las ubicaciones de la entrada de los cables. transformador, verifique lo siguiente:
a) La resistencia del aislamiento, desde el núcleo

Advertencia: No intente cambiar las hasta el primario, desde el núcleo hasta el
conexiones o las derivaciones a menos que el secundario, y desde el primario hasta el secundario,
transformador esté desenergizado y todos las debe ser superior a 10k ohmnios.
bobinas estén conectados a tierra. b) Antes de energizar y conectar cualquier carga, mida
y verifique que el voltaje de salida coincida con las
Se recomienda que la entrada de los cables sea especificaciones de la placa de identificación.
lateral, ya que evita que se obstruyan las áreas c) Verifique que las conexiones de fase sean
ventiladas. correctas. Consulte el diagrama vectorial de la placa
Se pueden usar conectores de cable, recubiertos de identificación.
de cobre o aluminio para conectarse a las terminales del d) La carga de un embobinado secundario delta con
transformador. Los terminales deben limpiarse y se una derivación central de 120 voltios no debe
recomienda el uso de compuestos para conexiones superar la corriente normal para el embobinado.
eléctricas en todas las conexiones eléctricas. Esta derivación central está diseñada para un
Consulte la placa de identificación del máximo del 5% de los kVA que figuran en la placa
transformador para ver las combinaciones de conexión de identificación.
para los voltaje primario y secundario y las posiciones
para las derivaciónes del primario y/o secundario, según e) Cuando los embobinados se conectan en paralelo
sea el caso. (como en el caso de primarios de doble voltaje), las
Los transformadores recibidos de fábrica deberán derivaciones del primario de todas las bobinas se
tener los cables conductores conectados en la posición deben conectar en las posiciones de derivación con
de la derivación de voltaje nominal o 100%. El resto de porcentaje idéntico para evitar el cortocircuito de las
las posiciones de derivación estarán recubiertas de vueltas. Para conocer las posiciones de derivación,
material para impregnación y de aislamiento. consulte la placa de identificación del transformador.
Para cambio de taps, es necesario quitar con f) El gabinete debe estar conectado a tierra con el
delicadeza todo contaminante y aislante de la superficie conductor del tamaño apropiado.
de arriba y de abajo de los taps (omegas o lugs) lijando
g) La carga total entre todas las fases debe
los lugs hasta limpiarlos.
equilibrarse lo más posible para un óptimo
La superficie del tap deberá estar limpia y cubierta
rendimiento de las bobinas de los transformadores.
con compuesto eléctrico para todo contacto no platinado
Cualquier carga trifásica o monofásica puede
entre la terminal del jumper y el tap. Ensamble el jumper
conectarse al transformador, pero la carga de kVA
al tap según el Apéndice D (Dibujo 1 para conductor
de cada fase no debe superar 1/3 de la potencia de
sencillo de omega y taps de lugs o Dibujo 2 para doble
kVA que figura en la placa de identificación.
conductor de taps de omegas).
h) Se debe verificar que todas las conexiones
eléctricas respeten la distancia de seguridad y estén
NOTA: Después de la instalación de los
ajustadas.
cables y los conectores, se debe mantener un
espacio mínimo de separación de 2,54 cm (1 i) Si hay algún motivo para sospechar que el
transformador ha sido expuesto a la humedad
pulgada) entre las partes energizadas y todas durante el traslado o el almacenamiento, debe
las partes del gabinete. revisarse que el transformador esté seco antes de
la energización. Esto se puede hacer mediante una
prueba de resistencia al aislamiento. Los
CONEXIÓN A TIERRA procedimientos de secado se encuentran en la
página 30.
Todos los conjuntos de núcleo y bobina estan
solidamente conectados a tierra internamente en el
gabinete, para garantizar que todas las piezas metálicas OPERACIÓN
conductoras tengan el mismo potencial.
El gabinete del transformador también debe tener Para todas las instalaciones relativamente
una conexión a tierra segura y eficaz como precaución normales y limpias, los transformadores de tipo seco
de seguridad. funcionarán satisfactoriamente en condiciones normales
Esta conexión a tierra debe cumplir con las normas de energización y carga.
de los códigos eléctricos nacionales. Para su referencia, los transformadores de tipo
seco totalmente cargados pueden estar calientes al tacto,
especialmente en la cubierta de la unidad.
- 29 -
Las normas permiten que las temperaturas de la
cubierta sean de 65 ºC (149° F) superiores a la cubiertas de acceso si el transformador está energizado.
temperatura ambiente. Esto representa una carga normal
y no debe ser motivo de preocupación. El mantenimiento interno se debe realizar con
Los transformadores de tipo seco están diseñados un transformador desenergizado, aislado y
para funcionar en forma continua a la potencia total de con los terminales con conexión a tierra.
kVA que figura en la placa de identificación.
La norma ANSI C57.96 ofrece pautas para la carga de El mantenimiento debe incluir limpieza interna,
transformadores en diferentes condiciones, ajuste de enlaces y conexiones atornilladas, inspección y
entre ellas: reparación de dispositivos auxiliares.
Temperaturas ambiente que varían de las
 Los conductos de aire no deben tener
temperaturas ambiente requeridas para el acumulaciones de polvo ni desechos, y las conexiones
funcionamiento de los transformadores. atornilladas de los terminales deben estar en buenas
condiciones.
Sobrecarga de corta duración que se relaciona con
 El vacío o el soplado de aire comprimido de arriba
el tiempo y la temperatura y la correspondiente hacia abajo es una práctica aceptable para quitar el polvo
pérdida de la vida útil del transformador. de los conductos de la bobina de un transformador. Debe
utilizarse aire seco y de baja presión para evitar una
Sobrecarga que provoque la reducción de la
 contaminación mayor de los bobinados con materiales
expectativa de vida útil del transformador. extraños.
También se debe verificar la conexión a tierra para
Si el transformador presenta aumento de garantizar que sea una conexión de baja impedancia. La
temperatura, se deben considerar de inmediato las acumulación de hielo, nieve o cualquier otro objeto que
siguientes características de carga: bloquee la ventilación debe limpiarse de inmediato
durante el funcionamiento del transformador.
Cargas de arranque del motor rigurosas u otra
 En unidades para uso en exteriores en las que se
carga de tipo impacto para la cual se requiere un han instalado filtros, la exposición a la atmósfera exterior
transformador específico para esa aplicación. puede hacer que los filtros se ensucien rápidamente. La
Excitación excesiva de la unidad debido a un
 revisión periódica de los filtros ayudará a evitar que se
exceso del voltaje o la corriente de la línea de atasquen y se sobrecaliente el transformador. Además,
alimentación. nunca arranque el transformador sin que los filtros estén
ubicados correctamente en su lugar.
Temperaturas ambiente superiores a las estándar.

SECADO DE LOS
Sobrecarga superior a la indicada en las pautas

ANSI C57.96. TRANSFORMADORES
Distorsiones armónicas del voltaje y las corrientes
 En caso de que los transformadores hayan estado
de la línea de alimentación. expuestos a humedad como condensación o lluvia, se
aconseja secar todas las unidades antes de la
Si se observa sobrecalentamiento, cualquier intento energización.
para agregar ventiladores de enfriemiento suplementarios El secado se puede realizar con aire caliente, calor
se, debe cumplir con las pautas de instalación de la radiante o calor interno a través de las bobinas. Se debe
fábrica. Los ventiladores mal instalados pueden dirigir permitir que el aire caliente suba por los bobinas durante
mal el flujo de aire y provocar deterioro grave de la vida un mínimo de veinticuatro (24) horas después de que la
útil del aislamiento en la bobina de un transformador. evidencia de condensación ya no sea visible.
Los transformadores de tipo seco pueden apagarse Es posible que los transformadores que han sido
y almacenarse durante períodos de tiempo prolongados expuestos a inundaciones, lluvia directa o rociadores no
sin ningún deterioro. Debe tenerse cuidado de limpiar y puedan secarse adecuadamente. Comuníquese con la
secar las unidades antes de la energización, como se ha compañía productora de los transformadores para ver
descrito anteriormente. cuáles son las medidas adecuadas que puede se tomar.
MANTENIMIENTO ACCESORIOS
En condiciones normales ambientales y de Para los transformadores tipo seco hay disponible
funcionamiento, los transformadores de tipo seco no una variedad de accesorios para facilitar su instalación.
requieren mantenimiento. Sin embargo, es una buena Consulte a su agente o distribuidor local para comprar
práctica realizar el cuidado y la inspección periódica, cualquiera de los elementos que puedan estar en
dependiendo especialmente de las condiciones inventario.
ambientales en que se instale la unidad.
La inspección periférica y la limpieza externa del 1) Soportes para el montaje en la pared
polvo se puede realizar mientras el transformador está en
Los transformadores encapsulados tienen
funcionamiento. Sin embargo, no se deben abrir las
- 30 -
capacidades de montaje integral en la pared para
unidades de hasta 129,27 kg (285 libras). Las unidades APÉNDICE A
de más de 129,27 kg (285 libras) deben montarse CLASIFICACIONES DE AMPERAJE
únicamente en el piso.
Los transformadores de tipo seco con ventilación
PARA LAS CONEXIONES
normalmente están diseñados para montarse en el piso A. Para un transformador monofásico
únicamente. Sin embargo, algunas unidades ventiladas
Amperes de línea = volt-amperes
de hasta 51 kVA se suministran en gabinetes con volt de línea

capacidades de montaje integral en la pared. Estas
unidades son prácticas para montarse en paredes, vigas B. Para un transformador trifásico
o postes.
Los transformadores de tipo seco convencionales Amperes de línea = volt amperes
con ventilación abierta tienen una pantalla inferior para la 3 X volt de línea
convección del aire. Cuando los transformadores se
montan por encima de la superficie de la tierra, debe
instalarse una placa receptora debajo de cada Tabla de corriente de carga completa
transformador como precaución de seguridad contra toda Transformador monofásico
partícula caliente que pueda caer por la pantalla en caso
de alguna condición defectuosa. Consulte el Apéndice B Potencia Corriente en amperios
y C (página 32). de kVA 120V 240V 416V 480V 600V
2) Almohadillas aisladoras de ruido 3 25,0 12,5 7,21 6,25 5,00
Todos los transformadores de tipo seco tienen 5 41,6 20,8 12,0 10,4 8,33
almohadillas de goma para la absorción del ruido 7,5 62,5 31,2 18,0 15,6 12,5
colocadas internamente entre el conjunto de núcleo y 10 83,3 41,6 24,0 20,8 16,6
bobina y el gabinete. 15 125 62,5 36,0 31,2 25,0
Para la absorción máxima de la vibración y de
25 208 104 60,0 52,0 41,6
ruidos, se recomienda la instalación de almohadillas
aisladoras de ruido adicionales entre el transformador y 37,5 312 156 90,1 78,1 62,5
la superficie de montaje. 50 416 208 120 104 83,3
Estos conjuntos moldeados de neopreno y placa de 75 625 312 180 156 125
acero prácticamente eliminan el ruido causado por la 100 833 416 240 208 166
vibración entre el transformador y la superficie de 150 1250 625 360 312 250
montaje. 167 1391 695 401 347 278
Consulte el catalogo del fabricante para obtner el 250 2083 1041 600 520 416
número de parte correcto de la almohadilla de
aislamiento requerida. 333 2775 1387 800 693 555
3) Conectores
Hay disponibles conectores para la instalación de Tabla de corriente de carga completa
los transformadores de tipo seco. Estos conectores son Transformador trifásico
adecuados para los cables de cobre o aluminio.
Los conectores deben clasificarse según su tamaño Potencia Corriente en amperios
e instalarse de conformidad con los requisitos del código de kVA 208V 240V 380V 416V 480V 600V
de electricidad local, haciendo lo posible para garantizar
el funcionamiento seguro y confiable. Deben limpiarse las 2 5,55 4,81 3,03 2,77 2,40 1,92
superficies de los cables y utilizarse compuestos 3 8,32 7,21 4,55 4,16 3,60 2,88
eléctricos para todos los empalmes. 6 16,6 14,4 9,11 8,32 7,21 5,77
9 24,9 21,6 13,6 12,4 10,8 8,66
Selección de los conectores
15 41,6 36,0 22,7 20,8 18,0 14,4
a) Determine la corriente del primario para el 30 83,2 72,1 45,5 41,6 36,0 28,8
transformador requerido según el Apéndice A.
45 124 108 68,3 62,4 54,1 43,3
b) De manera similar, determine la clasificación de 75 208 180 113 104 90,2 72,1
corriente del secundario para el transformador 112,5 312 270 170 156 135 108
según el Apéndice A. 150 416 360 227 208 180 144
225 624 541 311 312 270 216
c) Para conexiones de voltaje de 120/240, la corriente
300 832 721 455 416 360 288
debe basarse en 240 voltios.
450 1249 1082 683 624 541 433
d) Para conexiones de voltaje de 240/480, la corriente 500 1387 1202 759 693 601 481
debe basarse en 480 voltios. 600 1665 1443 911 832 721 577
750 2081 1804 1139 1040 902 721
- 31 -
APÉNDICE B
UBICACIÓN DE LOS SOPORTES PARA EL MONTAJE EN LA PARED Y PLACAS
RECEPTORAS PARA EL GABINETE SERIE NH3 TIPO 3R
Soporte opcional para

el montaje en la pared
Placa receptora, donde Soporte opcional para

Placa receptora, donde sea exigido por el código local el montaje en la pared
sea exigido por el código local
APÉNDICE C
UBICACIÓN DE LOS SOPORTES PARA EL MONTAJE EN LA PARED Y PLACAS
RECEPTORAS PARA LOS GABINETES SERIE NH5 Y NH6 TIPO 3R
Ubicaciones de los
orificios para el montaje
en la pared
Placa receptora, donde

Ubicaciones de los
sea exigido por el código local
orificios para el montaje
en el piso/cielorraso
- 32 -
APÉNDICE D
Dibujo del Ensamble del Jumper
DRAWING 1 :
DIBUJO
EYELOOP
Lugs de Tap de Omega Conductor Sencilllo
Vista Desde Arriba
Whasa
STEEL FLATPlana de Acero
WASHER
Conector
CONNECTOR
TINNED de
Whasa BRASS WASHER
Laton Estañada
Vista Lateral
TapON
TAP LOOP enCOIL
Bobina
Whasa
STEEL FLATPlana de Acero
WASHER
Whasa
STEELde Seguridad
LOCK WASHER de Acero
DRAWING 2 :
DIBUJO 2
Lugs de Tap de Omega Doble Conductor
Vista Desde Arriba
STEEL FLAT WASHER

Whasa Plana de Acero
Tap
TAP LOOP ON en
COILBobina
Whasa
TINNED de Laton
BRASS WASHEREstañada
Vista Lateral
Whasa
STEEL Plana de Acero
FLAT WASHER
STEEL LOCK
Whasa WASHER
de Seguridad de Acero
- 33 -
FIGURA 1
Conjunto típico de gabinete ventilado TIPO 3R, serie NH para transformadores trifásicos y
monofásicos.
Notas:
1. Manipulación: las unidades están diseñadas para levantarse con un montacargas por debajo de la tarima. La
colocación final de la unidad con la tarima retirada puede hacerse con un montacargas debajo del transformador con
las cuchillas de este entre los canales del transformador.
2. Envío: las unidades se envían en tarimas que se retiran en el momento de la instalación.
3. Instalación: este transformador puede instalarse en interiores o exteriores y brinda cierto grado de protección contra
lluvia, nieve y formación externa de hielo.
4. Todos los transformadores para uso general/drive aislados deben estar ubicados alejados de paredes o de otras
obstrucciones al menos 15,24 cm (6 pulgadas) cuando se montan en el piso y 10,16 cm (4 pulgadas) cuando se
montan en la pared.
5. NO bloquee el área de ventilación inferior.
Panel de acceso
frontal extraíble
Orificios extruidos para

tubeía para la entrada de
cables
(2 por cada lado)
Coloque el montacargas Para la colocación final con la

debajo de la tarima. tarima extraída, los puntos de
carge para el montacargas están
debajo del transformador.
- 34 -
FIGURA 2
Conjunto típico de gabinete ventilado TIPO 3R, serie NJ para transformadores trifásicos o
monofásicos.
Notas:
las cuchillas de este entre los canales. (Note: los transformadores cuyo peso sea mayor de 2350 lbs deben ser
levantados removiendo la tapa superior y accesando a los, aditamentos para levantar que se encuentran en el
conjunto núcleo y bobina.)
3. Instalación: este transformador puede instalarse en interiores o en exteriores si se brinda cierto grado de protección
contra lluvia, nieve y formación externa de hielo.
4. Todos los transformadores deben estar ubicados alejados de paredes o de otras obstrucciones al menos 15,24 cm (6
pulgadas) cuando se montan en el piso y 10,16 cm (4 pulgadas) cuando se montan en la pared. (Note: Estos gabinetes
no son para montarse en la pared. Debe ser montados en uns plataforma suministrada por el cliente.)
5. No bloquee el área de ventilación inferior.
Ubicación de entrada
Panel de acceso de cables recomendada
frontal extraíble (ambos lados).
Consulte el diagrama
para ver las
dimensiones exactas.
Coloque el montacargas
debajo de la tarima. Para la colocación final con la
tarima extraída, los puntos de
carga para el montacargas están
debajo del transformador.
- 35 -
FIGURA 3
Conjunto típico para gabinete sin ventilación TIPO 4 y 12, serie NH para transformadores trifásicos
o monofásicos.
Notas:
las cuchillas de este entre los canales.
3. Instalación: esta es una caja sin ventilación para interiores o exteriores diseñado principalmente para brindar cierto
grado de protección contra suciedad, lluvia, nieve, polvo traído por el viento, agua que salpica, agua de manguera, y
que no sufrirá daños por la formación externa de hielo en el gabinete. Es adecuado para áreas donde es posible la
exposición a grandes cantidades de agua provenientes de cualquier dirección. (Nota: No sumergible)
4. Todos los transformadores de uso general/drive aislados deben estar ubicados alejados de paredes o de otras
obstrucciones al menos 15,24 cm (6 pulgadas) cuando se montan en el piso y 10,16 cm (4 pulgadas) cuando se
montan en la pared.
Gancho de elevación
Panel de acceso
frontal extraíble
Ubicación de entrada de cables

recomendada (cualquiera de los dos
Coloque el montacargas lados). Consulte el diagrama para ver
debajo de la tarima. las dimensiones exactas.
- 36 -
NOV PART NO.:
IOMGPOW
INSTALLATION, OPERATION AND MAINTENANCE GUIDE
FOR INDOOR/OUTDOOR DRY-TYPE TRANSFORMERS

WHICH UTILIZE A NJ6, NJ7 OR P SERIES ENCLOSURE
*Note: This guide is Trilingual Literature No.: IOMGPOW

(English, French, Spanish)* Issue Date: January 2011
Page 2
Safety Precautions
(1) Do not lift or move a transformer without proper equipment and experienced
personnel. Lifting provisions are provided on inside of enclosure on the core
& coil only. Always use all lifting provisions provided by manufacturing.
DO NOT LIFT THE TRANSFORMER BY THE ENCLOSURE.
Rolling and skidding are recommended on transformers with a pre-ordered
skidding base.
(2) Do not off-load the transformer until a full inspection has been completed.
(3) Use terminals only for electrical connections. Flexible connectors are recom-
mended for bus connections. The transformer terminals are not designed to
support the weight of supply or load cable. Uni-strut supports can be added in
the field providing proper clearances are maintained.
(4) Connections should only be in accordance with the nameplate diagram or con-
nection drawings.
(5) Make sure all power is disconnected before attempting any work on the
transformer or inside of control box and ground all windings.
(6) Make certain all ground connections, line terminals and selected taps are com-
plete and tightened before energizing the transformer.
(7) Do not attempt to change any taps - primary or secondary, while the
transformer is energized.
(8) Do not change connections when the transformer is energized.
(9) Do not tamper with control panels, alarms, interlocks or control circuits.
(10) Do not adjust or remove any accessories or cover plates while the transformer
is energized.
(11) No supply cables should come in contact with the core or any live part except
the terminal that it is intended for. Ensure that minimum clearances are main-
tained. (refer to section 10 of Field Testing)
Page 3
CONTENTS
Scope 4
Receiving & Inspection 4
Lifting Procedures 5
Storage 7
Installation precautions 7
Dry-out 8
Location 8
Sound Levels 9
Grounding 10
Field Testing 10
Maintenance 12
Cleaning 13
Field Service 13
Page 4
SCOPE A claim should be filed with the carrier at once and

the manufacturer should be notified.
This guide covers the recommendations for the
Ventilated dry-type transformers are shipped either
application, installation, operation and maintenance
completely assembled in a sheet metal enclosure or
of single and three phase dry-type transformers and
as a core and coil assembly with or without a separate
iron core reactors with or without enclosure. It is
enclosure. All parts and components are wrapped
emphasized that these abbreviated instructions should
in clear plastic sheets and covered with a shipping
be used in conjunction with all standards covering
tarpaulin. Drawings may also accompany the shipment
such work and should be referenced accordingly.
in a separate package that detail assembly if required.
These recommended practices are for general
Once the unit has been received, remove the covers
applications and any special requirements should be
or panels and proceed with an internal inspection for
referenced back to the transformer manufacturer and/
any evidence of damaged or displaced parts, loose
or their representative.
or broken connections, damaged terminal boards, dirt
It is further recommended that installation work be
or foreign materials and for the presence of any water
governed by ANSI/IEEE C57.94. This is the IEEE
or moisture. If any damage is evident, contact the
Recommended Practice for Installation, Application,
transformer manufacturer and/or your representative
Operation and Maintenance of Dry-type General
immediately.
Purpose Transformers.
RECEIVING & INSPECTION
Before any equipment is off-loaded, transformers

should first be inspected for correctness of shipping
information. Confirm that the identifying part number
on the nameplate of the transformer matches the
packing list and Bill of Lading.
Inspect the transformers immediately upon receipt for

evidence of damage or indication of rough handling
that may have been caused during shipment.
Examination should be made before removing

transformers from shipping vehicles. Inspection should
also be made for any evidence of water or other
contaminants that may have entered the transformer
during transit.
NJ TYPE ENCLOSURE
Page 5
REMOVE THE COVER

LIFTING PROCEDURES PLATE
Lifting provisions are provided on all dry-type transformers.

Lifting provision can be 2 or 4 of 5/8” (16 mm) or 3/4”
(19 mm) shouldered eye bolts or a pair of lifting angles
(see figure 1) based on the total weight of transformer.
Shouldered eye bolts used for the unit weight is less than
15,000 lbs (6,804 kgs). Lifting angles used for the unit
FIGURE 3
weight is 15,000 lbs (6804 kgs) and greater. Use of slings
for an angular lift is strongly recommended. (2) Inspect that the lifting eye bolts or lifting angles are
properly seated and tight.
(3) Verify lifting capacity of chains or slings, crane or

other means refer to the weight of transformer on
the nameplate.
(4) Measure the distance between the eye bolts or lifting

Shouldered Lifting Angle
Eye Bolts angles (see figure 4 & 5).
FIGURE 1
Procedure
Before a lift is made, the following instructions should be

read and understood.
(1) Remove the roof of NJ type of enclosure (see figure

2) or lifting cover plate on roof of power enclosure
(see figure 3). DISTANCE
BETWEEN
EYE BOLTS
FIGURE 4
DISTANCE BETWEEN
FIGURE 2 LIFTING ANGLES
FIGURE 5
Page 6
(6) The direction of the pull (sling line) must be in-line

with the plane of the eye bolts. When lifting a
transformer with a 4-legged sling, align all four
eyebolts to the center of the unit (see figure 5).
When lifting a unit with a 2-legged sling, ensure
that the eye bolts are installed at opposite corners
CHAIN LENGTH of the unit and align to the center of the unit (see
SLING figure 7).

ANGLE
FIGURE 7
DISTANCE BETWEEN (7) Always use all the eye bolts or lifting holes
EYE BOLTS
provided in angles when making a lift to avoid
FIGURE 6
overrating of bolts or torsion of frames.
TABLE 1
*Eye Chain Length (ft)
Center 33’ 4’ 5’ 6’ 7’ 8’ 9’ 10’
10” 8° 6° 5° 4° 3° 3° 3° 2°
12” 10° 7° 6° 5° 4° 4° 3° 3°
14” - 8° 7° 6° 5° 4° 4° 3°
16” - 10° 8° 6° 5° 5° 4° 4°
18” - - 9° 7° 6° 5° 5° 4°
20” - - 10° 8° 7° 6° 5° 5°
22” - - - 9° 8° 7° 6° 5°
24” - - - 10° 9° 8° 6° 6°
26” - - - 10° 9° 8° 7° 6° FIGURE 8
28” - - - - 10° 8° 7° 7° (8) Lift the power transformer by core & coil only
30” - - - - 10° 9° 8° 7°
through cutout in enclosure roof (see figure 8).
32” - - - - - 10° 9° 8°
34” - - - - - 10° 9° 8° Do not lift transformer by the enclosure.
36” - - - - - - 10° 9° Do not lift power transformer with shipping hooks.
*Note: Distance between lifting eyes on front and Do not lift transformer from beneath the enclosure.
rear frames
Do not jerk lift to avoid mechanical stresses.
(5) Ensure that the sling angle is less than 10 degrees Do not push, drag or pull the transformer directly on
(see figure 6 & table 1).
the floor unless it is supplied with skid base.
Page 7
STORAGE dry-type transformers and need to be installed

on site. When installing the anti-vibration pads
Units must be stored in a warm, dry location, free of beneath transformer base beam, ensure that
dust or air borne contaminants. The relative humidity lifting the transformer by core & coil only. If the
to which the electrical insulation materials are exposed enclosure is provided and attached to the core
should be kept as low as practical. It is preferred to & coil by shipping angles, make sure that the
store in warm dry location to avoid moisture issues shipping hooks and shipping angles are removed
but may be able to be stored in temperature to -40°C in all locations (see figure 9 and 10) and then lift
(104°F). Transformer may be energized when the the transformer by core & coil only to install the
coil temperature is as low as -25°C (-13°F) but it is anti-vibration pads (or other vibration isolations
recommended they not be loaded until the coils reach required per design).
0°C (32°F). Fluctuating temperatures can cause
condensation issues requiring a Dry-Out procedure.
The floor on which the transformer is stored should
be impervious to the upward migration of water vapor.
Take precaution to guard against water from any
SHIPPING
SHIPPING
source such as roof leaks, broken water or steam HOOKS
HOOKS
SHIPPING
SHIPPING ANTIVIBRATION
ANTIVIBRATIONPADS
PADS
lines, windows, etc. It is not recommended that dry- ANGLES
ANGLES (SHIPPED
(SHIPPEDWITH
WITHTRANSFORMER)
TRANSFORMER)
type units be stored outdoors. If that is unavoidable, FIGURE 9

units must be well protected from snow, rain and other
elements. Protection should include an initial wrap
of first quality canvas with a final outside covering of
plastic tarpaulin. It would also be desirable to include a
desiccant such as a silica gel dry-out system to reduce
the moisture content inside the assembly. If units are
stored outdoors, dry-out is recommended as described ANTIVIBRATION
PADS
on the following page. (IN FINAL LOCATION)
FIGURE 10
INSTALLATION PRECAUTIONS (2) Cable type, size and entry location shall confirm to
Local Electrical Code.
(1) It is recommended that anti-vibration pads or
(3) Terminals and terminal board shall not be used to
other vibration isolation devices be present when
support the weight of supply or load cables.
installing dry-type transformer. Some dry-type
transformers may have pre-installed anti-vibration (4) Maintain the appropriate clearance between
pads or other vibration isolation devices. Most of supply cables and live parts of transformer based
time the anti-vibration pads are provided with the on system voltages. (refer to section 10 of Field
Testing)
Page 8
(5) Use of flexible connectors for bus connections is ventilation openings cleared. Recommended
recommended. temperature should not exceed 105°C (221°F).
Continue this for a minimum of 24 hours or until all
evidence of moisture or condensation is no longer
visible.
(3) Electric heaters could be installed inside the

enclosure - particularly for units stored outdoors.
These heaters should be located under the
windings on both sides of the core. If heaters are
used, air circulation through the enclosure must
still be permitted. Fiberglass furnace filters may
be mounted temporarily over the inlet and outlet
(6) Recommend the supply cables come in from
ventilation openings to minimize dust accumulation
bottom and/or side and shall not block ventilation
within the enclosure. These filters must be
openings.
removed before the transformer is put into service.
(7) If any drilling needs to be done, please ensure
Recommended temperature should not exceed
that core and coil assembly must be protected by
105°C (221°F).
a cover sheet (e.g. Tarp) so that nothing can land
(4) For dry-out using internal heating through the
on or in coil during or after drilling and when cover
shorted terminal method, please contact the
sheet is removed.
transformer manufacturer for specific instructions.
The principles of this method require to short
DRY-OUT
circuit LV and supply current to HV no more than
If a transformer has been exposed to moisture 100% of nameplate current rating. The winding
such as condensation or rain, or stored in a high temperature should not exceed 105°C (221°F)
humidity environment, the unit must be dried out refer to section 4 of Field Testing.
prior to energization. First, immediately remove the It is emphasized that only specifically qualified
transformer from service. Megger test at intervals to personnel undertake this work.
indicate a change is taking place with the moisture
Transformers that have been exposed to flood
content in the insulation. Then proceed with any of the
conditions, direct rain or sprinklers, may not be able to
following dry-out methods:
be dried out appropriately. Consult the manufacturer
(1) Free moisture should be blown or wiped off any for further instructions.
Surface of the transformer to reduce the time of
the dry-out period. LOCATION
(2) Direct external forced air, hot or warmed, or
Ventilated dry-type transformers normally are designed
radiant heat-up through the windings with all the
for installation indoors in dry locations. They will
Page 9
operate successfully where the humidity is high, Directed air in the room near the transformer can
but under this condition it may be necessary to take disturb the natural air flow for cooling through the
precautions to keep them dry if they are de-energized winding.
for appreciable periods. Refer to dry out instructions. Adequate ventilation is essential for the proper cooling
Dry-type units covered by this guideline are designed of transformers. Clean, dry air is desirable. If the
for operation at altitudes not exceeding 1000 m (3300 location has unusually high airborne contaminants,
ft.) unless transformer has been specifically designed optional filters may be required. If transformers are
for higher altitude. installed in vaults or other places with restricted air
Environmental Considerations: flow, sufficient ventilation shall be provided to maintain
Ventilated dry-type transformers should not be correct air temperatures. The limits are specified
located in environments containing contaminants by CSA or ANSI standards and are measured near
including dust, fertilizer, excessive moisture, the transformer ventilation openings. The area of
chemicals, corrosive gases, oils or chemical vapors. ventilation openings required depends on the height
Locations where dripping water is present are to be of the vault or transformer room and the location of
avoided. If this is not possible, suitable protection transformer ventilation openings. For self-cooled
must be provided to prevent water from entering the transformers, the required effective area must be at
transformer enclosure. least one square foot each of inlet and outlet per 100
kVA of rated transformer capacity, after deduction of
Dry-type transformer should not be installed in areas
the area occupied by screens, gratings, or louvers.
accessible to the public unless specially designed for
that. This is necessary to provide sufficient free circulation
of air through and around each unit. This will also
Dry-type transformers can be located outdoors,
permit ready access for maintenance.
but they must be designed especially for outdoor
environmental protection. Suitable weather resistant If the transformer is to be located near combustible
and tamper-proof enclosures are required in locations materials, the minimum distance established by The
where there is driven water, snow, dust and sand Local Electrical Code should be maintained.
particles should be avoided. Consult the transformer

SOUND LEVELS
manufacturer for further information.
The audible sound produced by transformers is due
Transformer with open bottom, should not be installed
to energizing of the core by the alternating voltage
on or over combustible surfaces.
applied to the windings. This creates vibrations
Ventilation:
whose fundamental frequency is twice the frequency
Transformers must be located at least 2 feet away
of the applied voltage. The vibrations producing
from walls, obstructions, adjacent transformers or
audible sound can occur in the core mounting and
other reflecting surfaces on ventilation side unless
in the housing. The transmission of sound from
otherwise marked. Or further if there is another
the transformer can be by various media such as
heat source.
Page 10
air, metal, concrete, wood or any combination. If noise levels are a factor in the location of any
Amplification of audible sound can occur in a given transformer, special consideration should be given
area due to the presence of reflecting surfaces or to the installation site and attenuation equipment.
mounting surfaces. Interrupting the sound transmission medium with the
Sound levels for transformers can vary from 60 dBA installation of sound absorbing foam or fiberglass
for a 500 kVA to 76 dBA for a 10,000 kVA and more. material on the ceiling or walls, could be considered.
These sound levels are determined by CSA and

GROUNDING
ANSI Standards and are based on the following:
• Sound levels specified are for a non-loaded All non-current carrying metal parts in transformers
condition at rated voltage and frequency
must be grounded, including the core and enclosure.
• Units are tested in a low ambient noise
Standard construction has the core grounded through
environment
direct contact with the clamping structure. Cores that
• Walls or reflecting surfaces are at least 10'
away from all sides of the transformer. have metal bolts passing through them are insulated
from the core clamps and grounded at a single point.
It should be noted therefore that operating Isolating the core in this manner is necessary on
transformers when connected to a load, will exhibit these transformers only to determine if there is an
higher sound levels than the standards referenced. insulation failure in any through-bolts that might cause
Additionally, transformers are frequently installed a high circulating current or hot spot. There are no
in more confining electrical rooms which will have requirements for isolating cores in any standards
the effect of increasing the apparent sound level. including UL, ANSI, CSA, IEEE and IEC.
Transformers will exhibit higher than normal sound
levels if installed on suspended floors that may FIELD TESTING
resonate. It is a good practice to install power units on
It is recommended that separate field testing and
the ground floor or basement level to avoid suspended
inspection be made before placing a transformer in
floors and away from office or living quarters. Vibration
service to determine that it is in satisfactory operating
dampeners or spring isolators are also recommended
condition and to obtain data for future comparison.
to attenuate sound levels.
Tests and procedures as recommended in ANSI/IEEE
Flexible connectors can be installed between the bus
is recommended as a minimum.
bars and other equipment to avoid vibration transfer.
Where low-frequency applied-voltage, induced-
Ensure all mounting bolts are tightened and that
voltage, insulation resistance or megger, for
the transformer housing is securely assembled and
acceptance are conducted the test voltages shall not
separate from the transformer itself.
exceed 75% of factory test values. When field tests
Transformers installed in close proximity to each other
are made on a periodic basis, it is recommended
can experience a resonant frequency between them
that the test voltages be limited to 65% of factory test
that results in higher than normal sound levels.
values. Disconnect surge arrestors if supplied. It is
Page 11
emphasized that any tests should be conducted by block. For winding > 30kV BIL, do not put probe in
competent or qualified personnel in accordance with the coil unless instructed to do so.
recognized safety standards and codes, particularly
NFPA 70E or CSA Z462.
(1) If the transformer has been shut down for a period

of time, it must first be visually inspected for
evidence of condensation or moisture, also dust
and dried out as described earlier. Thermowell stick type Thermowell tube type
(2) Fans, motors, relays and other devices should be (5) Check for tightness and cleanliness of all electrical
inspected to be certain they are working correctly. connections including taps, phase connections
Accessories such as lightning arresters must be and grounds.
installed in accordance with the assembly drawing RECOMMENDED BOLT TORQUE FOR BOLTED
provided. ELECTRICAL CONNECTIONS
BOLT SIZE CARBON ST. BRASS S.S STEEL
GRADE 5 GRAD 5 B8 OR B8M
ft-lbs [Nm] ±5% ft-lbs [Nm] ±5% ft-lbs [Nm] ±5%

1/4-20 UNC 8 [10.8] 5 [6.8] 5 [6.8]
3/8-16 UNC 30 [40.7] 15 [2.3] 20 [27.1]
1/2-13 UNC 75 [102] 35 [47.4] 50 [67.8]
(3) Verify the selection of taps, as per the nameplate (6) An insulation resistance test should be conducted
and ratio the connections - all taps should be in on each unit. It determines the integrity of the
the identical position on each coil (note there may insulation. An insulation resistance test is of value
be more than one set of taps on coil). Taps can for future comparative purposes and for
only be changed when the unit is de-energized. determining the suitability of the transformer for a
high potential test. This test should be completed
(4) Some units are provided with winding temperature
before the high potential or Hi-Pot test.
equipment. An instruction manual, complete with
drawings, will have been provided. These devices Variable factors affecting the construction and
consist of a temperature indicator and a thermal use of dry-type transformers makes it difficult to
sensing bulb. Ensure that all parts have been set limits for the insulation resistance. Experience
assembled and installed correctly. Failure to install to date indicates that 2 megohms, (one minute
this sensing bulb into the correct insulated sleeve reading at approximately 25°C) per 1000 volts of
can result in severe damage to the transformer. nameplate voltage rating, but in no case less than
Maintain electrical clearance if installing sensing 2 megohms total, may be a satisfactory value for
probes from the temperature monitor or terminal insulation resistance. Insulation megger test (500
Page 12
V or 1000 V DC). Tests to be done between:

MAINTENANCE
LV to HV + Ground
HV to LV + Ground CAUTION
Core to Ground (if the core is isolated) The transformer must be de-energized
Note: If the transformer core is isolated, then the prior to any maintenance. It is also
core strap between the core and the top core recommended that all terminals be
clamp, must be disconnected before taking the grounded.
reading from core to ground.
(7) Polarity or phase relation. FAILURE TO DE-ENERGIZE

(8) Resistance measurements of windings.
THE TRANSFORMER BEFORE
(9) Ratio test for full winding and for all tap positions.
OPENING THE ENCLOSURE
(10) Ensure that minimum clearances are maintained
for all current carrying parts including windings, COULD RESULT IN SERIOUS
internal cable connections, NGR, CT’s, auxiliary
PERSONAL INJURY OR DEATH
transformer and bus bars.
The following table may be used as a guide for Periodic Inspection and Maintenance:
minimum clearance for altitude not exceeding 1000 m Generally, very little maintenance is required for
(3300 ft). Above 1000 m (3300 ft) consult factory. dry-type transformers. However, periodic care and
inspection is required to ensure long-term, successful
Transformer Minimum Minimum
operation. The frequency of inspection will depend on
Voltage Class Clearance (mm) Clearance (in.)
the conditions where the transformer is installed.
1.2 KV 25 1
For clean, dry locations, an annual inspection is
2.5 KV 50 2 normally sufficient. For other locations where the air is
5.0 KV 100 4 contaminated with dust or chemical vapors, inspection

at three or six month intervals may be required.
8.7 KV 130 5.3
With the transformer de-energized, remove all access
15 KV 200 8 panels on the enclosure and ground the terminals.
18 KV 250 10 Inspect for dirt particularly on insulating surfaces or
any surface which tends to restrict air flow. Insulators,
25 KV 300 12
terminals and terminal boards should be inspected
34.5 KV 400 16 for discharge (tracking), breaks, cracks or burns and
Note: “Some specific component parts of a transformer may require tightness of hardware. It is necessary to clean these
clearances different than those indicated above. For those exceptions,
you should comply with the instructions provided in the assembly draw- parts to prevent flashover due to the accumulation of
ings or installation procedure.”
the contaminant.
Page 13
Evidence of rusting, corrosion, and deterioration of (1) Overcurrent

the paint should be checked and corrective measures Fully loaded transformers may appear warm to the
taken where necessary. Fans, motors, and other touch. Standards permit the temperature of the
auxiliary devices should also be inspected and transformer enclosure cover to be 65°C (149°F) [80°C
serviced. (176°F) in not readily accessible location] over ambient
which at 40°C(104°F) ambient could be a maximum of
CLEANING
105°C (212°F) [120°C (248°F) in not readily accessible
If excessive accumulation of dirt is apparent on the location] continuous. In this condition, the temperature
transformer windings or insulators, the dirt must be on a thermometer could be at the maximum of 220°C
removed to permit the circulation of air. Particular (428°F).
attention should be given to cleaning the top and When temperatures exceed this, overheating of the
bottom ends of the winding assemblies and to cleaning transformer occurs and damage may result. Check for
ventilation ducts. these conditions:
The windings may be cleaned with a vacuum cleaner,  continuous overload or overloads for long
blower, or with compressed air. A vacuum cleaner periods
is preferred as a first step followed by the use of  wrong external connections

compressed air. The compressed air should be clean  excessive input voltage or current
and dry and applied at a relatively low pressure
 voltage or current harmonics
(not over 25 pounds per square inch). Leads, lead
 poor room ventilation or heating from other
supports, coil support, terminal boards, bushings and
sources
other major insulating surfaces should be brushed
 high ambient temperatures [standards
or wiped with a dry cloth. The use of liquid cleaners
permit 30°C (86°F) average, 40°C (104°F)
is undesirable due to solvents which could have a
maximum]
detrimental effect on insulating materials.
 blocked air ducts or ventilation openings
FIELD SERVICE  accumulation of dirt and dust restricting air
circulation.
The following is intended as a trouble shooting
(2) Noise and Vibration
guide to help determine corrective measures for
power transformers in the field. It is emphasized Sound levels for power transformers can vary from
that only qualified personnel should be permitted to 60 dB(A) for a 500 kVA to 76 dB(A) for a 10000
examine installed transformers. Transformer must kVA. These sound levels are determined by national
be de-energized before any work is conducted on a standards and are based on the following:
transformer. It is also recommended that all terminals  values are for a non-loaded condition
be grounded.  tested in a low ambient noise environment
Page 14
 walls or reflecting surfaces at least 10’ [3m] possible sources. As well, reduced output voltage may
away from all sides of the transformer. be from an incorrectly selected tap position.
Transformers are frequently installed in more confining (4) Excess Secondary Voltage
electrical rooms, and additionally, when connected to Can be caused by higher input voltage or an incorrect
the load, will exhibit higher sound levels than standard. tap position.
Excessive noise can be caused by:
(5) Smoke from Transformer
 high input voltage Uncured or excessive varnish or encapsulation
 high frequency material burning clear on start-up may cause smoke.
 unbalanced loads This is usually not a reason for either concern or a
 excessive load current long term risk for the transformer.
 voltage and current harmonics from Smoke and or fumes on start up is common and is the
nonlinear loads result of oils and lubricants used in the manufacturing
 loosened core clamps process. The smoke is considered an irritant and
 hardware or enclosures loosened due to should be temporarily ventilated. It is not a long term
shipping or handling health risk.
shipping plates are not removed

(6) High Core Loss
anti-vibration pads are not installed

Causes are high input voltage and/or lower frequency.
 transformer location
 gap in core
Transformers will exhibit higher than normal sound
(7) Burned Insulation or Insulation Failure
levels if installed on suspended floors that may
With evidence of burned insulation, check for the
resonate. It is a good practice to install power units on
following:
the ground floor or basement level to avoid suspended
floors. Vibration dampeners or spring isolators are  continuous overload condition
recommended to attenuate sound levels. Additionally,  excessive harmonics
flexible connectors should be installed between  overheating due to ventilation
the bus bars and other equipment to avoid vibration  lightening surge
transfer.  switching or line disturbance

 broken leads or arresters
Transformers installed in close proximity to each other
 damaged terminals or terminal boards
can also experience a resonant frequency between
 shorted turns or mechanical damage
them that will result in higher than normal sound
 contamination (insulation failure)
levels.
If transformer cores show evidence of overheating and
(3) Reduced or Zero Voltage
discoloration, insulation near the core may also appear
Loose connections on transformer terminals or
discolored. Very high core temperatures are caused
terminal boards, broken lead wires or shorted turns are
by:
Page 15
 high input voltage voltage will be subjected to the terminals of the

 lower frequency or saturation of the transformer. This occurs most often when a
core due to voltage harmonics. vacuum breaker is used and is a direct result of the
characteristic of the vacuum breaker to chop current.
(8) Ferroresonance
These current chops and subsequent re-ignitions
Significant over voltages may occur on transformers
produce a transient voltage at the terminals of the
due to the phenomena of ferroresonance.
transformer that is oscillatory, of high frequency
Ferroresonance is caused by both the use of single
and prolonged duration. When this applied voltage
pole switching with ungrounded primaries and
has a frequency component near one of the natural
capacitor switching restrike.
frequencies of the transformer and of sufficient
The transient voltages generated are well in excess
duration, internal damage to the insulation
of the transformer’s inherent ability to withstand over
structure of the transformer will result.
voltage. Transformers are designed to operate at 6%
When a transformer is used with vacuum or SF6 circuit
over voltage at rated load, and 10% under voltage at
breakers, we recommend that the system engineer
no load.
reviews the possibilities of oscillatory switching
In order to reduce the risk and help protect the
transients and employs appropriate mitigating methods
transformer, the user may want to consider that
to avoid transformer insulation damage.
transformers operating at 60 kV BIL or higher, have
metal oxide arrestors installed at the entry point to the (11) Core Grounding
transformer on all phases. This applies to either the All non-current carrying metal parts in transformers
primary or secondary, if either is rated 60 kV BIL or must be grounded, and this includes the core.
higher. Ferroresonance may cause significant damage Transformer cores with through bolts must be
to electrical equipment, particularly transformers and insulated from the core clamps and grounded at
protection is a single point. Isolating the core in this manner is
recommended. necessary to determine if there is an insulation failure
in any through-bolts that might cause a high circulating
(9) High Exciting Current
current or hot spot. Through-bolts are not used in
Can be caused by:
modern power transformer construction and core
 high input voltage
isolation is not necessary. There are no requirements
 low frequency
for isolating cores in any standards including UL,
 shorted turns
ANSI, CSA, IEEE and IEC. If there is a low megger
 gaps in the core due to shifting during
reading, or low resistance between the core and
shipment or handling.
ground on power transformers, causes may include:
(10) Oscillatory Switching Transients
 dirt, dust or moisture bridging the
Occasionally, when a transformer is switched into
insulation between the core and the core
or out of a system, a transient recovery voltage
frames
containing a large component of high frequency
Page 16
 shifted insulation due to shipping or should be directed through the windings. This should
handling. continue for 24 hours or until after the evidence of
condensation is no longer visible.
It is emphasized that low megger readings - an
indication of low insulation levels between the core Transformers that have been exposed to flood
and ground- are not of concern unless there are conditions, direct rain or sprinklers, may not be able
through bolts. The core is intended to be grounded in to be dried out appropriately. Consult the factory for
any event. further instructions.
(12) Coil Distortion If any of the above conditions are evident, the
Short circuited coils exhibit severe distortion from their transformer should be immediately removed from
normal round or symmetrical appearance. service. Corrective measure should be undertaken in

consultation with the manufacturer representatives or
(13) High Conductor Loss
qualified personnel.
Overloads, or terminal boards not on the identical tap
After an evaluation has been completed, the
position can result in conductor heating.
transformer may be reenergized after the appropriate
(14) Breakers/Fuses Opening reworking, or the unit may have to be returned to the
Breakers and fuses opening can be caused by: factory for further evaluation or repair.
 overload conditions
 voltage or current harmonics
 short circuit
 insulation failure that causes excessive
current.
 voltage too high when energized
 setting too low to allow for inrush current
(15) Excessive Cable Heating

Causes include:
 improperly bolted or crimped connections

 loose connectors
 loose lead wires or terminals
 incorrectly sized cables or terminals
 overload condition
(16) Moisture
If a transformer has been exposed to moisture such as
condensation or rain, the unit should be dried out prior
to energization. (refer to Dry-Out section on page 7)
Hot or warmed air, radiant heat or internal heat
INSTALLATION, FONCTIONNEMENT ET ENTRETIEN
POUR TRANSFORMATEURS SECS INTÉRIEURS ET EXTÉRIEURS

AVEC BOÎTIER DES SÉRIES NJ6, NJ7 OU P
*Remarque : Ce guide contient des explications N° de document : IOMGPOW

en trois langues (anglais, français, espagnol)* Date de parution : Janvier 2011
Page 18
Consignes de sécurité
1) Ne levez pas et ne déplacez pas un transformateur sans disposer de l’équipement
approprié et du personnel expérimenté. Les accessoires pour le levage sont fournis
dans le boîtier sur le noyau-bobines uniquement. Utilisez toujours tous les accessoires
de levage fournis par le fabricant.
NE SOULEVEZ PAS LE TRANSFORMATEUR PAR LE BOÎTIER.
Il est recommandé de faire rouler et glisser les transformateurs équipés à l’origine d’un
traîneau.
2) Ne déchargez pas le transformateur tant qu’une inspection complète n’a pas été
exécutée.
3) N’utilisez les bornes que pour les branchements électriques. Il est recommandé
d’installer des connecteurs flexibles sur les barres omnibus. Les bornes de connexion
du transformateur ne sont pas conçues pour supporter le poids d’un câble d’alimentation
ou de charge. Il est possible d’ajouter des supports Unistrut pour conserver les
dégagements minimaux appropriés.
4) Les branchements doivent respecter le schéma de la plaque signalétique ou les

diagrammes de connexion.
5) Vérifiez que la source d’alimentation est coupée avant de commencer à travailler sur
le transformateur ou dans la boîte de commande, et reliez tous les enroulements à la
terre.
6) Vérifiez que toutes les liaisons à la terre, les bornes de lignes et les prises sélectionnées
sont complètes et bien serrées avant de mettre le transformateur sous tension.
7) Ne tentez pas de changer des prises (primaires ou secondaires), alors que le

transformateur est sous tension.
8) Ne changez pas les connexions lorsque le transformateur est sous tension.
9) Ne modifiez pas les panneaux de commande, les alarmes, les verrouillages ni les circuits
de commande.
10) Ne réglez pas et ne retirez pas les accessoires ou les plaques de recouvrement lorsque
le transformateur est sous tension.
11) Aucun câble d’alimentation ne doit entrer en contact avec le noyau-bobines ou une
pièce sous tension, sauf la borne qui est prévue à cet effet. Veillez à conserver les
dégagements minimaux prévus (consultez la section 10 de Essai pratique).
Page 19
TABLE DES MATIÈRES
Domaine d’application 20
Réception et inspection 20
Procédures de levage 21
Entreposage 23
Précautions concernant
l’installation 23
Séchage 24
Emplacement d’installation 25
Niveaux de bruit 25
Mise à la terre 26
Essai pratique 26
Entretien 28
Nettoyage 29
Service après-vente 29
Page 20
Le cas échéant, une réclamation doit être remplie avec

DOMAINE D’APPLICATION
le transporteur, et le fabricant doit être prévenu.
Ce guide donne des recommandations concernant Les transformateurs secs ventilés sont livrés tout assemblés
l’application, l’installation, le fonctionnement et l’entretien dans un boîtier en métal ou sous forme d’un ensemble
des transformateurs secs monophasés et triphasés et des de noyaux-bobines avec ou sans boîtier en métal. Toutes
bobines de réactance à noyau de fer avec ou sans boîtier. Il les pièces et composantes sont emballées dans des
est important de comprendre que ces consignes abrégées feuilles de plastique transparent et recouvertes d’une
doivent être suivies en conformité avec toutes les normes bâche d’expédition. Au besoin, des schémas détaillant
relatives à ce type de travail et doivent être vérifiées dans ce l’assemblage sont joints à l’envoi dans un emballage séparé.
contexte. Après avoir reçu l’appareil, retirez les couvercles ou les
Les méthodes recommandées dans ce guide concernent panneaux et inspectez l’intérieur pour voir si des pièces
des applications générales. Toute utilisation particulière sont abîmées ou déplacées, si des connexions sont
doit faire l’objet d’une vérification auprès du fabricant du desserrées ou brisées, si des barrettes de connexions sont
transformateur ou de son représentant. endommagées, ou s’il y a présence de saleté, de matériaux
Il est fortement recommandé d’effectuer l’installation en étrangers, d’eau ou d’humidité. En cas de dommages
conformité avec la norme ANSI/IEEE C57.94. Il s’agit de la visibles, communiquez immédiatement avec le fabricant du
méthode IEEE recommandée pour l’installation, l’application, transformateur ou votre représentant.
le fonctionnement et l’entretien des transformateurs secs

d’usage général.
RÉCEPTION ET INSPECTION
Avant tout déchargement, il convient d’inspecter

l’exactitude des renseignements relatifs à l’expédition des
transformateurs. Vérifiez que le numéro de pièce indiqué sur
la plaque signalétique du transformateur correspond bien à
celui du bordereau d’emballage et du connaissement.
Inspectez les transformateurs immédiatement à la réception

pour voir s’il existe des dégâts ou des signes de manutention
brusque durant l’expédition.
Cet examen doit avoir lieu avant que les transformateurs ne

soient déchargés du véhicule de transport. Il faut également
rechercher tout signe d’eau ou de contaminants pouvant
avoir touché le transformateur au cours du transport.
BOÎTIER DE TYPE NJ
Page 21
RETIRER LE
PROCÉDURES DE LEVAGE COUVERCLE
Des consignes concernant le levage sont fournies avec

tous les transformateurs secs. En fonction du poids total du
transformateur, les accessoires de levage consisteront en 2 ou
4 boulons à oeil à épaulement de 16 mm (5/8 po) ou 19 mm
(3/4 po) ou en une paire de cornières élévatrices (voir figure 1).
Les boulons à oeil à épaulement sont utilisés pour les appareils
d’un poids inférieur à 6 804 kg (15 000 lb). Les cornières
élévatrices sont utilisées pour les appareils d’un poids égal ou FIGURE 3
supérieur à 6 804 kg (15 000 lb). Il est fortement recommandé
2) Vérifiez que les boulons à oeil à épaulement pour le levage
d’utiliser des élingues lors du levage en angle.
ou les cornières élévatrices sont bien fixés et bien serrés.
3) Vérifiez la capacité de levage des chaînes ou des élingues,
de la grue ou des autres moyens utilisés. Consultez le
poids du transformateur inscrit sur la plaque signalétique.
4) Mesurez la distance entre les boulons à oeil à épaulement
et les cornières élévatrices (voir figures 4 et 5).
Boulons à œil Cornière élévatrice
à épaulement
FIGURE 1
Procédure
Il est impératif de lire et de comprendre les consignes suivantes

avant de procéder au levage.
1) Retirez le toit s’il s’agit d’un boîtier de type NJ (voir figure 2)
DISTANCE
ou le couvercle de levage situé sur le toit du boîtier ENTRE LES
BOULONS À OEIL
d’alimentation (voir figure 3). À ÉPAULEMENT
FIGURE 4
DISTANCE ENTRE LES

CORNIÈRES ÉLÉVATRICES
FIGURE 2
FIGURE 5
Page 22
6) Le sens de traction (ou ligne d’élingue) doit se trouver

dans l’alignement du niveau de l’œil des boulons. Si vous
levez le transformateur avec une élingue quadruple,
alignez les quatre boulons à œil par rapport au centre
de l’appareil (voir figure 5). Si vous levez l’appareil avec
une élingue double, veillez à ce que les boulons soient
LONGUEUR DE
LA CHAÎNE
ANGLE DE
L'ÉLINGUE
FIGURE 7
installés à des angles opposés de l’appareil et alignez-les
par rapport à son centre (voir figure 7).
7) Lors du levage, utilisez toujours tous les boulons à œil
et tous les trous de levage des cornières pour éviter de
DISTANCE ENTRE
LES BOULONS À surcharger les boulons ou de tordre le châssis.
OEIL À ÉPAULEMENT
FIGURE 6
TABLEAU 1
*Centre Longueur de la chaîne (pi)
de l’œillet 3 pi 4 pi 5 pi 6 pi 7 pi 8 pi 9 pi 10 pi
10 po 8° 6° 5° 4° 3° 3° 3° 2°
12 po 10° 7° 6° 5° 4° 4° 3° 3°
14 po - 8° 7° 6° 5° 4° 4° 3°
16 po - 10° 8° 6° 5° 5° 4° 4°
18 po - - 9° 7° 6° 5° 5° 4°
20 po - - 10° 8° 7° 6° 5° 5°
22 po - - - 9° 8° 7° 6° 5°
24 po - - - 10° 9° 8° 6° 6°
26 po - - - 10° 9° 8° 7° 6° FIGURE 8
28 po - - - - 10° 8° 7° 7°
30 po - - - - 10° 9° 8° 7° 8) Soulevez l’appareil par le noyau et la bobine seulement,
32 po - - - - - 10° 9° 8° grâce à la découpe ménagée dans le toit du boîtier (voir
34 po - - - - - 10° 9° 8° figure 8).
36 po - - - - - - 10° 9° Ne soulevez pas le transformateur par le boîtier.
*Remarque : Distance entre les œillets de levage sur les Ne soulevez pas le transformateur avec des crochets de
châssis avant et arrière
levage.
1 po = 2,5 cm
1 pi = 0,3 m Ne soulevez pas le transformateur par-dessous le boîtier.
5) Vérifiez que l’angle de l’élingue est inférieur à 10 degrés Ne secouez pas l’appareil lors du levage afin d’éviter le
(voir figure 6 et tableau 1). stress mécanique.
Page 23
Ne poussez pas, ne glissez pas et ne tirez pas le dispositifs d’isolation des vibrations. La plupart du
transformateur directement sur le sol à moins qu’il ne temps, les coussinets antivibrations sont fournis avec
soit muni d’un traîneau. les transformateurs secs et doivent être installés sur
place. Lors de l’installation des coussinets antivibrations
ENTREPOSAGE sous la traverse de soutien du transformateur, veillez
à ne lever l’appareil que par le noyau-bobines. Si le
Les appareils doivent être entreposés dans un emplacement boîtier est fourni et s’il est fixé au noyau-bobines par les
chaud, sec et exempt de poussière ou de contaminants de cornières d’élévation, veillez à retirer tous les crochets
l’air. L’humidité relative à laquelle les matériaux d’isolation de levage et les cornières d’expédition (voir figures 9
électrique sont exposés doit être aussi basse que possible. et 10), puis levez le transformateur par le noyau-bobines
Il est préférable d’entreposer l’appareil dans un endroit uniquement afin d’installer les coussinets antivibrations
chaud et sec pour éviter les problèmes d’humidité. Il peut (ou les autres dispositifs antivibratoires nécessaires
cependant être entreposé à des températures pouvant pour l’appareil).
descendre jusqu’’à -40 ºC (104 ºF). Le transformateur doit
être mis sous tension lorsque la température de la bobine
descend à -25 ºC (-13 ºF). Il est cependant recommandé de
ne pas le charger avant que la bobine atteigne 0 ºC (32 ºF).
La variation de température peut entraîner des problèmes de
condensation nécessitant une procédure de séchage. Le sol
sur lequel repose le transformateur doit être imperméable
CROCHETS
à la montée de la vapeur d’eau. Prenez des mesures pour D'EXPÉDITION
CORNIÈRES COUSSINETS ANTIVIBRATIONS
D'EXPÉDITION (ENVOYÉS AVEC
protéger l’appareil de l’eau pouvant provenir de fuites sur le LE TRANSFORMATEUR)
toit, de bris de canalisations ou de conduites de vapeur, des FIGURE 9

fenêtres, etc. Il est déconseillé d’entreposer les appareils
secs à l’extérieur. Si vous ne pouvez pas l’éviter, protégez-
les bien contre la neige, la pluie et les autres intempéries.
Cette protection doit être constituée d’une première couche
de toile de première qualité et recouverte par une bâche
de plastique conçue pour l’extérieur. Il est également
recommandé d’y inclure un produit dessiccatif comme
un système asséchant au gel de silicone afin de réduire
COUSSINETS
l’humidité se trouvant dans l’appareil. Si les appareils sont ANTIVIBRATIONS
(DANS L'EMPLACEMENT FINAL)
entreposés à l’extérieur, il est recommandé de procéder au
FIGURE 10
séchage selon la méthode indiquée à la page suivante.
2) Le type, la taille et l’emplacement du câble doivent
PRÉCAUTIONS CONCERNANT respecter les exigences du Code de l’électricité.
L’INSTALLATION 3) Les bornes de connexion et le bornier ne doivent pas
servir à supporter le poids des câbles d’alimentation ou
1) Il est recommandé d’utiliser des coussinets de charge.
antivibrations ou des dispositifs d’isolation des vibrations
4) Respectez le dégagement minimal entre les
lors de l’installation du transformateur sec. Il se peut
câbles d’alimentation et les pièces sous tension du
que certains transformateurs secs aient été équipés
transformateur, en fonction de la tension du système
en usine de coussinets antivibrations ou d’autres
(consultez la section 10 de Essai pratique)
Page 24
5) Il est recommandé d’installer des connecteurs flexible 2) Envoyez l’air forcé, chaud ou réchauffé ou encore
s sur les barres omnibus. le chauffage rayonnant à travers les enroulements
en dégageant toutes les bouches de ventilation. La
température recommandée ne doit pas dépasser 105 ºC
(221 ºF). Poursuivez l’opération pendant 24 heures ou
jusqu’à ce qu’il n’y ait plus aucune trace d’humidité ni de
condensation.
3) Il est possible d’installer des appareils de chauffages
électrique dans le boîtier, surtout s’il s’agit d’appareils
entreposés à l’extérieur. Ces appareils de chauffages
devraient être placés sous les enroulements, de
chaque côté du noyau. Si vous utilisez des appareils de
chauffages, la circulation d’air doit être possible dans le
6) Il est recommandé de faire sortir les câbles boîtier. Les filtres de fournaise en fibre de verre peuvent
d’alimentation par le bas ou le côté. Ils ne doivent pas être montés temporairement sur les bouches d’entrée et
bloquer les bouches de ventilation. de sortie d’air pour réduire l’accumulation de poussière
dans le boîtier. Ces filtres doivent être retirés avant
7) Si vous devez percer le boîtier, veillez à ce que le
la mise en service du transformateur. La température
noyau-bobine soient bien protégés (p. ex. bâche) fin que
recommandée ne doit pas dépasser 105 ºC (221 ºF).
rien ne puisse tomber sur ou dans la bobine pendant ou
après le perçage, lorsque vous retirez la protection. 4) Si vous désirez sécher avec un chauffage interne en
court-circuit les bornes, communiquez avec le fabricant
SÉCHAGE du transformateur pour obtenir des consignes. Les

principes de cette méthode consistent à court-circuiter
Si le transformateur a été exposé à l’humidité, comme la la basse tension et à alimenter la haute tension au
condensation ou la pluie, ou entreposé dans un milieu très maximum du courant nominal indiqué sur la plaque
humide, il doit être séché avant d’être mis sous tension. signalétique. La température de l’enroulement ne doit
Commencez par mettre immédiatement le transformateur pas dépasser 105 ºC (221 ºF). Consultez la section 4 de
hors service. Procédez périodiquement à un test avec un Essai pratique.
mégohmmètre pour voir s’il y a un changement d’humidité Il est important que seules des personnes qualifiées
dans l’isolation. Effectuez ensuite l’une des procédures de effectuent cette tâche.
séchage ci-dessous : Il peut être difficile de sécher correctement des
1) Séchez ou essuyez l’humidité se trouvant sur la surface transformateurs ayant été soumis à une inondation, de la
du transformateur pour réduire la période de séchage. pluie directe ou des sprinkleurs. Consultez le fabricant pour
obtenir d’autres consignes.
Page 25
EMPLACEMENT D’INSTALLATION L’air orienté dans la pièce près du transformateur peut

perturber le débit naturel de refroidissement dans
Les transformateurs secs ventilés sont normalement conçus l’enroulement.
pour être installés à l’intérieur, dans des endroits secs. Ils
Pour pouvoir se refroidir suffisamment, les transformateurs
fonctionnent malgré tout lorsque l’humidité est élevée, mais il
doivent être bien ventilés. L’air doit être propre et sec. Si le
est nécessaire de les garder au sec s’ils sont éteints pendant
taux de contaminants atmosphériques est anormalement
de longues périodes. Consultez les consignes de séchage.
élevé, il faudra utiliser des filtres supplémentaires. Si
Les appareils de type sec concernés par cette directive
les transformateurs sont installés dans des chambres
sont faits pour fonctionner à une altitude ne dépassant pas
d’appareillage ou d’autres endroits dans lesquels la
1 000 m (3 300 pi), sauf dans les cas ou le transformateur a
circulation de l’air est restreinte, il faut ventiler suffisamment
spécialement été conçu pour une altitude plus élevée.
pour maintenir une température adéquate. Les limites
Considérations environnementales : sont définies par les normes de la CSA ou de l’ANSI et se
Les transformateurs secs ventilés ne doivent pas être utilisés mesurent près des bouches de ventilation du transformateur.
dans des environnements contenant des contaminants La superficie des bouches de ventilation requise dépend
comme de la poussière, des engrais, de l’humidité de leur emplacement sur le transformateur et de la hauteur
excessive, des produits chimiques, des gaz corrosifs, ou des de la chambre d’appareillage. S’il s’agit de transformateurs
vapeurs d’huile ou chimiques. La proximité d’eau ruisselante autorefroidis, chaque entrée et chaque sortie doivent
doit être évitée. Si ce n’est pas possible, il faut alors prévoir avoir une superficie d’au moins 0,09 m² (1 pi²) pour un
une protection adéquate pour éviter que l’eau ne pénètre transformateur d’une capacité nominale de 100 kVA, après
dans le boîtier du transformateur. déduction de la surface occupée par les grillages ou les
Le transformateur sec ne doit pas être installé dans un persiennes.
endroit accessible du public, sauf s’il a été conçu à cet effet. Cette distance est nécessaire afin de laisser une circulation
Les transformateurs secs peuvent être installés à l’extérieur, d’air suffisante à travers et autour de chaque appareil. Ces
si toutefois ils ont été spécialement conçus avec une distances permettent également l’accès pour l’entretien.
protection extérieure. Ils doivent être équipés de boîtiers à Si le transformateur doit être installé près de matières
l’épreuve des intempéries et inviolables et ne doivent pas combustibles, la distance minimale définie par le Code de
être placés dans des endroits battus par l’eau, la neige, la l’électricité doit être respectée.
poussière et le sable. Consultez le fabricant pour obtenir
d’autres renseignements. NIVEAUX DE BRUIT
Les transformateurs à fond ouvert ne doivent pas être
Le bruit provenant des transformateurs est dû à la mise
installés sur des surfaces combustibles ou près de celles-ci.
sous tension du noyau par le courant alternatif envoyé aux
Ventilation : enroulements. Ce phénomène entraîne des vibrations dont
Sauf avis contraire, les transformateurs doivent se la fréquence de base est deux fois supérieure à la tension
trouver à 61 cm (2 pi) au moins des murs, des obstacles, utilisée. Les vibrations produisant un son audible peuvent
des transformateurs proches ou des autres surfaces provenir du noyau du boîtier. Le bruit peut être transmis par
réfléchissantes, ou plus loin s’il existe une autre source divers médias comme l’air, le métal, le béton, le bois ou une
de chaleur. combinaison de ces éléments. Il peut être amplifié à certains
endroits par la présence de surfaces réfléchissantes ou
d’assemblage.
Page 26
Le niveau de bruit émanant d’un transformateur peut aller Si les niveaux de bruit sont un critère de choix pour
de 60 dBA pour un appareil de 500 kVA à 76 dBA pour un l’emplacement du transformateur, il convient de porter
appareil de 10 000 kVA ou plus. une attention particulière à l’endroit de l’installation et à
Ces niveaux de bruit sont définis par les normes de la l’équipement d’atténuation du bruit. Il faut alors envisager
CSA et de l’ANSI en fonction des éléments suivants : de réduire la transmission du son en installant de la mousse
• Les niveaux de bruit indiqués correspondent à des isophonique ou des matériaux en fibre de verre dans le
appareils à vide à une tension et une fréquence plafond ou les murs.
nominales.
• Les appareils sont testés avec un bruit ambiant MISE À LA TERRE
faible.
Toutes les parties métalliques du transformateur qui ne sont
• Les murs ou les surfaces réfléchissantes se trouvent
pas sous tension doivent être mises à la terre, notamment
à 3 m (10 pi) au moins des côtés du transformateur.
le noyau et le boîtier. La méthode standard de fabrication
veut que le noyau soit directement mis à la terre par contact
Il faut cependant noter que lorsque les transformateurs direct avec la structure de fixation. Les noyaux traversés
en marche sont branchés à une charge, le niveau de bruit par des boulons de métal sont isolés à partir des fixations
devient supérieur aux normes indiquées. En outre, les et mis à la terre à un seul endroit. Il est nécessaire d’isoler
transformateurs sont souvent installés dans des locaux le noyau de cette manière pour savoir si l’un des boulons
électriques plus exigus, ce qui tend à augmenter le niveau d’assemblage peut présenter un problème d’isolation qui
de bruit apparent. Les transformateurs dépasseront la norme entraînerait une circulation élevée du courant ou un point
de niveau de bruit s’ils sont installés sur des planchers chaud. Aucune norme n’impose l’isolation des noyaux, y
suspendus pouvant résonner. La bonne méthode consiste compris les normes UL, ANSI, CSA, IEEE et IEC.
à installer les appareils au rez-de-chaussée ou au sous-sol,
niveaux dépourvus de planchers suspendus, et à l’écart ESSAI PRATIQUE
des bureaux ou des espaces d’habitation. Il est également
recommandé d’installer des amortisseurs de vibration ou des Il est recommandé de procéder à des essais pratiques
isolateurs à ressort pour atténuer le niveau de bruit. distincts avant de mettre un transformateur en service,
afin de savoir si les conditions de fonctionnement sont
Il est possible d’installer des connecteurs flexibles entre les
satisfaisantes et d’obtenir des données en vue d’une
barres omnibus et le reste de l’équipement pour éviter le
comparaison. Les essais et les procédures recommandées
transfert des vibrations. Veillez à ce que les vis de fixation
par l’ANSI/IEEE constituent un minimum.
soient bien serrées et que le boîtier soit bien assemblée et à
distance du transformateur. Lorsque l’on procède à des essais diélectriques - tension
appliquée, tension induite, par résistance d'isolation ou par
Les transformateurs installés très près les uns des autres
mégohmmètre, les tensions utilisées pour l’essai ne doivent
peuvent émettre une fréquence de résonance produisant un
pas dépasser 75 % des tensions d’essai en usine. Si les
niveau de bruit supérieur à la normale.
essais pratiques sont faits régulièrement, les tensions d’essai
doivent être limitées à 65 % des tensions d’essai en usine.
Débranchez les limiteurs de surtension, le cas échéant. Il
est important que seules des personnes compétentes ou
qualifiées effectuent les essais conformément aux normes
et codes de sécurité en vigueur, particulièrement les normes
NFPA 70E ou CSA Z462.
Page 27
1) Si le transformateur est éteint depuis une longue

période, il doit d’abord faire l’objet d’une inspection
visuelle pour déceler des signes de condensation, de
poussière ou d’humidité, et séché selon la procédure
décrite plus haut.
2) Les ventilateurs, les moteurs, les relais et autres pièces
doivent être inspectés et leur bon fonctionnement doit Sonde thermométrique Sonde thermométrique
en forme de bâton en forme de tube
être vérifié.
Des accessoires comme des parafoudres doivent être
5) Vérifiez l’étanchéité et la netteté de toutes les
installés conformément au dessin d’assemblage.
connexions électriques, y compris les prises, les
branchements aux bornes et la mise à la terre.
FORCE DE SERRAGE RECOMMANDÉE DES

CONNEXIONS ÉLECTRIQUES BOULONNÉES
TAILLE DU ACIER AU LAITON ACIER INOX
BOULON CARBONE Catégorie 5 B8 OU B8M
Catégorie 5
pi-lb [N.m] ± 5 % pi-lb [N.m] ± 5 % pi-lb [N.m] ± 5 %

1/4-20 UNC 8 [10,8] 5 [6,8] 5 [6,8]
3) Vérifiez les prises selon la plaque signalétique et par
3/8-16 UNC 30 [40,7] 15 [2,3] 20 [27,1]
rapport aux connexions. Toutes les prises devraient
1/2-13 UNC 75 [102] 35 [47,4] 50 [67,8]
être dans la même position sur chaque bobine (il peut y
avoir plus d’un ensemble de prises dans la bobine). Les
prises ne peuvent être changées que lorsque l’appareil 6) Un essai de la résistance d’isolation doit être effectué
est hors tension. sur chaque appareil. Il détermine l’intégrité de l’isolation.

L’essai de la résistance d’isolation est important pour
4) Certains appareils sont équipés d’un dispositif pour
obtenir des valeurs de comparaison et permet de
mesurer la température des enroulements. Un mode
déterminer si le transformateur est en mesure de subir
d’emploi complet comprenant des schémas a été
un essai diélectrique. L’essai de la résistance d’isolation
fourni avec ce matériel. Ces appareils comprennent un
doit être effectué avant l’essai diélectrique.
indicateur de température et un bulbe thermostatique.
Vérifiez que toutes les pièces sont bien assemblées Les variables influençant la construction et l’utilisation
et bien installées. Si ce bulbe n’est pas installé dans de transformateurs secs compliquent l’établissement de
le bon manchon isolé, votre transformateur risque limites pour la résistance à l’isolation. Jusqu’à présent,
de subir de graves dégâts. Respectez les distances l’expérience indique que la valeur de 2 mégohms
d’isolement lors de l’installation de sondes de détection (lecture d’une minute à 25 ºC [77 ºF] environ) par
à partir du contrôleur de température ou du bornier. Si 1 000 volts de la capacité en voltage de la plaque
l’enroulement est supérieur à 30 kV TTC, n’installez pas signalétique, et jamais moins de 2 mégohms au total,
de sonde dans la bobine, sauf instruction contraire. constitue une valeur satisfaisante en matière de
résistance à l’isolation.
Page 28
Essai d’isolation au moyen d’un mégohmmètre ENTRETIEN

(500 V ou 1 000 V CC). Essais à effectuer entre :
BT vers HT + Terre AVERTISSEMENT
HT vers BT + Terre Le transformateur doit être mis hors tension
Noyau vers Terre (si le noyau est isolé) avant l’entretien. Il est également recommandé
Remarque: Si le noyau du transformateur est isolé, alors de mettre toutes les bornes à la terre.
le feuillard de mise à la terre du noyau se trouvant entre
ce dernier et la fixation du haut doit être débranché
avant que la mesure soit prise entre le noyau et la terre.
NÉGLIGER DE METTRE LE
7) Polarité ou relation de phase. TRANSFORMATEUR HORS
8) Mesure de la résistance des enroulements. TENSION AVANT D’OUVRIR LE
9) Essai de rapport de tout l’enroulement et de toutes les
BOÎTIER PEUT CAUSER DES
positions des prises.
10) Veillez à conserver les dégagements minimaux prévus
BLESSURES GRAVES OU
pour tous les éléments sous tension, notamment les MÊME LA MORT.
enroulements, les branchements des câbles internes,
les connexions, la liaison du neutre à la terre, les prises Inspection et entretien réguliers :
médianes, les transformateurs auxiliaires et les barres De manière générale, les transformateurs secs n’ont besoin
omnibus. que de peu d’entretien. Il est cependant nécessaire de

procéder à une inspection et un entretien réguliers pour
Le tableau suivant constitue un guide d’espacement
garantir leur bon fonctionnement à long terme. La fréquence
minimum à une altitude maximale de 1 000 m (3 300 pi).
des inspections dépend des conditions d’installation.
Pour les altitudes supérieures à 1 000 m (3 300 pi),
consultez le fabricant. Si l’appareil est installé dans un endroit propre et sec, une
inspection annuelle est normalement suffisante. S’il est
Cat. de tension Dégagement Dégagement
du transformateur minimum (mm) minimum (po) installé dans un endroit où l’air contient de la poussière ou
des vapeurs chimiques, l’inspection doit avoir lieu à des
1,2 kV 25 1 intervalles de trois à six mois.
Lorsque le transformateur est hors tension, enlevez tous les
2,5 kV 50 2
panneaux d’accès du boîtier et reliez les bornes à la terre.
5,0 kV 100 4 Éliminez la saleté, particulièrement sur les surfaces isolées
ou les surfaces sur lesquelles elle a tendance à obstruer le
8,7 kV 130 5,3
passage de l’air. Recherchez sur les isolateurs, les bornes
15 kV 200 8 et les barrettes de connexions des signes de décharge

(cheminement), des bris, des fentes ou des brûlures et une
18 kV 250 10 contraction du matériel. Il est nécessaire de nettoyer ces
pièces pour éviter le contournement dû à l’accumulation de
25 kV 300 12
contaminants.
34,5 kV 400 16 Recherchez les traces de rouille, de corrosion et de
Remarque : Certaines pièces du transformateur ont besoin de moins détérioration de la peinture, et prenez les mesures correctives
d’espace de dégagement que ce qui est indiqué ci-dessus. Pour ces
qui s’imposent. Les ventilateurs, moteurs et autres appareils
exceptions, respectez les consignes données dans les schémas ou
la procédure d’installation de l’appareil. auxiliaires doivent également être inspectés et réparés.
Page 29
NETTOYAGE  surcharge continue ou durant de longues périodes;

 mauvaises connexions externes;
S’il existe une accumulation excessive de saleté sur les
 tension ou courant excessif à l’entrée;
enroulements ou les isolateurs du transformateur, il faut
l’éliminer pour permettre la circulation de l’air. Il convient de  des harmoniques de tension ou de courant;
nettoyer tout particulièrement les extrémités supérieure et  mauvaise ventilation de la pièce ou chaleur
inférieure des enroulements et les conduits de ventilation. provenant d’autres sources;
Les enroulements peuvent être nettoyés à l’aide d’un  températures ambiantes élevées (normes de 30 ºC
aspirateur, d’un ventilateur ou d’air comprimé. Il est [86 ºF] en moyenne, 40 ºC [104 ºF] maximum);
préférable d’utiliser d’abord un aspirateur, puis de terminer  conduites d’air ou bouches de ventilation bloquées;
avec l’air comprimé. L’air comprimé doit être propre et sec,  accumulation de saleté et de poussière limitant la
et sa pression doit être assez basse (pas plus de 172,4 kPa circulation d’air.
[25 lb/po²]). Les fils de sortie, leurs supports, le support de
2) Bruit et vibrations
la bobine, les cavaliers de connexions, les traversées et les
Le niveau de bruit émanant d’un transformateur de
autres surfaces isolantes importantes doivent être brossés
puissance peut aller de 60 dBA pour un appareil de
ou essuyés avec un chiffon sec. Il est déconseillé d’utiliser
500 kVA à 76 dBA pour un appareil de 10 000 kVA ou plus.
des nettoyants liquides dont les solvants peuvent causer des
Ces niveaux de bruit sont définis par les normes nationales
dégâts sur les matériaux isolants.
en fonction des éléments suivants :
 les valeurs indiquées correspondent à des
SERVICE APRÈS-VENTE
appareils à vide;
Cette partie se veut un guide de dépannage qui vous  les appareils sont testés avec un bruit ambiant faible;
aidera à définir les mesures correctives à apporter aux  les murs ou les surfaces réfléchissantes se trouvent
transformateurs de puissance. Cependant, seules des à 3 m (10 pi) au moins des côtés du transformateur.
personnes qualifiées devraient pouvoir examiner les
Les transformateurs sont souvent installés dans des locaux
transformateurs installés. Il est indispensable de couper la
électriques plus exigus. En outre, lorsqu’ils sont branchés à
source d’alimentation électrique avant d’entreprendre des
la charge, ils dépassent la norme de niveau de bruit. Un bruit
travaux sur un transformateur. Il est également recommandé
excessif peut être causé par :
de mettre toutes les bornes à la terre.
 une tension d’alimentation très élevée;
1) Surtension
 une fréquence élevée;
Des transformateurs en pleine charge peuvent sembler
 des charges déséquilibrées;
chauds au toucher. Les normes autorisent une température
 un courant de charge trop élevé;
de 65 ºC (149 ºF) [80 ºC (176 ºF) dans les endroits
 les harmoniques de tension ou de courant des
difficilement accessibles] pour le boîtier du transformateur,
charges non linéaires;
ce qui, à une température ambiante de 40 ºC (104 ºF) peut
 les fixations du noyau desserrées;
donner un maximum continu de 105 ºC (212 ºF) [120 ºC
 du matériel ou des boîtiers desserrés à la suite de
(248 ºF) dans les endroits difficilement accessibles].
l’expédition ou de la manutention;
Dans cette situation, la température du thermomètre peut
les cales d’expédition n’ont pas été retirées;

atteindre 220 ºC (428 ºF) au maximum.
les coussinets antivibrations ne sont pas installés;

Si la température est supérieure à 220 ºC (428 ºF), le  l’emplacement du transformateur.
transformateur est en surchauffe et des dégâts peuvent
survenir. Vérifiez les points suivants :
Page 30
Les transformateurs dépasseront la norme de niveau légère surtension;


de bruit s’ils sont installés sur des planchers suspendus commutation ou perturbation de la ligne;

pouvant résonner. La bonne méthode consiste à installer fils de sortie ou parafoudres brisés;

les appareils au rez-de-chaussée ou au sous-sol, niveaux bornes ou cavaliers de connexions endommagées;

dépourvus de planchers suspendus. Il est recommandé courts-circuits ou dégâts mécaniques;

de recourir aux amortisseurs de vibration ou aux isolateurs contamination (défaut de l’isolation).

à ressort pour atténuer le niveau de bruit. En outre, il est
Si les noyaux du transformateur montrent des signes de
possible d’installer des connecteurs flexibles entre les
surchauffe et de décoloration, l’isolation toute proche pourra
barres omnibus et le reste de l’équipement pour éviter le
également apparaître décolorée. La température très élevée
transfert des vibrations.
du noyau est due à :
Les transformateurs installés très près les uns des autres
 une tension d’alimentation très élevée;
peuvent également émettre une fréquence de résonance à
 une fréquence plus basse ou la saturation du noyau
cause d’un niveau de bruit supérieur à la normale.
par les harmoniques de la tension.
3) Tension réduite ou inexistante
8) Ferrorésonance
Il peut s’agir de connexions desserrées sur les bornes ou
Le phénomène de ferrorésonance peut entraîner
les cavaliers de connexions du transformateur, ou encore
d’importantes surtensions du transformateur. La
de courts-circuits. La réduction de la tension de sortie peut
ferrorésonance est causée à la fois par l’utilisation d’une
également provenir de la mauvaise position d’une prise.
variation de pôles unique avec primaires non mis à la terre
4) Tension induite excessive
et d’une seconde commutation des condensateurs.
Peut provenir d’une tension d’entrée plus élevée ou de la
La tension transitoire générée ainsi dépasse la capacité
mauvaise position d’une prise.
intrinsèque du transformateur de résister à la surtension. Les
5) Fumée provenant du transformateur transformateurs sont conçus pour fonctionner avec un taux
La présence de vernis non traité ou en excès, ou encore de surtension de 6 % en charge et un taux de sous-tension
l’encapsulation d’un matériau qui brûle au démarrage peut de 10 % à vide.
provoquer de la fumée. Il ne s’agit généralement pas d’un Pour réduire les risques et protéger le transformateur,
problème ni d’un risque à long terme pour le transformateur. l’utilisateur pourra envisager de le faire fonctionner à 60
L’émission de fumées au démarrage est courante et provient kV TTC ou plus, et d’installer des parafoudres au point
de l’utilisation d’huiles et de produits lubrifiants lors de la d’entrée du transformateur, sur toutes les phases. Cette
fabrication. La fumée est un irritant qui doit être évacué. Elle mesure s’applique aux primaires ou secondaires de 60
ne constitue cependant pas un risque sanitaire à long terme. kV TTC ou plus. La ferrorésonance peut causer des dégâts
importants à l’équipement électrique, particulièrement
6) Perte élevée au noyau
aux transformateurs. Il est recommandé de prévoir une
Phénomène causé par une tension d’alimentation élevée ou
protection.
une fréquence plus basse.
lacunes dans le noyau
 9) Courant d’excitation élevé
7) Isolation brûlée ou défaillante Peut être causé par :
S’il y a des signes d’isolation brûlée, effectuez les  une tension d’alimentation très élevée;
vérifications suivantes :  une fréquence faible;
surcharge continue;
  des courts-circuits;
harmoniques excessives;
  des lacunes dans le noyau à la suite de
surchauffe due à la ventilation;

 déplacements dus à l’expédition ou la manutention.
Page 31
Il est important de noter qu’un résultat médiocre de l’essai

10) Tension transitoire de commutation oscillante
d’isolation (indication de faibles niveaux d’isolation entre le
Occasionnellement, lorsqu’un transformateur est mis en
noyau et la terre) n’est pas préoccupant, sauf en présence
fonction dans un système ou hors de celui-ci, une tension
de boulons d’assemblage. Le noyau doit être mis à la terre
transitoire de rétablissement, composée pour une large
en toutes circonstances.
part de tension à haute fréquence, est envoyée aux
bornes du transformateur. Ce phénomène se produit le 12) Distorsion de l’enroulement
plus souvent lorsqu’un disjoncteur sous vide est utilisé et Les enroulements ayant subi un court-circuit montrent
provient directement de la caractéristique de ce dispositif d’importants signes de distorsion par rapport à leur aspect
consistant à hacher le courant. Ce hachage et les reprises normal circulaire ou symétrique.
qui s’ensuivent créent aux bornes du transformateur une 13) Perte élevée au conducteur
tension transitoire oscillante, à haute fréquence et à durée L’échauffement du conducteur peut provenir de surcharges
prolongée. S’il existe dans cette tension appliquée un ou de cavaliers de connexions n’étant pas sur la même
élément de fréquence proche des fréquences naturelles du position de prise.
transformateur et d’une durée suffisante, la structure isolante
14) Déclenchement des disjoncteurs/fusibles
est endommagée.
Le déclenchement des disjoncteurs ou des fusibles peut être
Lorsqu’un transformateur est équipé de disjoncteurs sous vide
provoqué par :
ou de disjoncteurs SF6, nous recommandons que l’ingénieur
de système étudie la possibilité de tensions transitoires de une surcharge;

commutation oscillantes et utilise des techniques d’atténuation des harmoniques de la tension ou du courant;

pour éviter d’endommager l’isolation du transformateur. un court-circuit;

une défaillance de l’isolation entraînant un courant

11) Mise à la terre du noyau
excessif;
Toutes les parties métalliques du transformateur qui ne sont
une tension trop élevée lors de la mise sous

pas sous tension doivent être mises à la terre, notamment
tension;
le noyau. Le noyau des transformateurs comportant des
un réglage trop faible pour permettre les courants

boulons d’assemblage est isolé depuis les fixations et mis à
élevés.
la terre à un seul endroit. Il est nécessaire d’isoler le noyau de
cette manière pour savoir si l’un des boulons d’assemblage 15) Échauffement excessif du câble
peut présenter un problème d’isolation qui entraînerait une Les causes en sont :
circulation élevée du courant ou un point chaud. Les boulons
des connexions mal vissées ou serties;

d’assemblage ne sont pas utilisés dans les transformateurs
des connecteurs desserrés;

de puissance modernes. Il est donc inutile d’isoler le noyau.
des fils de sortie ou bornes desserrés;

Aucune norme n’impose l’isolation des noyaux, y compris
des câbles ou bornes de la mauvaise taille;

les normes UL, ANSI, CSA, IEEE et IEC. Si les résultats de
une surcharge.

l’essai d’isolation sont médiocres, ou s’il existe une faible
résistance entre le noyau et le transformateur de puissance 16) Humidité
mis à la terre, il peut s’agir de ce qui suit : Si le transformateur a été exposé à l’humidité, comme la
condensation ou la pluie, ou entreposé dans un milieu très
 saleté, poussière ou humidité traversant l’isolation
humide, il doit être séché avant d’être mis sous tension.
entre le noyau et son châssis;
(Consultez la section Séchage, page 7.)
 isolation déplacée au cours de l’expédition ou de la
manipulation. Envoyez l’air chaud ou réchauffé, ou encore le chauffage
rayonnant ou interne à travers les enroulements. Poursuivez
Page 32
l’opération pendant 24 heures ou jusqu’à ce qu’il n’y ait plus

aucune trace d’humidité ou de condensation.
Il peut être difficile de sécher correctement des

transformateurs ayant été soumis à une inondation, de la
pluie directe ou des sprinkleurs. Consultez le fabricant pour
obtenir d’autres consignes.
Si l’une des situations ci-dessus se produit, le transformateur

doit immédiatement être mis hors service. Des mesures
correctives doivent être apportées en consultation avec les
représentants du fabricant ou le personnel qualifié.
Après évaluation, le transformateur sera remis sous tension

dès que la réparation aura été effectuée, ou il sera envoyé à
l’usine pour être évalué plus en détail ou remis en état.
GUÍA DE INSTALACIÓN, OPERACIÓN Y MANTENIMIENTO
PARA TRANSFORMADORES TIPO SECO PARA INTERIOR/EXTERIOR

QUE UTILICEN RECINTOS DE LAS SERIES NJ6, NJ7 O P.
*Nota: Esta guía es trilingüe N.º de folleto: IOMGPOW

(Inglés, francés, español)* Fecha de emisión: Enero 2011
Página 34
Precauciones de seguridad
(1) No levante ni traslade un transformador sin equipo apropiado ni personal experimentado.
Se incluyen puntos de levantamiento en el interior del gabinete sólo en el núcleo y
bobina. Siempre utilice todos los puntos de levantamiento proporcionados por el
fabricante. NO LEVANTE EL TRANSFORMADOR POR EL GABINETE.
Se recomienda rodar o deslizar los transformadores con base deslizante (pedida por
adelantado).
(2) No instale el transformador hasta que se haya realizado una inspección completa.
(3) Utilice únicamente los terminales para conexiones eléctricas. Se recomienda utilizar
conectores flexibles para las conexiones de las barras colectoras. Los terminales del
transformador no están diseñados para soportar el peso del cable de suministro o de
carga. Los soportes Uni-strut pueden ser instalados en el campo siempre y cuando se
mantengan los espacios adecuados.
(4) Las conexiones solo deben realizarse siguiendo el diagrama de la placa de identificación
o los diagramas de conexión.
(5) Asegúrese de que el suministro eléctrico esté completamente desconectado antes de

intentar hacer reparaciones en el transformador o en el interior de la caja de control y
conecte a tierra todos los bobinados.
(6) Asegúrese de que todas las conexiones a tierra, los terminales de línea y las derivaciones
se hayan instalado correctamente y que estén bien apretadas antes de energizar el
transformador.
(7) No intente cambiar una derivación, primaria o secundaria, mientras el transformador

está energizado.
(8) No cambie las conexiones cuando el transformador esté energizado.
(9) No altere los paneles de control, las alarmas, los engranajes ni los circuitos de
control.
(10) No ajuste ni retire accesorios ni cubiertas protectoras mientras el transformador esté

energizado.
(11) Ningún cable de suministro debe entrar en contacto con el núcleo ni con ninguna pieza
energizada excepto el terminal que le corresponde. Asegúrese de mantener los espacios
mínimos. (Consulte la sección 10 de las pruebas de campo)
Página 35
CONTENIDO
Alcance 36
Recibo e inspección 36
Procedimientos de elevación 37
Almacenamiento 39
Precauciones de instalación 39
Secado 40
Ubicación 41
Niveles de ruido 41
Conexión a tierra 42
Pruebas de campo 42
Mantenimiento 44
Limpieza 45
Servicio de campo 45
Página 36
ALCANCE De encontrar tal evidencia, deberá formalizar

inmediatamente un reclamo con la compañía de transporte
Esta guía cubre las recomendaciones para la aplicación, y notificar al fabricante.
instalación, operación y mantenimiento de transformadores
Los transformadores tipo seco con ventilación se envían
sencillos y trifásicos tipo seco y de reactores de núcleo
completamente ensamblados en un gabinete de metal o
de hierro con o sin gabinete. Enfatizamos que estas
como conjunto de núcleo y bobina con o sin gabinete. Todas
instrucciones abreviadas deben ser usadas conjuntamente
las piezas y componentes están envueltos en plástico
con todas las normas que rigen estas funciones y por
transparente y cubiertos con una lona de transporte. Un
consiguiente deben ser consultadas.
paquete separado (también incluido en el envío) contiene
Estas prácticas recomendadas son para aplicaciones ilustraciones que, de requerirlo, detallan el ensamblaje del
generales. Cualquier requerimiento especial debe ser transformador.
consultado con el fabricante del transformador y/o su
Una vez que haya recibido la unidad, retire las cubiertas
representante.
o paneles y proceda con la inspección interna en busca
Además, se recomienda que la instalación sea realizada de cualquier evidencia de piezas dañadas o movidas,
según la norma ANSI/IEEE C57.94. Estas son las prácticas conexiones flojas o interrumpidas, tableros de terminales
recomendadas por la IEEE para la instalación, aplicación, dañados, sucio o materias extrañas, y la presencia de
operación y mantenimiento de transformadores tipo seco cualquier cantidad de agua o humedad. Si observa
para uso general. cualquier daño, póngase en contacto inmediatamente con el
fabricante del transformador y/o con su representante.
RECIBO E INSPECCIÓN
Antes de descargar cualquier equipo, se debe inspeccionar

los transformadores para comprobar que la información
de envío sea correcta. Confirme que el número de
identificación que se encuentra en la placa de información
del transformador concuerde con la lista de empaque y con
el conocimiento de embarque.
Inspeccione inmediatamente los transformadores apenas

los reciba y tome nota de cualquier evidencia de daños o de
maltrato que puedan haber sido causados durante el envío.
La inspección debe ser realizada antes de retirar los

transformadores de los vehículos de transporte. Durante la
inspección, busque evidencia de la presencia de agua o de
cualquier otro contaminante que pudiera haber entrado en el
transformador durante el transporte.
GABINETE TIPO NJ
Página 37
RETIRE LA
PROCEDIMIENTOS DE ELEVACIÓN CUBIERTA
Se proporcionan puntos de levantamiento en todos los

transformadores tipo seco. Los puntos de levantamiento
pueden ser 2 o 4 armellas de anclaje de 5/8” (16 mm) o 3/4”
(19 mm) o un par de ángulos de elevación (vea la Fig. 1)
dependiendo del peso total del transformador. Las armellas
utilizadas son para las unidades de menos de 15.000 lbs
(6.804 kg) de peso. Los ángulos de elevación son para unidades
FIGURA 3
de 15.000 lbs (6.804 kg) de peso o más. Se recomienda utilizar
una eslinga para los ángulos de elevación. (3) Verifique la capacidad de levantamiento de las cadenas o
eslingas, de la grúa o de cualquier otro método que vaya
Procedimiento
a utilizar (consulte el peso del transformador en la placa
de información).
(4) Mida la distancia entre las armellas o los ángulos de
levantamiento (vea las figuras 4 y 5).
(5) Asegúrese de que el ángulo de la eslinga sea menos de
Armellas Ángulo de elevación
10 grados (vea la figura 6 y la tabla 1).
FIGURA 1
Antes de levantar una unidad, lea y comprenda las siguientes

instrucciones.
(1) Retire el techo del gabinete tipo NJ (vea la Fig. 2) o levante
la cubierta del techo del recinto eléctrico (vea la Fig. 3).
(2) Inspeccione las armellas o los ángulos de levantamiento
y asegúrese de que estén debidamente asentados y bien
apretados.
DISTANCIA
ENTRE
ARMELLAS
FIGURA 4
FIGURA 2
DISTANCIA ENTRE
ÁNGULOS DE ELEVACIÓN
FIGURA 5
Página 38
Cuando levante un transformador con eslinga de 4

patas, alinee las cuatro armellas al centro de la unidad
(vea la Fig. 5). Cuando levante una unidad con una
eslinga de 2 patas, asegúrese de que las armellas estén
en esquinas opuestas de la unidad y alineadas con el
centro de la misma (vea la Fig. 7).
LONGITUD DE
LA CADENA
ÁNGULO DE
ESLINGA
FIGURA 7
(7) Siempre utilice todas las armellas o agujeros de

levantamiento en ángulos durante el levantamiento para
evitar sobrecargar los pernos y la torsión de los marcos.
DISTANCIA ENTRE
ARMELLAS
FIGURA 6
TABLA 1
*Agujero de Longitud de la cadena (pies)
la armella
Centro 33’ 4’ 5’ 6’ 7’ 8’ 9’ 10’
10” 8° 6° 5° 4° 3° 3° 3° 2°
12” 10° 7° 6° 5° 4° 4° 3° 3°
14” - 8° 7° 6° 5° 4° 4° 3°
16” - 10° 8° 6° 5° 5° 4° 4°
18” - - 9° 7° 6° 5° 5° 4°
20” - - 10° 8° 7° 6° 5° 5°
FIGURA 8
22” - - - 9° 8° 7° 6° 5°
(8) Levante el transformador eléctrico por el núcleo y
24” - - - 10° 9° 8° 6° 6°
bobina sólo a través de la abertura en el techo del
26” - - - 10° 9° 8° 7° 6°
gabinete (vea la Fig. 8).
28” - - - - 10° 8° 7° 7°
30” - - - - 10° 9° 8° 7° No levante el transformador por el gabinete.
32” - - - - - 10° 9° 8° No levante el transformador eléctrico con ganchos de
34” - - - - - 10° 9° 8° envío.
36” - - - - - - 10° 9° No levante el transformador por debajo del gabinete.
*Nota: distancia entre los agujeros de las armellas del No lo levante bruscamente para evitar tensión mecánica.
marco delantero y trasero No empuje, arrastre o tire del transformador
(6) La dirección del punto de carga (línea de eslinga) debe directamente sobre el piso a menos que tenga una base
estar alineada con el plano de las armellas. deslizante.
Página 39
ALMACENAMIENTO almohadillas contra vibraciones debajo de la viga

base del transformador, asegúrese de levantar el
Las unidades deben ser almacenadas a temperaturas
transformador sólo por el núcleo y bobina. Si el gabinete
cálidas y en lugares secos y libres de polvo y otros
incluye y está fijado al núcleo y bobina a través de
contaminantes ambientales. La humedad relativa a la que
ángulos de envío, asegúrese de que los ganchos de
están expuestos los materiales de aislamiento eléctrico debe
transporte y los ángulos de envío sean retirados en
mantenerse lo más baja posible. Es preferible almacenarlo
todas las ubicaciones (vea las figuras 9 y 10) y luego
en un lugar seco y cálido para evitar problemas de
levante el transformador (sólo por el núcleo y bobina)
humedad, pero puede ser almacenado a temperaturas de
para instalar las almohadillas contra vibración
hasta 40°C (104°F). El transformador puede ser energizado
(o cualquier otro dispositivo de aislamiento de
con la temperatura de la bobina a un mínimo de -25°C
vibraciones según lo requiera el diseño).
(-13°F) pero se recomienda no aplicar carga hasta que
las bobinas alcancen una temperatura de 0°C (32°F). La
fluctuación de las temperaturas puede causar problemas
de condensación, los cuales podrían requerir la realización
de un procedimiento de secado. El piso sobre el cual
se almacene el transformador debe ser impermeable al
ascenso de vapor de agua. Proteja el equipo del agua de
cualquier origen (goteos del techo, tuberías de vapor o de GANCHOS DE
TRANSPORTE ÁNGULOS
agua rotas, ventanas, etc.). No se recomienda almacenar DE ENVÍO
ALMOHADILLAS ANTIVIBRACIÓN
(INCLUDIO CON EL TRANSFORMADOR)
unidades de tipo seco al aire libre. Si no se puede evitar,

FIGURA 9
proteja bien la unidad de la nieve, la lluvia y otros elementos.
La protección debe incluir una envoltura inicial de lona
de primera calidad y una cubierta exterior final de lona
de plástico. También se recomienda incluir un desecador
como el sistema de secado de gel de silicona para reducir
la humedad en el interior del gabinete. Si se almacena la
unidad al aire libre, se recomienda secarla como se describe
en la página siguiente.
ALMOHADILLAS
PRECAUCIONES DE INSTALACIÓN ANTIVIBRACIÓN
(EN SU UBICACIÓN FINAL)
(1) Se recomienda usar almohadillas o cualquier otro FIGURA 10

dispositivo de aislamiento de vibraciones durante
(2) El tipo de cable, su tamaño y su ubicación de entrada
la instalación del transformador tipo seco. Algunos
deben cumplir con el código local de electricidad.
transformadores de tipo seco pueden tener almohadillas
(3) Ni los terminales ni el tablero de terminales deben ser
u otros dispositivos para aislar las vibraciones. La
utilizados para soportar el peso de la fuente eléctrica o
mayoría del tiempo, las almohadillas contra vibraciones
de los cables.
vienen incluidas con los transformadores de tipo seco
y deben ser instaladas en el sitio. Cuando instale las (4) Mantenga el despeje adecuado entre los cables de
suministro y las piezas energizadas del transformador
según los voltajes del sistema. (Consulte la sección 10
de las pruebas de campo)
Página 40
(5) Se recomienda el uso de conectores flexibles para las (2) Dirija aire forzado externo caliente o calentado o calor
conexiones colectoras. radiante a través de los bobinados con todas las
aberturas de ventilación despejadas. La temperatura
recomendada no debe exceder los 105°C (221°F).
Siga con este procedimiento durante por lo menos
24 horas o hasta que todos los rastros de humedad o
condensación hayan desaparecido.
(3) Los calentadores eléctricos pueden ser instalados en
el interior del recinto, especialmente en las unidades
instaladas al aire libre. Estos calentadores deben ser
ubicados debajo de los bobinados a ambos lados del
núcleo. Si utiliza calentadores, asegúrese de permitir
la circulación del aire a través del gabinete. Puede
(6) Se recomienda que los cables de suministro entren a instalar temporalmente filtros de fibra de vidrio para
través de la parte inferior y/ lateral y que no bloqueen hornos de calefacción sobre las aberturas de admisión
las aberturas de ventilación. y escape de aire para minimizar la acumulación de
(7) Si debe taladrar, asegúrese de que el conjunto de polvo en el interior del gabinete. Estos filtros deben
núcleo y bobina esté protegido con una cubierta (por ser desinstalados antes de poner en servicio el
ejemplo, una lona) para que nada caiga sobre la bobina transformador. La temperatura recomendada no debe
o en su interior durante o después del taladrado ni exceder los 105°C (221°F).
después de remover la cubierta. (4) Para secar la unidad usando calefacción interna a
través del método del terminal en corto, póngase en
SECADO contacto con el fabricante del transformador para
obtener instrucciones específicas. Los principios en los
Si un transformador se ha expuesto a la humedad (por que se basa este método requieren que se realice un
ejemplo, por condensación o lluvia) o se ha almacenado corto en el circuito de baja tensión y se aplique corriente
en un ambiente altamente húmedo, se debe secar la al circuito de alta tensión a un máximo de un 100% de
unidad antes de la energización. En primer lugar, retire el la corriente nominal indicada en la placa de información.
transformador de servicio. Haga pruebas de megóhmetro a La temperatura del embobinado no debe exceder los
intervalos para indicar que está ocurriendo un cambio en el 105°C (221°F); consulte la sección 4 de las pruebas de
contenido de humedad del aislamiento. Luego proceda con campo.
cualquiera de los siguientes métodos de secado: Queremos enfatizar que esta operación sólo debe ser
(1) La humedad suelta debe ser soplada o limpiada de realizada por personal específicamente calificado para
cualquier superficie del transformador para reducir el tal fin.
tiempo de secado. Es posible que los transformadores que han sido expuestos
a inundaciones, lluvia directa o rociadores no puedan
secarse adecuadamente. Consulte al fabricante para
obtener instrucciones adicionales.
Página 41
UBICACIÓN Las corrientes de aire dirigido en la habitación cerca del

transformador pueden afectar el flujo natural del aire
Los transformadores ventilados tipo seco generalmente necesario para el enfriamiento del embobinado.
están diseñados para ser instalados bajo techo en
Se requiere ventilación adecuada para el enfriamiento
ubicaciones secas. Estos transformadores funcionarán
correcto de los transformadores. Es preferible la presencia
correctamente en ambientes de humedad alta. Sin embargo,
de aire limpio y seco. Si la ubicación tiene contaminantes
bajo estas condiciones es necesario tomar precauciones
aéreos en exceso, es posible que deba utilizar filtros
para mantenerlos secos si se desenergizan por un largo
opcionales. Si se instalan los transformadores en bóvedas
tiempo. Consulte las instrucciones de secado. Las unidades
o en otras ubicaciones con flujo de aire restringido,
tipo seco a las que se refiere esta pauta están diseñadas
proporcione ventilación suficiente para mantener las
para ser operadas a altitudes menores de 1.000 m
temperaturas del aire a niveles adecuados. Los límites
(3.300 pies) a menos que el transformador haya sido
de temperatura se especifican en las normas CSA o
diseñado específicamente para grandes alturas.
ANSI y se miden cerca de las aberturas de ventilación
Consideraciones ambientales: del transformador. El área requerida para las aberturas
Los transformadores ventilados tipo seco no deben ser de ventilación depende de la altura de la bóveda o sala
ubicados en ambientes con contaminantes tales como polvo, eléctrica y la ubicación de las aberturas de ventilación del
fertilizante, humedad excesiva, productos químicos, gases transformador. Para los transformadores autoenfriantes, el
corrosivos, aceite o gases químicos. Evite las ubicaciones área efectiva de ventilación debe ser por lo menos un pie
donde haya goteos de agua. Si no es posible evitar estos cuadrado para cada admisión y escape por cada 100kVA de
lugares, se debe proteger adecuadamente el transformador capacidad nominal del transformador después de deducir el
para evitar que entre agua en el gabinete. área ocupada por mallas, rejillas o persianas.
El transformador tipo seco no debe ser instalado en áreas Esto es necesario para proporcionar suficiente circulación
accesibles al público a menos que haya sido diseñado libre de aire alrededor y a través de cada unidad. Esto
específicamente para tal fin. también facilita el acceso al transformador para su
Los transformadores tipo seco pueden ser ubicados al aire mantenimiento.
libre, pero deben estar diseñados específicamente con Si se va a ubicar el transformador cerca de materiales
protección ambiental para exteriores. En estos casos, se combustibles, mantenga la distancia mínima establecida por
requiere el uso de gabinetes resistentes a la intemperie y el código local de electricidad.
que no puedan ser accedidos o modificados. Evite lugares
donde fluya agua, nieve, polvo y partículas de arena. NIVELES DE RUIDO
Consulte al fabricante del transformador para obtener
El ruido producido por los transformadores se debe a
información adicional.
la energización del núcleo por el voltaje alternado al
El transformador con base abierta no debe ser instalado
embobinado. Esto crea vibraciones cuya frecuencia
sobre superficies combustibles o por encima de ellas.
fundamental es el doble de la frecuencia de la tensión
Ventilación: aplicada. Las vibraciones que producen ruido pueden ocurrir
Los transformadores deben estar ubicados por lo en el núcleo, el soporte de instalación y el alojamiento. La
menos a 2 pies de distancia de paredes, obstrucciones, transmisión de ruido del transformador puede ocurrir a través
transformadores adyacentes o cualquier otra superficie de distintos medios como el aire, metal, concreto, madera
reflectora en el costado de ventilación a menos que o cualquier combinación de ellos. La amplificación del ruido
se indique lo contrario. Si hay otra fuente de calor, la puede ocurrir en un área específica debido a la presencia de
distancia debe ser mayor. superficies reflexivas u otras superficies de instalación.
Página 42
El nivel de ruido de los transformadores puede variar entre Si el nivel de ruido es un problema en la ubicación de
60 dBA para las unidades de 500 kVA y 76 dBA para las cualquier transformador, se debe prestar atención especial
unidades de 10.000 kVA, y más. al lugar donde se instale y al equipo de reducción de ruido
Estos niveles de ruido se determinan según las normas que se utilice. Para estos casos, se puede considerar
CSA y ANSI y se basan en lo siguiente: interrumpir el medio de transmisión de ruido con la
• Los niveles de ruido especificados son para instalación de espuma o fibra de vidrio aislante de ruido en
condiciones sin carga a niveles de voltaje y el techo o las paredes.
frecuencia nominales
• Las unidades se prueban en situaciones de entornos
CONEXIÓN A TIERRA
ruidosos
Todas las piezas de metal que no transmitan corriente en el
• Las paredes o superficies reflectoras están por
transformador deben ser conectadas a tierra. Esto incluye
lo menos a 10 pies de todos los costados del
el núcleo y el gabinete. La fabricación estándar establece la
transformador.
conexión a tierra del núcleo a través del contacto directo con
la estructura de sujeción. Los núcleos con pernos metálicos
Por lo tanto, tenga en cuenta que la operación de que los atraviesan están aislados de los sujetadores del
transformadores con carga presentarán niveles de ruido núcleo y conectados a tierra en un solo punto. El aislamiento
superiores a los mencionados en las normas. Además, del núcleo de esta manera es necesario (sólo en estos
los transformadores se instalan frecuentemente en salas transformadores) para determinar si existe una falla de
eléctricas generalmente confinadas, lo cual tendrá el aislamiento en cualquiera de los pernos pasantes que
efecto de un aparente aumento en el nivel de ruido. Los pueda causar una corriente circulante alta o un punto de
transformadores presentarán niveles de ruido más altos si concentración. Ninguna norma requiere el aislamiento de los
se instalan sobre pisos suspendidos que pueden resonar. núcleos (inclusive las normas IEC, IEEE, UL, ANSI y CSA).
Se considera ideal instalar los transformadores en la planta
baja o a nivel del sótano para evitar los pisos suspendidos y PRUEBAS DE CAMPO
alejados de espacios de oficina o residenciales. También se
recomienda usar amortiguadores de vibración o aislantes de Se recomienda que se realicen algunas inspecciones y
resorte para reducir los niveles de ruido. pruebas de campo por separado antes de poner en servicio
un transformador para determinar si está en condiciones
Se pueden instalar conectores flexibles entre las barras
satisfactorias de funcionamiento y para obtener datos
colectoras y otros equipos para evitar la transferencia de
para comparaciones futuras. Se recomienda realizar como
vibración. Asegúrese de que todos los pernos de fijación
mínimo las pruebas y procedimientos especificados en las
estén bien apretados y que el alojamiento del transformador
normas ANSI/IEEE.
esté firmemente ensamblado y separado del transformador
mismo. Donde se realicen pruebas de aceptación de tensión
inducida, tensión aplicada de baja frecuencia, resistencia
Los transformadores que se instalen cerca los unos de
del aislamiento o medición de megóhmetro, los voltajes de
los otros pueden presentar una frecuencia de resonancia
prueba no deberán exceder el 75% de los valores de prueba
entre ellos, lo que causa niveles de ruidos superiores a los
de fábrica.
normales.
Página 43
Cuando se realicen pruebas de campo con frecuencia, se de temperatura o le tablero de terminales. Para los
recomienda limitar los voltajes de prueba a un 65% de los embobinados de más de 30kV BIL, no coloque la
valores de prueba de fábrica. Desconecte los supresores sonda en el núcleo a menos que se le de la instrucción
de picos si vienen provistos. Enfatizamos que cualquier específica.
prueba que se realice debe ser llevada a cabo por personal
competente o calificado de acuerdo con las leyes y normas
de seguridad establecidas, en especial las normas NFPA
70E o CSA Z462.
1) Si el transformador ha estado apagado por un tiempo,
primero debe ser inspeccionado visualmente en busca
de evidencia de condensación, humedad o polvo y Termopozo tipo varilla Termopozo tipo tubo
luego ser secado como se describió anteriormente. (5) Verifique que todas las conexiones, incluyendo las
(2) Los ventiladores, motores, relés y otras piezas deben derivaciones, conexiones de fase y conexiones a tierra,
ser inspeccionadas para asegurarse de que funcionan estén apretadas y limpias.
correctamente. Los accesorios como los pararrayos
TORSIÓN (TORQUE) RECOMENDADO PARA LOS
deben ser instalados según la ilustración de ensamblaje
TORNILLOS PARA LAS CONEXIONES ELÉCTRICAS
provista.
TAMAÑO ACERO AL LATÓN ACERO
DEL CARBONO GRADO 5 INOXIDABLE
TORNILLOS GRADO 5 B8 O B8M
pies-lb [Nm] ±5% pies-lb [Nm] ±5% pies-lb [Nm] ±5%
1/4-20 UNC 8 [10,8] 5 [6,8] 5 [6,8]
3/8-16 UNC 30 [40,7] 15 [2,3] 20 [27,1]
1/2-13 UNC 75 [102] 35 [47,4] 50 [67,8]
(6) A cada unidad se le debe realizar una prueba de

3) Verifique la selección de derivaciones según la placa
resistencia de aislamiento. Esta prueba determina la
de información y mida las conexiones: todas las
integridad del aislamiento. La prueba de resistencia de
derivaciones deben estar en posición idéntica en
aislamiento es importante para comparaciones futuras
cada bobina (tenga en cuenta que puede haber más
y para determinar la aptitud del transformador para una
de un conjunto de derivaciones en la bobina). Las
prueba de alta tensión. Esta prueba debe ser realizada
derivaciones sólo pueden ser cambiadas cuando se
antes de la prueba de alta tensión.
desenergice la unidad.
Los factores variables que afectan la fabricación y el uso
(4) Algunas unidades incluyen equipo de temperatura
de los transformadores tipo seco dificulta establecer los
de embobinado. Estas unidades también incluyen
límites de la resistencia de aislamiento. La experiencia
un manual de instrucciones con ilustraciones. Estos
práctica hasta la fecha indica que 2 megohmios (lectura
dispositivos consisten de un indicador de temperatura y
de un minuto a aproximadamente 25°C) por cada
de una bombilla de sensor térmico. Asegúrese de que
1.000 voltios de tensión nominal indicada en la placa de
todas las piezas hayan sido ensambladas e instaladas
información, y en ningún caso menos de 2 megohmios
correctamente. Si no se instala esta bombilla de sensor
en total, pueden ser suficientes como valor de resistencia
en la cubierta aislada correcta, el transformador podría
de aislamiento. Prueba de resistencia de aislamiento por
sufrir daños graves. Mantenga el despeje eléctrico
megóhmetro (500 V o 1000 V CC).
si va a instalar sondas de medición desde el monitor
Página 44
Las pruebas deben ser realizadas entre: MANTENIMIENTO

Baja tensión a Alta tensión + Tierra
Alta tensión a Baja tensión + Tierra PRECAUCIÓN
Núcleo a tierra (si el núcleo está aislado) Se debe desenergizar el transformador antes
Nota: Si el núcleo del transformador está aislado, la de realizar cualquier mantenimiento. También
cinta del núcleo entre el núcleo y el sujetador superior se recomienda poner a tierra todos los
del núcleo debe ser desconectada antes de realizar la terminales.
medición de la conexión del núcleo a tierra.
(7) Polaridad o relación de fase. SI NO DESENERGIZA EL
(8) Mediciones de resistencia de bobinados.
TRANSFORMADOR ANTES DE
(9) Prueba de bobinado completo y para todas las
posiciones de derivación. ABRIR EL RECINTO PODRÍA
(10) Asegúrese de mantener los despejes mínimos para RESULTAR EN LESIONES
todas las piezas conductoras de electricidad, incluyendo
los embobinados, las conexiones internas de los cables, PERSONALES GRAVES O
los NGR, los CT, el transformador auxiliar y las barras
LA MUERTE
colectoras.
Puede utilizar la siguiente tabla como guía para conocer las Inspección y mantenimiento periódicos:
distancias mínimas para altitudes menores de 1.000 m Generalmente no se necesita mucho mantenimiento para
(3.300 pies). Para alturas superiores a los 1.000 m los transformadores tipo seco. Sin embargo, se requiere la
(3.300 pies), consulte con el fabricante. inspección y el cuidado periódicos para asegurar que los
transformadores funcionen correctamente a largo plazo. La
Transformador Distancia Distancia
frecuencia de la inspección dependerá de las condiciones
Tipo de tensión mínima (mm) mínima (pulg.)
en las que se instale el transformador.
1,2 KV 25 1 En ubicaciones secas y limpias, una inspección al año es
suficiente en términos generales. Para otras ubicaciones
2,5 KV 50 2
donde el aire esté contaminado con polvo o gases químicos,
5,0 KV 100 4 es posible que se requieran inspecciones cada tres o
seis meses.
8,7 KV 130 5,3
Con el transformador desenergizado, retire todos los
15 KV 200 8 paneles de acceso del gabinete y conecte los terminales
a tierra. Inspeccione la unidad en busca de polvo,
18 KV 250 10 especialmente en las superficies aislantes o cualquier
superficie que tienda a restringir la circulación del aire. Los
25 KV 300 12
aislantes, terminales y tableros de terminales deben ser
34,5 KV 400 16 inspeccionados en busca de descargas (marcas), daños,
grietas o quemaduras. También se debe inspeccionar que
Nota: "Algunos componentes del transformador pueden requerir el equipo y las conexiones estén firmes. Es necesario
distancias diferentes a indicadas indicados arriba. Para tales
excepciones, siga las instrucciones proporcionadas en las ilustraciones
limpiar estas piezas para evitar contorneamiento debido a la
de ensamblaje proporcionadas o el procedimiento de instalación." acumulación de contaminantes.
Página 45
Busque evidencia de oxidación, corrosión y deterioro de temperatura ambiente, lo que significa que si la temperatura
la pintura y tome las medidas necesarias para corregir la ambiente es de 40°C (104°F), la temperatura de la cubierta
situación. Los ventiladores, motores y otros dispositivos puede llegar a una temperatura continua máxima de 105°C
auxiliares también deben ser inspeccionados y reparados. (212°F) [120°C (248°F) en lugares poco accesibles]. En
estas condiciones, la temperatura del termómetro podría
LIMPIEZA estar al máximo de 220°C (428°F).
Cuando las temperaturas exceden este límite, el
Si observa acumulación excesiva de polvo en el
transformador se sobrecalienta y podrían ocurrir daños.
embobinado o aislantes del transformador, tal suciedad
Verifique las siguientes condiciones:
debe ser limpiada para permitir la circulación adecuada del
sobrecarga continua por largos períodos de tiempo

aire. Se debe prestar atención especial a la limpieza de los
extremos superior e inferior de los conjuntos de bobinado y  conexiones externas erradas
a la limpieza de los conductos de ventilación.  corriente o tensión de entrada excesiva
Puede limpiar el embobinado con una aspiradora, un  armónicos de corriente o tensión

ventilador o con aire comprimido. Se recomienda usar una  poca ventilación en la habitación o calor
aspiradora primero y luego usar aire comprimido. El aire proveniente de otras fuentes
comprimido debe estar limpio y seco y ser aplicado a presión  temperaturas ambiente altas [las normas permiten
relativamente baja (menos de 25 psi). Use un cepillo o paño un promedio de 30°C (86°F) y un máximo de 40°C
seco para limpiar los cables, el soporte de la bobina, los (104°F)]
soportes de los cables, los tableros de terminales, los forros
 conductos o aberturas de ventilación tapados
y otras superficies aislantes principales. No se recomienda
 acumulación de polvo y suciedad que restringe la
el uso de limpiadores líquidos ya que los solventes podrían
circulación del aire.
tener efectos adversos sobre los materiales aislantes.
(2) Ruido y vibración
SERVICIO DE CAMPO El nivel de ruido de los transformadores puede variar entre

60 dB(A) para las unidades de 500 kVA y 76 dB(A) para
Las siguientes instrucciones se proporcionan a modo de las unidades de 10000 kVA. Estos niveles de ruido se
guía de localización y solución de averías para ayudar determinan según las normas nacionales y se basan en lo
a determinar las medidas a tomar para reparar los siguiente:
transformadores eléctricos en servicio. Enfatizamos que los  os valores se basan en condiciones sin carga
transformadores instalados sólo deben ser inspeccionados
 as pruebas son realizadas en situaciones de ruido
por personal calificado. Se debe desenergizar el
ambiental bajo
transformador antes de realizar cualquier trabajo en él.
 las paredes o superficies reflectoras están por lo
También se recomienda poner a tierra todos los terminales.
menos a 10 pies (3 m) de todos los costados del
(1) Sobretensión
transformador.
Los transformadores con carga completa pueden parecer
calientes al tacto. Las normas permiten que la cubierta
del gabinete del transformador llegue a los 65°C (149°F)
[80°C (176°F) en lugares poco accesibles] por encima de la
Página 46
Los transformadores se instalan frecuentemente en salas (4) Tensión secundaria excesiva

eléctricas más confinadas, y, además, cuando están Puede ser causada por tensión de entrada más alta o una
conectados al suministro eléctrico, emiten niveles de ruido posición de derivación incorrecta.
más altos de lo normal. El exceso de ruido puede ser
(5) Humo proveniente del transformador
causado por:
El exceso de barniz, el barniz no curado o el material
 alta tensión de entrada de encapsulado que se quemen con el encendido
 frecuencia alta pueden producir humo. Esto generalmente no es causa
 cargas desbalanceadas de preocupación o de riesgos a largo plazo para el
corriente de carga excesiva
 transformador.
 armónicos de corriente y tensión provenientes de La presencia de humo o vapor durante el encendido inicial
cargas no lineales es común y es causado por el uso de aceites y lubricantes
 sujetadores de núcleo sueltos durante el proceso de fabricación. Este humo se considera
 piezas o alojamientos sueltos por el envío o irritante y debe ser ventilado temporalmente. No representa
transporte un riesgo a la salud a largo plazo.
no se retiraron las placas de envío

(6) Pérdida alta en el núcleo
no se instalaron las almohadillas contra vibraciones

Las causas son baja frecuencia y/o alta tensión de entrada.
 ubicación del transformador.
espacio en el núcleo

Los transformadores presentarán niveles de ruido más altos
(7) Aislamiento quemado o falla del aislamiento
si se instalan sobre pisos suspendidos que pueden resonar.
Con evidencia de aislamiento quemado, verifique lo
Se considera ideal instalar los transformadores en la planta
siguiente:
baja o a nivel del sótano para evitar los pisos suspendidos.
También se recomienda usar amortiguadores de vibración condición de sobrecarga continua

o aislantes de resorte para reducir los niveles de ruido. armónicos excesivos


Además, se pueden instalar conectores flexibles entre las sobrecalentamiento causado por la ventilación

barras colectoras y otros equipos para evitar la transferencia picos causados por rayos

de vibración. perturbación de la línea o de conmutación


pararrayos o cables dañados

Los transformadores que se instalen cerca los unos de
tableros o terminales dañados

los otros pueden presentar una frecuencia de resonancia
cortocircuito de las marchas o daños mecánicos

entre ellos, lo que causa niveles de ruidos superiores a los
contaminación (falla de aislamiento).

normales.
Si el núcleo del transformador muestra evidencia de
(3) Tensión reducida o nula
sobrecalentamiento y decoloración, el aislamiento cercano
Las posibles causas son conexiones flojas de terminales o
al núcleo también parecerá descolorido. Las temperaturas
tableros, cables dañados o cortocircuitos de las marchas.
excesivamente altas en el núcleo son causadas por:
También, la tensión de salida reducida puede ser causada
por una posición de derivación seleccionada de manera  alta tensión de entrada
incorrecta.  frecuencia baja o saturación del núcleo por

armónicos de tensión.
Página 47
tiene un componente de frecuencia cercana a una de las

(8) Ferrorresonancia
frecuencias naturales del transformador y tiene la duración
La sobretensión severa puede ocurrir en los
suficiente, la estructura del aislamiento del transformador
transformadores por el fenómeno de la ferrorresonancia.
sufrirá daños internos.
La ferrorresonancia es causada por el uso en conjunto de
Cuando se usa un transformador con disyuntores de
conmutación monopolar con primarios sin conexión a tierra y
vacío o SF6, recomendamos que el ingeniero del sistema
el recebado de la conmutación de condensadores.
revise las posibilidades de tensión transitoria oscilante de
Los voltajes oscilantes generados exceden en gran medida
conmutación y que utilice métodos mitigantes adecuados
la capacidad inherente del transformador de soportar la
para evitar daños al aislamiento del transformador.
sobretensión. Los transformadores están diseñados para
operar a 6% de sobretensión al nivel de carga nominal y a (11) Puesta a tierra del núcleo
10% de subtensión. Todas las piezas de metal que no transmitan corriente en el
Para reducir riesgos y ayudar a proteger el transformador, transformador deben ser conectadas a tierra. Esto incluye el
tenga en cuenta que los transformadores que operan a núcleo. Los núcleos de transformador con tornillos que los
60 kV BIL o más tienen pararrayos de óxido metálico atraviesan deben ser aislados de los sujetadores del núcleo
instalados en el punto de entrada al transformador en y ser puestos a tierra en un solo punto. El aislamiento del
todas las fases. Esto aplica a los bobinados primarios o núcleo de esta manera es necesario para determinar si
secundarios si alguno de ellos funciona nominalmente a existe una falla de aislamiento en cualquiera de los tornillos
60 kV BIL. La ferrorresonancia puede causar daños severos pasantes que pueda causar una corriente circulante alta
a los equipos eléctricos, especialmente los transformadores, o un punto de concentración. Los tornillos pasantes no
y se recomienda protegerlos. se usan en la fabricación de transformadores eléctricos
(9) Corriente magnetizante alta modernos, en cuyo caso el aislamiento del núcleo no es
Puede ser causada por: necesario. Ninguna norma requiere el aislamiento de los
núcleos (inclusive las normas IEC, IEEE, UL, ANSI y CSA).
 alta tensión de entrada
Si la lectura del megóhmetro es baja, o hay una resistencia
 frecuencia baja
baja entre el núcleo y la conexión a tierra del transformador
 cortocircuito en las vueltas
eléctrico, las causas pueden incluir:
 espacio en el núcleo debido al desplazamiento
ocasionado durante el envío.  polvo, suciedad o humedad que hacen puente a
través del aislamiento entre el núcleo y el marco
(10) Tensión transitoria oscilante de conmutación
del núcleo
Ocasionalmente, cuando se introduce o retira un
 aislamiento desplazado durante el envío o
transformador del sistema, una tensión transitoria de
transporte.
recuperación con un componente grande de tensión de
frecuencia alta afectará a los terminales del transformador.
Enfatizamos que las lecturas bajas del megóhmetro
Esto ocurre con mayor frecuencia cuando se utiliza un
(indicativas de niveles bajos de aislamiento entre el núcleo
disyuntor de vacío, y es resultado directo de la capacidad de
y tierra) no son causa de preocupación a menos que sean
tal disyuntor de cortar la corriente. Estos cortes de corriente
tornillos pasantes. El núcleo está diseñado para estar
y sus reencendidos correspondientes producen una tensión
conectado a tierra de cualquier manera.
transitoria oscilante de alta tensión y larga duración en los
terminales del transformador. Cuando esta tensión aplicada
Página 48
(12) Distorsión de la bobina con el representante del fabricante o con personal calificado
Las bobinas con cortocircuito muestran distorsión severa para tal fin.
comparada con su apariencia normal redonda o simétrica. Después de terminar la evaluación, el transformador puede
(13) Pérdida alta de conductor ser reenergizado al terminar la reparación adecuada, o la
La sobrecarga o los tableros de terminales que no estén unidad deberá ser llevada a la fábrica para evaluación o
en posiciones de derivación idénticas pueden causar el reparaciones adicionales.
sobrecalentamiento del conductor.
(14) Disyuntores o fusibles abiertos

Las causas de que los disyuntores y fusibles estén abiertos
pueden ser:
 condiciones de sobrecarga
 armónicos de corriente o tensión
 cortocircuito
 falla de aislamiento que cause corriente excesiva
 tensión demasiado alta cuando se energiza
 ajuste demasiado bajo como para permitir la
entrada de corriente.
(15) Sobrecalentamiento de los cables

Las causas incluyen:
 conexiones fijadas incorrectamente o prensadas

 conectores sueltos
 cables o terminales sueltos
 cables o terminales de calibre incorrecto
 condición de sobrecarga.
(16) Humedad
Si el transformador se ha expuesto a la humedad (como la
proveniente de la condensación o de la lluvia), la unidad
debe ser secada antes de ser energizada. (Consulte la
sección sobre secado en la página 7)
Para tal fin, se debe dirigir aire caliente o calentado, calor
radiante o calor interno a través de los bobinados. Este
procedimiento debe realizarse durante 24 horas o hasta que
todos los rastros de condensación hayan desaparecido.
Es posible que los transformadores que han sido expuestos

a inundaciones, lluvia directa o rociadores no puedan
secarse adecuadamente. Consulte al fabricante para
obtener instrucciones adicionales.
Si nota cualquiera de las condiciones descritas
anteriormente, retire inmediatamente el transformador de
servicio. Tome medidas correctivas diseñadas en consulta
NOV PART NO.:
LB0036
NOV PART NO.:
LB0036-MAN
SAFETY
and
INSTRUCTION
MANUAL
for
Dynamic Braking Resistor
Drawing Number: LB0036
Customer: National Oilwell Varco
Telema & Berger Resistors, Inc. 1002 Ford Circle, Milford, OH 45150
ph: 513.831.7300 fax: 513.831.3444 email: inquiries@tbresistors.com
Index
Section 1 - COMPLIANCE
 1.1 Compliance with Manual Instructions
 1.2 Compliance with Installation Procedures
 1.3 Relevant Design Standards
Section 2 – SHIPPING AND RECEIVING
 2.1 Shipping
 2.2 Receiving
 2.3 Storage
Section 3 – GENERAL DESCRIPTION
 3.1 Enclosure
 3.2 Grid Type Resistor Banks
 3.3 Incoming Cable Connections
 3.4 Outgoing Cable Connections
 3.5 General Description Drawing
Section 4 – INSTALLATION AND SITE REQUIREMENTS
 4.1 Access Clearances
 4.2 Ventilation Clearances
 4.3 Enclosure Operational Temperatures
 4.4 Mounting Surface
 4.5 Assembly
 4.6 Tool and Equipment Requirements
 4.7 Installation Procedure
Section 5.0 - COMMISSIONING
 5.1 Resistance Test
 5.2 Insulation Test
Section 6.0 – OPERATIONAL PROCEDURES
 6.1 Personnel Safety
 6.2 Required Skills
Section 7.0 – MAINTENANCE PROCEDURES
 7.1 Equipment Isolation
 7.2 Routine Maintenance
 7.3 Standard Procedures
Section 8.0 – REPLACEMENT PARTS
 8.1 Parts List
1.0 COMPLIANCE
1.1 Compliance with Manual Instructions
It is essential that the Purchaser/User comply with all

instructions and information contained in this manual, and that
all personnel associated with the apparatus supplied under this
contract are thoroughly familiar with the information contained
herein.
1.2 Compliance with Installation Procedures
It is the Purchaser/User’s responsibility to ensure that the

apparatus supplied under this contract is correctly installed in a
suitable location by technically qualified and competent persons.
Apparatus supplied as loose components, devices or sub-

assemblies may, when energized, constitute a safety hazard.
The Purchaser/User must ensure that such apparatus is
installed in a secure location, and that all necessary safety
information about the installation is provided to all personnel
associated with it.
1.3 Relevant Design Standards
Resistors: IEEE32-1972
Enclosure: IEEE32-1972, N.E.M.A.
Enclosure Finish: A.N.S.I.
2.0 SHIPPING AND RECEIVING
2.1 Shipping
The unit is shipped in ready-to-use state except for the cable

entrance bushing (if applicable), which is packed inside the
enclosure to prevent breakage during shipment.
2.2 RECEIVING
Once received, the unit should be unloaded and moved by forklift or

crane. Top-mounted eyebolts are provided for easy handling by
crane.
IMPORTANT NOTES
1.) The unit must not be lifted by placing forks under the unit!
Lifting the unit from underneath with a fork lift will damage or
destroy it, and will void the warranty. If the unit is to be moved
with a forklift, use chains or cables through the lifting
eyebolts.
2.) Do not remove the temporary wooden shipping braces prior

to setting the unit at the permanent installation location.
At this time a preliminary inspection of the unit should be made to

assure it was properly handled during shipment. For more on
inspection procedures, see “Site Installation.”
2.3 STORAGE
While the D.B.R. is designed for indoor and outdoor use, if it is to

be stored for any length of time prior to installation, it should be
covered to protect it against moisture and the accumulation of dust
and dirt. The unit should be stored in a dry, enclosed area, or
covered with a waterproof cover. ALWAYS BE SURE THE UNIT IS
DRY AND CLEAN BEFORE USE.
3.0 GENERAL DESCRIPTION
3.1 Enclosure
Standard enclosures will have a vented bottom and pitched top with
four (4) eye bolts. The sides are solid and not removable. Front and
back covers are removable for installation.
3.2 Grid Type Resistor Banks
Each resistor bank is built up from a number of individual,

replaceable grids arranged in banks to meet your specification.
T&B resistor grids are manufactured from stainless steel alloy plate
stamped into suitable resistor grids and fitted with reinforcing
capsules. The grids are mounted on ceramic insulators, which are
supported by stainless steel center rods. Each grid has stainless
steel terminals at each end. The grid design and mounting
arrangement allows for free expansion and contraction of the
resistor elements without imposing strain on the grids or terminals.
The grids are assembled into banks suitable for high-temperature
service.
3.3 Incoming Cable Connections
A bottom-mounted bushing, or side/top mounted ceramic bushing

of suitable voltage and current rating is provided and terminated
with a NEMA, 2-hole connector.
3.4 Outgoing Cable Connections
A bottom-mounted bushing, or side/top mounted ceramic bushing

of suitable voltage and current rating is provided and terminated
with a NEMA, 2-hole connector.
4.0 INSTALLATION and SITE REQUIREMENTS
4.1 Access Clearances
At least 36 inches is required around all removable covers for

access. This may be subject to local or site regulations requiring
greater clearances.
4.2 Ventilation Clearances
A free-air flow environment is required around the resistor

enclosure with a recommended minimum of approximately 10
inches.
4.3 Enclosure Operational Temperatures
During normal service, either due to steady state current flow (if
specified), or a fault condition, both the issuing air temperature and
the enclosure surface temperature may exceed 100º C.
Important Note
Equipment or combustible materials must not lie on the top cover of
the enclosure or be in contact with the sides.
4.4 Mounting surface
A flat foundation or other suitable square and plumb mounting

arrangement is required.
4.5 Assembly
The Dynamic Braking Resistor is supplied assembled and ready to

be connected.
4.6 Tools and equipment
Ordinary hand tools are all that are needed for assembly. No
special tools are required. Lifting equipment must be capable of
keeping the unit in an upright position while in motion.
4.7 Installation procedure
1. Place the Dynamic Braking Resistor on the prepared base.

2. Remove front covers.
3. Remove all internal packaging/bracing material.
4. Check the integrity of resistors and insulators.
5. Examine for signs of damage during transit.
6. Secure the Dynamic Braking Resistor onto its base.
7. Connect power to fan.
8. Connect control wires to temperature and pressure switches.
9. Connect the power cable to resistor bus bar.
10. Make sure all connections are tight.
11. Reinstall the enclosure covers.
12. Be sure all enclosure hardware is correctly installed and
tightened.
5.0 COMMISSIONING
5.1 Resistance test
Check for proper fan rotation. Air should be entering the bottom of
the unit and exiting the top. Check the resistance value, using a
Kelvin double bridge or a digital low-resistance ohmmeter. It must
be the value stamped on the nameplate +10%.
5.2 Insulation test
Check the insulation resistance between the resistor elements and

the enclosure, using a 1000 Vdc megger. It should be greater than
100MΩ.
Alternatively: Perform an AC high-potential test. Maximum applied

voltage = (2.25 x phase voltage) + 2000V at 60 Hz.
6.0 OPERATION PROCEDURES
6.1 Personnel Safety
The rules in the section must be followed to ensure the safety of

personnel associated with this apparatus.
1.) During Normal Use, ensure that the plant operators:
a.) Are fully familiar with all controls, particularly those for
emergency shutdown.
b.) Comply with all safety warning notices and keep all
enclosure covers on during operation.
c.) Are trained to recognize signs of faulty operation, and know
what action to take in the event of trouble.
2.) During Maintenance and Testing, ensure the following:
a.) Only technically competent and authorized persons are

permitted to carry out work.
b.) Personnel comply with all statutory requirements.
c.) Personnel are thoroughly familiar with the unit and the
system of which it is a part, and can recognize any potential
safety hazards.
d.) Unit is isolated completely before opening enclosures and
make absolutely certain it is dead before starting work. All
possible precautions, e.g., lockouts, must be taken to ensure
that the isolated apparatus cannot become live at any time while
it is being worked on.
e.) All service personnel comply with all safety procedures for
the protection of themselves and of others, including the use of
temporary barriers and warning notices.
f.) Personnel are completely familiar with all pertinent
information provided, particularly on safety matters.
g.) Personnel understand the hazards inherent in working on
live electrical apparatus and take all necessary precautions.
h.) Personnel considers that the unit may have been modified
without proper reference to the manufacturer and take extreme
caution at all times before, during and after any work is carried
out.
j.) Always thoroughly check and test the unit in accordance
with this manual and good working practice before putting the
unit back in service.
6.2 Skills Required for Specific Tasks
To ensure that the unit is safe for use in normal plant operation it
has been designed and tested in accordance with relevant U.S.
and International Standards. Information is provided in this manual
regarding the conditions necessary for safety against hazards
reasonably foreseeable during normal use and the precautions
taken to counteract them.
It is the Purchaser/User’s responsibility to ensure that the unit is

maintained in a safe condition by technically competent and
authorized personnel only who act in compliance with all
appropriate safety procedures.
7.0 MAINTENANCE
7.1 Equipment Isolation
The equipment must be completely isolated from all power before

performing any maintenance.
7.2 Routine maintenance
Very little maintenance is required on this equipment, but routine

inspections should be carried out at regular periods to ensure that
the equipment is kept in a good and reliable condition. The
frequency of the inspection depends upon site conditions i.e.
atmospheric pollution, safe access to the equipment, etc. but
initially could be done every 6 months.
7.3 Standard Procedure
1. Access the resistor units by removing either the front or back

cover and lifting the cover away.
2. Remove all dirt from cable terminals and insulators and confirm
all connections are tight.
3. Test the resistance value of the unit to confirm still correct.
4. Inspect the enclosure for damage or excessive corrosion and
repair as needed.
5. Test fan rotation to confirm still functioning properly.
6. After inspection, be sure all covers are securely fastened.
8.0 REPLACEMENT PARTS
8.1 Should it be necessary to replace any part of this equipment, the

customer should contact the manufacturer. Refer to the drawing
number of the equipment (on the nameplate) and give the part
number and a description of the part required.
QANTITY PART NUMBER DESCRIPTION
2 LB0036-02-E End Resistor Bank

4 LB0036-02-M Middle Resistor Banks
1 TS017302-000 Thermal Switch
1 PS1823-00 Pressure Switch
1 LB0036-01-X* Blower
1 BJ0086 Bus Jumper
*Determined by complete part number.

NOV PART NO.:
OSH-FDD759
NOV PART NO.:
RDCU
ABB Drives
Hardware Manual
RDCU Drive Control Units
3
RDCU Drive Control Unit Hardware Manual
RDCU layout
Designations A…C and J1 refer to the section Mechanical installation below. The
connectors (X…) are explained under Technical data further below.
A B A
X39
C
X20
X34
X21 X31
J1
X32
X22
X23 X33
C
X25
X26
X68
X27 X57
A B A

4
Safety instructions
Do not attempt any work on a powered drive. After switching off the mains, always
allow the intermediate circuit capacitors 5 minutes to discharge before working on
the frequency converter, the motor or the motor cable. It is good practice to check
(with a voltage indicating instrument) that the drive is in fact discharged before
beginning work.
Avoid touching the circuit board (RMIO) inside the RDCU unit in order to minimise
the risk of damage caused by static electricity.
Do not use excessive force when detaching connectors or removing the cover of the
unit.
Identifying different types of unit

Before installation, check that the RDCU unit has the correct application program for
the converter hardware in question. There is a label attached to the cover of the
RDCU unit that lists “SW TYPE”, “SW CODE” and “DEVICE TYPE”.
“SW TYPE” identifies the application program that is loaded into the RDCU unit.
Some of the most common “SW TYPE” codes are AMXRxxxx (ACS800 System
Application Program), ASxRxxxx (ACS800 Standard Application Program),
AHxRxxxx (ACS800 Pump Control Application Program), and IxxRxxxx (IGBT
Supply Unit Application Program). Check that the application program corresponds
to the original order.
Check also that the “DEVICE TYPE” indicated matches that of the converter
hardware.
General
The RDCU unit can be mounted on a vertical or horizontal 35 × 7.5 mm DIN rail.
The unit should be mounted so that air can freely pass through the ventilation holes
in the housing. Mounting directly above heat-generating equipment should be
avoided.
WARNING! Avoid installing the RDCU in the immediate vicinity of sources of

electromagnetic disturbance, such as relays, contactors, brake choppers and motor
cabling. The minimum recommended distance from such components is 500 mm.
Installing metallic screening between the unit and the source of disturbance is highly
recommended, and may reduce the required distance.
The RDCU is grounded to the mounting rail by two screws.
Fastening the unit to the mounting rail

Note: Set jumper J1 (if necessary; see the Isolation and grounding diagram) before
fastening the unit.

5
Setting J1 can be further facilitated by removing the cover (see Removal and
replacement of cover below for further instructions). The jumper can also be set
using long-nosed pliers or tweezers without removing the cover.
• Align the four retaining clips (A) at the top and bottom edges of the cover with the
mounting rail, and carefully press the module onto the rail until the clips catch on
the edges of the rail.
• Using two screws, fasten the base plate of the RDCU by the two mounting holes
(B) to the mounting rail. Make sure the contact surfaces are free from dirt or
grease. This is essential for the operation of the control unit since the screws
provide the grounding for the unit.
Removal of unit from mounting rail

• Remove the two screws (B) holding the base plate of the unit to the mounting rail.
Carefully bend the retaining clips (A) at the upper and lower edges of the cover
outwards to release the unit completely from the mounting rail.
Removal and replacement of cover

• Remove all detachable (screw-type) terminal plugs from the RDCU, and
disconnect any cables connected to the unit. Remove any optional modules.
If desired, the unit can be removed from the mounting rail as described above to
facilitate the following steps.
• With a screwdriver or similar tool, carefully release the four cover retaining clips
(C) on the right-hand side while simultaneously pulling the right-hand edge of the
cover gently away from the base plate.
• Shift the cover to the left to free its left-hand edge, then pull it to detach it
completely from the base and circuit board.
• Replace the cover in reverse order to the above (left-hand edge first). If the unit is
already mounted onto its mounting rail, align the retaining clips (A) so that they
catch on the mounting rail.

6
Wiring
General
The shields of the I/O cables should be grounded to the chassis of the cubicle as
close to the RDCU as possible.
Use grommets at all cable entries.
Handle fibre optic cables with care. When unplugging fibre optic cables, always grab
the connector, not the cable itself. Do not touch the ends of the fibres with bare
hands as the fibre is extremely sensitive to dirt.
The maximum long-term tensile load for the fibre optic cables included is 1 N; the
minimum short-term bend radius is 25 mm (1”).
Digital/Analogue input/output connections

See the Firmware Manual of the application program in question.
Installation of optional modules

Follow the instructions given in the user manual of the module.
Other connections
See also the wiring diagram below.
Powering the RDCU
The RDCU is powered through connector X34. The unit can be powered from the
power supply board of the inverter (or IGBT supply) module, provided that the
maximum current of 1 A is not exceeded.
The RDCU can also be powered from an external 24 V DC supply. Note also that the
current consumption of the RDCU is dependent on the optional modules attached.
(For current consumption of optional modules, see their respective user manuals.)
Fibre optic connection to inverter/IGBT supply module
Connect the PPCS link of the AINT (ACS 800 series modules) board of the inverter
(or IGBT supply) module to fibre optic connectors V57 and V68 of the RDCU.
Note: The recommended maximum distances for the fibre optic link is 10 m (for
plastic [POF] cable). In case longer distances are required, contact an ABB
representative.

7
Connection of control panel (CDP 312R)

Connect the control panel to X39.
RDCU Control Unit

RMIO
X39
V68 V57 X34

RXD TXD + –
I 0
CDP 312R
control panel
9 10 X17 (liquid-cooled
drives only)
V1 V2 1 2
R7i/R8i: APOW/X3
AINT 1 A max.
(ACS800 Series)
IGBT Supply or Inverter Module

8
Technical data
General
Mounting: Onto 35 × 7.5 mm DIN mounting rail
Housing materials: Zinc-plated steel (base); ABS/PC (cover)
Connector types
X20 (Constant voltage output): 2-pole detachable screw terminal block*
X21 (Analogue I/O): Four 3-pole detachable screw-type terminal blocks*
X22 (Digital inputs): One 3-pole and two 4-pole detachable screw-type terminal
blocks*
X23 (24 VDC output): 2-pole detachable screw-type terminal block*
X25-X27 (Relay outputs): Three 3-pole detachable screw-type terminal blocks*
X31 (Slot 1), X32 (Slot 2): 38-pin header (female), pitch 2 mm
X33 (DDCS): 20-pin header (female), pitch 2.54 mm
X34 (24 VDC power input): 3-pole detachable screw-type terminal block*
X39 (Control panel): 12-pin header (male), pitch 2.54 mm
V57, V68 (PPCS link): Fibre optic transmitter/receiver (10 MBd)
*Wire: 0.3 … 3.3 mm2 (22…12 AWG). Torque: 0.2 … 0.4 Nm (2…4 lbf.in.).
Pitch: 5.0 mm.
Constant voltage output (X20, X21:1)

Voltage: +10 VDC, 0, -10 VDC ±0.5% (Full scale range) at 25 °C (77 °F).
Temperature coefficient: ±100 ppm/°C (±56 ppm/°F) max.
Maximum load: 10 mA
Applicable potentiometer: 1 to 10 kohm
Analogue inputs (X21)

General: Two programmable differential current inputs (0 mA / 4 mA … 20 mA,
Rin = 100 ohm) and one programmable differential voltage input (-10 V / 0 V /
2 V … +10 V, Rin = 200 kohm). The analogue inputs are galvanically isolated as a
group (see Isolation and grounding below)
Isolation test voltage: 500 VAC, 1 min
Max. common mode voltage between the channels: ±15 VDC
Common mode rejection ratio: > 60 dB at 50 Hz
Resolution: 0.025% (12 bit) for the -10 V … +10 V input, 0.5% (11 bit) for the
0 … +10 V and 0…20 mA inputs
Inaccuracy: ±0.5% (Full scale range) at 25 °C. Temperature coefficient: ±100 ppm/
°C max.

9
Analogue outputs (X21)

General: Two programmable current outputs: 0 (4) … 20 mA, RL < 700 ohm
Resolution: 0.1% (10 bit)
Inaccuracy: ±1% (Full scale range) at 25 °C (77 °F). Temperature coefficient:
±200 ppm/°C (±111 ppm/°F) max.
Digital inputs (X22)

General: Six programmable digital inputs (common ground: 24 VDC,
-15% … +20%) and a start interlock input (DIIL). Group isolated, can be divided into
two isolated groups (see Isolation and grounding below).
Thermistor input: 5 mA, < 1.5 kohm “1” (normal temperature), > 4 kohm “0”
(high temperature), open circuit “0” (high temperature).
Internal supply for digital inputs (+24 VDC) is short-circuit proof. An external 24 VDC
supply can be used instead of the internal supply.
Isolation test voltage: 500 VAC, 1 min
Logical thresholds: < 8 VDC “0”, > 12 VDC “1”
Input current: DI1 to DI5: 10 mA; DI6: 5 mA
Filtering time constant: 1 ms
24 VDC power output (X23)

Voltage: 24 VDC ±10%, short-circuit proof
Maximum output current: 250 mA (without any optional modules inserted)
Relay outputs (X25, X26, X27)

General: Three programmable relay outputs
Switching capacity: 8 A at 24 VDC or 250 VAC; 0.4 A at 120 VDC
Minimum continuous current: 5 mA rms at 24 VDC
Maximum continuous current: 2 A rms
Isolation test voltage: 4 kVAC, 1 min
Slot 1 (X31)
General: For connection of I/O extension modules (such as RAIO and RDIO), pulse
encoder interface (RTAC), or fieldbus adapters (such as RPBA and RMBA)
Slot 2 (X32)
General: For connection of I/O extension modules (such as RAIO and RDIO) or
pulse encoder interface (RTAC)
DDCS (X33)
General: For connection of RDCO-0x(C) DDCS Communication module

10
24 VDC power input (X34)

Voltage: 24 VDC ±10%
Typical current consumption (without option modules): 250 mA
Maximum current consumption: 1200 mA (with option modules inserted)
Pin designations: 1 = not used; 2 = +24 V; 3 = 0 V
Control panel connection (X39)

General: For connection of CDP-312R control panel
PPCS link (V57, V68)

General: Optical fibre connection to inverter (or IGBT supply) module
Optical component type: 10 MBd
Protocol: ABB PPCS (Power Plate Communication System)
Jumper J1
General: See Isolation and grounding below
Pitch: 2.54 mm
LEDs
“Power”: Green; denotes +5 V power OK
“Fault”: Red
Ambient conditions
Operating temperature: +0 … +60 °C (32…140 °F)
Storage temperature: -40 … +70 °C (-40 … +158 °F)
Applicable standards
Immunity: IEC 61800-3 (Limits: Industrial, Second environment); EN 50081-2
(Limits: Industrial)
Emission: EN 50081-2 (Limits: Industrial)
PELV requirements: The terminals of the RMIO board as well as on the optional
modules attachable to the board fulfil the Protective Extra Low Voltage (PELV)
requirements stated in EN 50178 provided that the external circuits connected to the
terminals also fulfil the requirements.

11
Isolation and grounding
(Test voltage: 500 V AC)

X20
1 VREF
2 GND
X21
1 VREF
2 GND
3 AI1+
4 AI1- Common mode
voltage between
5 AI2+
channels ±15 V
6 AI2-
7 AI3+
8 AI3-
9 AO1+
10 AO1-
11 AO2+
12 AO2-
X22
1 DI1
2 DI2
3 DI3
4 DI4
Jumper J1 settings:
9 DGND
5 DI5 All digital inputs share a common

J1
6 DI6 ground. This is the default setting.
7 +24V
8 +24V Grounds of input groups
11 DIIL DI1…DI4 and DI5/DI6/DIIL
or
are separate (isolation
10 DGND voltage 50 V).
X23
1 +24 V
2 GND
X25
1 RO1
2 RO1
3 RO1
X26
1 RO2
2 RO2
3 RO2
X27
1 RO3
2 RO3
3 RO3
(Test voltage:
4 kV AC)
Ground

12
Dimensions

3AFE 64636324 REV C / EN
ABB Oy ABB Inc.

AC Drives Drives & Power Products
FIN-00381 HELSINKI New Berlin, WI 53151
FINLAND USA
Telephone: +358 10 22 11 Telephone: 262 785-3200
Fax: +358 10 22 22681 800 243-4384
Internet: http://www.abb.com Fax: 262 780-5135
FINAL DOCUMENTATION
Section 2.3
System Diagram & Specifications
www.nov.com
CHAPTER 2 INDEX 2.3

8434 SYSTEM DIAGRAM & SPECIFICATIONS
DOCUMENT NUMBER REV
10707935-IDX 01
www.nov.com
Revision 01
Page 2
2.3 ELECTRICAL SINGLE LINE DIAGRAM
8434-480VAC MCC ONE-LINE 10620273-DIA 01 C04
8434-VFD/GEN ONE-LINE 10620338-DIA 02 C04
www.nov.com
FINAL DOCUMENTATION
Section 2.4
Electrical/ Instrument
www.nov.com
CHAPTER 2 INDEX 2.4

8434 ELECTRICAL/ INSTRUMENT
DOCUMENT NUMBER REV
10707937-IDX 01
www.nov.com
Revision 01
Page 2
2.4 ELECTRICAL INTERNAL WIRING DIAGRAM
60A-BOP CUSTOMER SUPPLY PWR BOX 10551812-DIA 01 E03
8434-VFD CUB INTERCONNECT SCH 10620268-SCH 02 E03
8434-480VAC MCC FVNR STARTER 10620273-SCH 01 E03
8434-MCC I/O AUXILIARY CONTROL 10620305-SCH 01 E03
IDEAL RIG-TDS-11 AUX COMPONENTS 10620312-SCH 01 E03
8434-AC PLUG PANEL INTERCONNECT 10620313-SCH 01 E03
8434-GEN FIELD INTERCONNECT 10620318-DIA 01 E03
8434-(4) GENERATOR PLUG PANEL 10620318-SCH 01 E03
8434-208/120 LIGHTING PANEL 10620333-SCH 01 E03
8434 INC/RECT 1,600/690V,2500ADC 10622061-SCH 01 E03
8434 INC/RECT 2,600/690V,2500ADC 10622062-SCH 01 E03
8434 (2)INV 1 TD/RT,900KW/953AAC 10622066-SCH 02 E03
8434 (3)INV 2 DWA,1400KW/1414AAC 10622068-SCH 01 E03
8434 (3)INV 3 DWB,1400KW/1414AAC 10622069-SCH 01 E03
8434 (3)INV 4 MP1,1400KW/1414AAC 10622070-SCH 01 E03
8434 (3)INV 5 MP2,1400KW/1414AAC 10622071-SCH 01 E03
8434 (3)INV 6 MP3,1400KW/1414AAC 10622072-SCH 01 E03
8434 CUB-ASSIGNMENT,TD/RT 10622073-SCH 01 E03
8434 (2)CHOPPER,1200KW 10622074-SCH 01 E03
www.nov.com
Revision 01
Page 3
2.4 ELECTRICAL INTERNAL WIRING DIAGRAM
8434 DDCS TOPOLOGY/FIBER DIAGRAM 10623389-DIA 01 E03
8434-480VAC MCC FVNR HPU 10628392-SCH 01 E03
8434-480VAC MCC FVNR TRIP TANK 10628415-SCH 01 E03
8434-GENERATOR BASIC 10632262-SCH 03 E03
8434-GENERATOR INTERCONNECT 10632264-SCH 03 E03
8434-GENERATOR GND FLT & ESD 10632265-SCH 04 E03
8434-CUBICLE CAT BATT PACKAGE 10632266-SCH 02 E03
LOAD LIST
8434-208/120 LIGHTING PANEL 10620333-DAD 01 E08
www.nov.com
FROM SHT. #1
GEN PLUG PANEL

CB10 CB29
20/1 20/1
PIN1 PIN1 MUD PLUG PANEL
39 40
BLK-CB10 BLK-CB10 BLK-CB29 BLK-CB29
LP-CB10/ LP-CB29/
PIN2 G2-P12 MS-P12 PIN2
GEN 2 MS-P12
SKID LTS (MUD PUMP PNL LTS #2)
WHT-CB10 (3x12AWG) WHT-CB10 WHT-CB29 (3x12AWG) WHT-CB29
PIN3 PIN3
GRN-CB10 GRN-CB10 GRN-CB29 GRN-CB29
CB11 CB30
20/1 20/1
PIN1 PIN1 AC PLUG PANEL
41 42

LP-CB11/ LP-CB30/
GEN 3 PIN2 G3-P12 MS-P32 PIN2
MS-P32
SKID LTS (MUD SYS. SHAKERS)
PIN3 PIN3
CB12 CB31
20/1 20/1
PIN1 43 44 PIN1 GEN PLUG PANEL

LP-CB12/ LP-CB31/
GEN 4 PIN2 G4-P12 AD1-P01 PIN2 AD1-P01
SKID LTS (GEN PLUG PNL
WHT-CB12 (3x12AWG) WHT-CB12 WHT-CB31 (3x12AWG) WHT-CB31 AIR DRYER #1)
PIN3 PIN3
GEN 1 CUBICLE
CB13 CB32
20/1 20/1
45 46 PIN1 GEN PLUG PANEL
L0410 31 - 01
GEN 1
LP-CB32/
HTR
LP-CB13 AD2-P01 PIN2 AD2-P01
N0415 31 - 02 (GEN PLUG PNL
WHT-CB13 (2x12AWG) WHT-CB13 WHT-CB32 (3x12AWG) WHT-CB32 AIR DRYER #2)
PIN3
GRN-CB32 GRN-CB32
GEN 2 CUBICLE
CB14 CB33
20/1 20/1
47 48 PIN1 AC PLUG PANEL
L0410 31 - 01
GEN 2
HTR
LP-CB14 LP-CB33 PIN2
N0415 31 - 02 LP-CB33 (SPARE)
PIN3
GRN-CB33 GRN-CB33
GEN 3 CUBICLE
CB15 CB34
20/1 20/1
49 50 VFD HOUSE
L0410 31 - 01 L
GEN 3
HTR
LP-CB15 LP-CB34 LP-CB34
N0415 31 - 02 N (HOUSE LTS
WHT-CB15 (2x12AWG) WHT-CB15 WHT-CB34 (3x12AWG) WHT-CB34 J-BOX #1)
GND
GRN-CB34 GRN-CB34
GEN 4 CUBICLE
CB16 CB35
20/1 20/1
51 52 VFD HOUSE
L0410 31 - 01 L
GEN 4
HTR
LP-CB16 LP-CB35 LP-CB35
N0415 31 - 02 N (VFD HOUSE
WHT-CB16 (2x12AWG) WHT-CB16 WHT-CB35 (3x12AWG) WHT-CB35 EMERG LIGHTS)
GND
GRN-CB35 GRN-CB35
CAT. BATTERY CUB. CB17 CB36

20/1 20/1
53 54 VFD HOUSE
L1 60 - 01 L
BLK-CB17 LP-CB17 BLK-CB17 BLK-CB36 BLK-CB36
LP-CB17
(RIG POWER) (2x12AWG)
LP-CB36 LP-CB36
N/GND 60 - 02 N
WHT-CB17 WHT-CB17 WHT-CB36 (3x12AWG) (RECEPTACLES)
WHT-CB36
GND
GRN-CB36 GRN-CB36
55 56
SPACE SPACE
57 58
SPACE SPACE
59 60
SPACE SPACE
STD3422D REV0
V10
V3
V4
V5
V6
V7
V8
V9
V1
V2
X1
Chassis
RPBA-01
Profibus Adapter
GND
X1 Network
Bus
S1 Term.
Bus ID
S2 10x
Bus ID
S3 1x
Error
Host Indication
Online
Offline
V10
V3
V4
V5
V6
V7
V8
V9
V1
V2
X1
Chassis
RPBA-01
Profibus Adapter
GND
X1 Network
Bus
S1 Term.
Bus ID
S2 10x
Bus ID
S3 1x
Error
Host Indication
Online
Offline
V10
V3
V4
V5
V6
V7
V8
V9
V1
V2
X1
Chassis
RPBA-01
Profibus Adapter
GND
X1 Network
Bus
S1 Term.
Bus ID
S2 10x
Bus ID
S3 1x
Error
Host Indication
Online
Offline
V10
V3
V4
V5
V6
V7
V8
V9
V1
V2
X1
Chassis
RPBA-01
Profibus Adapter
GND
X1 Network
Bus
S1 Term.
Bus ID
S2 10x
Bus ID
S3 1x
Error
Host Indication
Online
Offline
V10
V3
V4
V5
V6
V7
V8
V9
V1
V2
X1
Chassis
RPBA-01
Profibus Adapter
GND
X1 Network
Bus
S1 Term.
Bus ID
S2 10x
Bus ID
S3 1x
Error
Host Indication
Online
Offline
V10
V3
V4
V5
V6
V7
V8
V9
V1
V2
X1
Chassis
RPBA-01
Profibus Adapter
GND
X1 Network
Bus
S1 Term.
Bus ID
S2 10x
Bus ID
S3 1x
Error
Host Indication
Online
Offline
FINAL DOCUMENTATION
Section 2.5
Calculations
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CHAPTER 2 INDEX 2.5

8434 CALCULATIONS
DOCUMENT NUMBER REV
10707938-IDX 01
www.nov.com
Revision 01
Page 2
2.5 SHORT CIRCUIT ANALYSIS
SYSTEM SHORT CIRCUIT DIAGRAM 10621760-DIA 01 G08
SYSTEM SHORT CIRCUIT STUDY 10621760-REP 02 G08
CB COORDINATION STUDY
SYSTEM BREAKER COORDINATION 10621770-REP 02 G09
HEAT LOSS STUDY
SYSTEM HEAT LOSS REPORT 10620338-REP 02 G10
HARMONIC DISTORTION STUDY
SYSTEM HARMONIC ANALYSIS 10621775-REP 02 G11
LOAD FLOW STUDY
SYSTEM LOAD FLOW DIAGRAM 10621765-DIA 01 G13
SYSTEM LOAD FLOW STUDY 10621765-REP 02 G13
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System Short Circuit Study
SYSTEM SHORT CIRCUIT STUDY REPORT

Ideal Rig 135 J258434 NOV – Galena Park
17 This document contains proprietary and confidential information National Oilwell Varco
which belongs to National Oilwell Varco; it is loaned for limited 11000 Corporate Center Dr.
REMARKS purposes only and remains the property of National Oilwell Varco.
Reproduction, in whole or in part; or use of this design or Suite 200
MAIN TAG NUMBER DISCIPLINE distribution of this information to others is not permitted without the Houston, TX 77041
CLIENT PO NUMBER event upon completion of the use for which it was loaned. Fax + 281-854-0607
 National Oilwell Varco
10621760-REP 02
Document number 10621760-REP
Revision 02
Page 2
REVISION HISTORY

01 26.04.2012 First Issue JAR BD JAR
www.nov.com
Revision 02
Page 3
TABLE OF CONTENTS
1 GENERAL......................................................................................................................... 4
1.1 Purpose .................................................................................................................. 4
1.2 Scope ..................................................................................................................... 4
1.3 Responsibility ......................................................................................................... 4
1.4 Filing / Retrieval ...................................................................................................... 4
2 INTRODUCTION ............................................................................................................... 5
2.1 Abbreviations and Nomenclature ............................................................................ 5
3 SINGLE LINE DIAGRAMS ............................................................................................... 6
4 INPUT DATA .................................................................................................................... 6
4.1 Generator Input Data .............................................................................................. 6
4.2 Transformer Input Data........................................................................................... 6
4.3 Motor Input Data ..................................................................................................... 7
4.4 Cable Input Data ..................................................................................................... 7
5 EQUIPMENT RATINGS .................................................................................................... 7
5.1 600VAC Main Bus Bar ............................................................................................ 7
5.2 480VAC MCC and 208/120 VAC Distribution Panel Bus Bar ................................. 7
5.3 Protective Devices .................................................................................................. 7
6 SHORT CIRCUIT CALCULATION RESULTS .................................................................. 8
6.1 Maximum Fault Currents ........................................................................................ 8
7 CONCLUSIONS ................................................................................................................ 9
8 PTW REPORT – WORST CASE SCENARIO ................................................................ 10
9 APPENDIX A: DRAWINGS ............................................................................................ 17
9.1 600V Single-Line Diagram .................................................................................... 17
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1 GENERAL
1.1 Purpose
The purpose of this document is to provide short circuit calculations based on IEC 60909
and analysis for the electrical power system.
1.2 Scope
The scope of the calculations covered by the document is as follows:
 Symmetrical short circuit currents (Ib)

 Initial symmetrical short circuit current (rms) (Ik”)
 Peak short circuit current (ip )
1.3 Responsibility
Any updates/revisions of this document will be the responsibility of the Engineering or

Commissioning Team.
Any deviations from this procedure will have to be documented.
In case of major changes in the work described in this procedure (e.g. reduced scope of
operating tests to be performed), a revision of the procedure is required.
1.4 Filing / Retrieval
The official versions of this procedure will at all times be the updated version stored at
Document Control.
Prior to any work starting on this procedure, the responsible party will ensure that the print-
out copy available at site has the latest revision number and contains the latest updated
information.
As the work proceeds, for each step of the job that has been performed, the package
responsible engineer or his/her delegate and the Client representative will verify by
signature that the work has been completed.
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Revision 02
Page 5
2 INTRODUCTION
The short circuit calculations contained in this document are to be used to determine
thermal and mechanical stress seen by the electrical equipment. The thermal and
mechanical stresses are then used to size equipment and determine power component
withstand capabilities.
Power Tools for Windows (PTW) was used to calculate the system short circuit currents for
this project. PTW assumes the following:
 All system capacitances are ignored

 Short circuit impedance is ignored
 The short circuit occurs in all three phases simultaneously (three phase fault)
 Unmeshed system
2.1 Abbreviations and Nomenclature
Abbreviation Meaning
BUS-MAIN 600V Main Bus
BUS-MCC 480V MCC Bus
BUS-DIST 208V Distribution Bus
Ik” Initial symmetrical short circuit current (rms)
Ik Steady-state short circuit current (rms)
ip Peak short circuit current
Ib Symmetrical short circuit breaking current (rms) voltage
PTW Power Tools for Windows (SKM) computer software
rms Root Mean Square
ms Millisecond
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Revision 02
Page 6
3 SINGLE LINE DIAGRAMS
The Single-Line Diagrams are too large to print in a report format and still be readable. See
Appendix A for the full-size drawings.
4 INPUT DATA
This section summarizes the main component input data for quick reference.
4.1 Generator Input Data
The system has (4) main engine-generator sets (each rated 1750kVA, 600VAC, 60Hz)
running at 1200rpm. All of the generators were modelled as swing. Table 4-1 displays the
input data.
Table 4-1: Generator input data
Rated Rated Rated X"d X"q X0 Xd X'd

Component
(kVA) (kW) (V) (pu) (pu) (pu) (pu) (pu)
GEN1 1750 1225 600 0.1770 0.146 0.012 2.112 0.314
GEN2 1750 1225 600 0.1770 0.146 0.012 2.112 0.314
GEN3 1750 1225 600 0.1770 0.146 0.012 2.112 0.314
GEN4 1750 1225 600 0.1770 0.146 0.012 2.112 0.314
4.2 Transformer Input Data
The system has (2) 600:480VAC, 1000kVA rated MCC transformer, and (1)
600:208/120VAC, (1)112.5 kVA rated distribution transformer. Table 4-2 displays the input
data.
Table 4-2: Transformer input data
Pri Sec
Connection Nominal Xpos Xzero Z%
Component Rated Rated X/R
Type (kVA) (%) (%) (%)
(V) (V)
MCCA XFMER Delta/Delta 1000 600 480 5.7112 0.99 5.66 5.75
DIST XFMER Delta/Wye 112.5 600 208/120 3.3938 1.41 4.79 5.00
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Revision 02
Page 7
4.3 Motor Input Data
To simulate the MCC and other motor loads, a single equivalent motor or load was used for
each respectively. The value for the equivalent load is determined by the scenarios defined
in section 6.
4.4 Cable Input Data
All power cables were modelled in PTW according to estimated lengths.
5 EQUIPMENT RATINGS
5.1 600VAC Main Bus Bar
The 600VAC main bus bar is designed to withstand 100kA rms short circuit current.
5.2 480VAC MCC and 208/120 VAC Distribution Panel Bus Bar
The 480VAC MCC bus bar is designed to withstand 42kA rms short circuit current. The
208/120 VAC distribution panel bus bar is designed to withstand 10kA rms short circuit
current.
5.3 Protective Devices
The protective devices are ABB circuit breakers. Ratings of these devices are listed in
table 5-1 below.
Table 5-1: Protective device data
Line
Sym. Amps
Consumers Model Voltage Rating
I.C.
(VAC)
Gen1-4 ABB E3S-A 600 2000 AF 75 kA
FB 02 ABB E3S 690 1250 AF 75 kA
CB-INC1,2 ABB E3S 690 2500 AF 75 kA
FB 01 ABB E3S-A 690 250 AF 80 kA
DSW ABB T4V 600 250 AF 100 kA
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6 SHORT CIRCUIT CALCULATION RESULTS
In order to analyse the short circuit situations for the power system, the worst scenario
were considered. All motor loads are considered to have a 0.7 lagging power factor. Listed
below are the scenarios considered.
Worst Scenerio (Drilling)
 (4) Generators running

 (2) 1000 kVA MCC transformer active
 (1) 112.5 kVA distribution transformer active
6.1 Maximum Fault Currents
The following table show the calculated short circuit currents produced by PTW for the
worst scenario listed above.
Table 6-1: Short circuit currents – Drilling Scenario
Ib(Sysm rms)(kA) Ib(Sysm rms)(kA)

Location Ik” (kA) Ip (kA)
t=T/2 t=2T
BUS-MAIN 61.23 118.71 69.02 49.56
BUS-MCC 19.97 45.31 25.98 18.98
BUS-DIST 6.29 12.48 7.11 6.29
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7 CONCLUSIONS
This report has adequately analyzed the short circuit currents in worst case scenarios. The
PTW computer software has aided in analyzing these short circuit currents.
In conclusion, this report has determined that the equipment supplied to the customer is
designed to withstand the maximum calculated fault currents. The 600VAC bus maximum
calculated fault currents of 45.5 kA are less than the circuit breaker capacity 75kA. The
480VAC bus maximum calculated fault currents of 19.9 kA are less than the manufacturer
rating of 42kA (MCC).The 208/120VAC distribution panel bus maximum calculated fault
currents of 6.3kA are less than the manufacturer rating of 10kA. This report also shows that
the main bus bracing is adequate to handle the calculated currents.
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8 PTW REPORT – WORST CASE SCENARIO

Apr 26, 2012 13:42:22
------------------------------------------------------------------------------
ALL INFORMATION PRESENTED IS FOR REVIEW, APPROVAL
INTERPRETATION AND APPLICATION BY A REGISTERED ENGINEER ONLY
SKM DISCLAIMS ANY RESPONSIBILITY AND LIABILITY RESULTING
FROM THE USE AND INTERPRETATION OF THIS SOFTWARE.
------------------------------------------------------------------------------
SKM POWER*TOOLS FOR WINDOWS
IEC 60909 FAULT ANALYSIS REPORT
COPYRIGHT(C) SKM SYSTEMS ANALYSIS, INC. 1995-2009
------------------------------------------------------------------------------
Voltage Factor Table

Voltage Range cmax cmin
====================================================================================
Specific Voltage 230 1.05 0.95
Specific Voltage 400 1.05 0.95
0 1000 1.05 1.00
1000 35000 1.10 1.00
35000 230000 1.10 1.00
230000 765000 1.10 1.00
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Apr 26, 2012 13:42:22 PAGE 2
T I M E V A R Y I N G I E C 6 0 9 0 9 F A U L T R E P O R T
System Frequency(Hz): 60 Tmin: 0.02 sec.
Calculate Maximum Short-Circuit Current
====================================================================================================
*FAULT BUS: BUS-DIST Voltage: 0.208 kV Eq. Volt. Source: 1.05 p.u.
3 Phase Fault---------------------------------------------------------------------------
R/X of Z(eq): 0.3135 Ik"(kA): 6.289

Ip(kA): 12.477 Ik(kA): 5.014
TIME (Cycles) 0.5 2.0 5.0 12.5

========================================================================================
Ib(Asym. RMS) (kA) 7.113 6.288 6.281 6.277
Ib(Sym. RMS) (kA) 6.288 6.286 6.281 6.277
i(DC) (kA) 3.324 0.174 0.000 0.000
Ib(Asym)/Ib(Sym) 1.131 1.000 1.000 1.000
GROUP CONTRIBUTIONS -------------------- referred to 0.208 kV

GROUP CONTRIBUTION THROUGH BRANCH : CBL- DIST XFMR
R/X: 0.313 Ik"(kA): 6.289
Ip(kA): 12.477 Ik(kA): 5.014
TIME (Cycles) 0.5 2.0 5.0 12.5

========================================================================================
Ib(Asym. RMS) (kA) 7.113 6.288 6.281 6.277
Ib(Sym. RMS) (kA) 6.288 6.286 6.281 6.277
i(DC) (kA) 3.324 0.174 0.000 0.000
Ib(Asym)/Ib(Sym) 1.131 1.000 1.000 1.000
Single Line to Ground Fault---------------------------------------------------------------
R/X of Z(eq): 0.3176 Ik"(kA): 6.349

Ip(kA): 12.552 Ik(kA): 0.000
TIME (Cycles) 0.5 2.0 5.0 12.5

==========================================================================================
Ib(slg)(Asym. RMS) (kA) 0.000 0.000 0.000 0.000
Ib(slg)(Sym. RMS) (kA) 0.000 0.000 0.000 0.000
iDC(slg)(kA) 0.000 0.000 0.000 0.000
Ib(Asym)/Ib(Sym) N/A N/A N/A N/A
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Apr 26, 2012 13:42:22 PAGE 3

GROUP CONTRIBUTION THROUGH BRANCH : CBL- DIST XFMR
TIME (Cycles) 0.5 2.0 5.0 12.5

========================================================================================
Ib(slg)(Asym. RMS) (kA) 0.000 0.000 0.000 0.000
Ib(slg)(Sym. RMS) (kA) 0.000 0.000 0.000 0.000
iDC(slg)(kA) 0.000 0.000 0.000 0.000
*FAULT BUS: BUS-MAIN Voltage: 0.600 kV Eq. Volt. Source: 1.05 p.u.
3 Phase Fault---------------------------------------------------------------------------
R/X of Z(eq): 0.0585 Ik"(kA): 45.507

Ip(kA): 118.675 Ik(kA): 13.371
TIME (Cycles) 0.5 2.0 5.0 12.5

========================================================================================
Ib(Asym. RMS) (kA) 69.025 49.516 34.676 28.764
Ib(Sym. RMS) (kA) 43.389 38.105 32.759 28.749
i(DC) (kA) 53.683 31.621 11.371 0.926
Ib(Asym)/Ib(Sym) 1.591 1.299 1.059 1.001

INDIVIDUAL CONTRIBUTIONS:
Device Name: GEN1
R/X: 0.053 Ik"(kA): 10.568
Ip(kA): 27.736 Ik(kA): 3.343
TIME (Cycles) 0.5 2.0 5.0 12.5

========================================================================================
Ib(Asym. RMS) (kA) 16.180 11.773 8.317 7.043
Ib(Sym. RMS) (kA) 10.088 8.930 7.824 7.039
i(DC) (kA) 12.651 7.672 2.821 0.231
Ib(Asym)/Ib(Sym) 1.604 1.318 1.063 1.001
Device Name: GEN2

R/X: 0.053 Ik"(kA): 10.568
Ip(kA): 27.736 Ik(kA): 3.343
TIME (Cycles) 0.5 2.0 5.0 12.5

========================================================================================
Ib(Asym. RMS) (kA) 16.180 11.773 8.317 7.043
Ib(Sym. RMS) (kA) 10.088 8.930 7.824 7.039
i(DC) (kA) 12.651 7.672 2.821 0.231
Ib(Asym)/Ib(Sym) 1.604 1.318 1.063 1.001
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Apr 26, 2012 13:42:22 PAGE 4
Device Name: GEN3

R/X: 0.053 Ik"(kA): 10.568
Ip(kA): 27.736 Ik(kA): 3.343
TIME (Cycles) 0.5 2.0 5.0 12.5

========================================================================================
Ib(Asym. RMS) (kA) 16.180 11.773 8.317 7.043
Ib(Sym. RMS) (kA) 10.088 8.930 7.824 7.039
i(DC) (kA) 12.651 7.672 2.821 0.231
Ib(Asym)/Ib(Sym) 1.604 1.318 1.063 1.001
Device Name: REST OF MCC A

R/X: 0.127 Ik"(kA): 3.242
Ip(kA): 7.749 Ik(kA): 0.000
TIME (Cycles) 0.5 2.0 5.0 12.5

========================================================================================
Ib(Asym. RMS) (kA) 4.331 2.567 1.470 0.595
Ib(Sym. RMS) (kA) 3.045 2.391 1.468 0.595
i(DC) (kA) 3.080 0.933 0.086 0.000
Ib(Asym)/Ib(Sym) 1.422 1.073 1.002 1.000
Device Name: GEN4

R/X: 0.053 Ik"(kA): 10.568
Ip(kA): 27.736 Ik(kA): 3.343
TIME (Cycles) 0.5 2.0 5.0 12.5

========================================================================================
Ib(Asym. RMS) (kA) 16.180 11.773 8.317 7.043
Ib(Sym. RMS) (kA) 10.088 8.930 7.824 7.039
i(DC) (kA) 12.651 7.672 2.821 0.231
Ib(Asym)/Ib(Sym) 1.604 1.318 1.063 1.001
R/X of Z(eq): 0.0000 Ik"(kA): 0.000

Ip(kA): 0.000 Ik(kA): 0.000
TIME (Cycles) 0.5 2.0 5.0 12.5

==========================================================================================
Ib(slg)(Asym. RMS) (kA) 0.000 0.000 0.000 0.000
Ib(slg)(Sym. RMS) (kA) 0.000 0.000 0.000 0.000
iDC(slg)(kA) 0.000 0.000 0.000 0.000
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Device Name: GEN1
R/X: 9999.000 Ik"(kA): 0.000
Ip(kA): 0.000 Ik(kA): 0.000
TIME (Cycles) 0.5 2.0 5.0 12.5

========================================================================================
Ib(slg)(Asym. RMS) (kA) 0.000 0.000 0.000 0.000
Ib(slg)(Sym. RMS) (kA) 0.000 0.000 0.000 0.000
iDC(slg)(kA) 0.000 0.000 0.000 0.000
Device Name: GEN2

R/X: 9999.000 Ik"(kA): 0.000
Ip(kA): 0.000 Ik(kA): 0.000
TIME (Cycles) 0.5 2.0 5.0 12.5

========================================================================================
Ib(slg)(Asym. RMS) (kA) 0.000 0.000 0.000 0.000
Ib(slg)(Sym. RMS) (kA) 0.000 0.000 0.000 0.000
iDC(slg)(kA) 0.000 0.000 0.000 0.000
Device Name: GEN3

R/X: 9999.000 Ik"(kA): 0.000
Ip(kA): 0.000 Ik(kA): 0.000
TIME (Cycles) 0.5 2.0 5.0 12.5

========================================================================================
Ib(slg)(Asym. RMS) (kA) 0.000 0.000 0.000 0.000
Ib(slg)(Sym. RMS) (kA) 0.000 0.000 0.000 0.000
iDC(slg)(kA) 0.000 0.000 0.000 0.000

R/X: 0.000 Ik"(kA): 0.000
Ip(kA): 0.001 Ik(kA): 0.000
TIME (Cycles) 0.5 2.0 5.0 12.5

========================================================================================
Ib(slg)(Asym. RMS) (kA) 0.000 0.000 0.000 0.000
Ib(slg)(Sym. RMS) (kA) 0.000 0.000 0.000 0.000
iDC(slg)(kA) 0.001 0.001 0.001 0.001
Ib(Asym)/Ib(Sym) 1.780 2.036 2.910 6.499
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Device Name: GEN4

R/X: 9999.000 Ik"(kA): 0.000
Ip(kA): 0.000 Ik(kA): 0.000
TIME (Cycles) 0.5 2.0 5.0 12.5

========================================================================================
Ib(slg)(Asym. RMS) (kA) 0.000 0.000 0.000 0.000
Ib(slg)(Sym. RMS) (kA) 0.000 0.000 0.000 0.000
iDC(slg)(kA) 0.000 0.000 0.000 0.000
*FAULT BUS: BUS-MCC Voltage: 0.480 kV Eq. Volt. Source: 1.05 p.u.
3 Phase Fault---------------------------------------------------------------------------
R/X of Z(eq): 0.1641 Ik"(kA): 19.966

Ip(kA): 45.822 Ik(kA): 12.418
TIME (Cycles) 0.5 2.0 5.0 12.5

========================================================================================
Ib(Asym. RMS) (kA) 25.956 18.975 17.095 15.800
Ib(Sym. RMS) (kA) 19.621 18.532 17.091 15.800
i(DC) (kA) 16.992 4.074 0.369 0.003
Ib(Asym)/Ib(Sym) 1.323 1.024 1.000 1.000

GROUP CONTRIBUTION THROUGH BRANCH : CBL-MCC XFMR
R/X: 0.186 Ik"(kA): 14.953
Ip(kA): 33.442 Ik(kA): 12.418
TIME (Cycles) 0.5 2.0 5.0 12.5

========================================================================================
Ib(Asym. RMS) (kA) 19.048 15.093 14.953 14.953
Ib(Sym. RMS) (kA) 14.953 14.953 14.953 14.953
i(DC) (kA) 11.800 2.050 0.062 0.000
Ib(Asym)/Ib(Sym) 1.274 1.009 1.000 1.000
R/X: 0.100 Ik"(kA): 5.027
Ip(kA): 12.412 Ik(kA): 0.000
TIME (Cycles) 0.5 2.0 5.0 12.5

========================================================================================
Ib(Asym. RMS) (kA) 6.991 4.121 2.166 0.850
Ib(Sym. RMS) (kA) 4.680 3.590 2.144 0.850
i(DC) (kA) 5.192 2.023 0.307 0.003
Ib(Asym)/Ib(Sym) 1.494 1.148 1.010 1.000
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R/X of Z(eq): 0.0000 Ik"(kA): 0.000

Ip(kA): 0.000 Ik(kA): 0.000
TIME (Cycles) 0.5 2.0 5.0 12.5

==========================================================================================
Ib(slg)(Asym. RMS) (kA) 0.001 0.001 0.001 0.001
Ib(slg)(Sym. RMS) (kA) 0.001 0.001 0.000 0.000
iDC(slg)(kA) 0.001 0.001 0.001 0.001
Ib(Asym)/Ib(Sym) 1.780 2.036 2.910 6.499

GROUP CONTRIBUTION THROUGH BRANCH : CBL-MCC XFMR
TIME (Cycles) 0.5 2.0 5.0 12.5

========================================================================================
Ib(slg)(Asym. RMS) (kA) 0.000 0.000 0.000 0.000
Ib(slg)(Sym. RMS) (kA) 0.000 0.000 0.000 0.000
iDC(slg)(kA) 0.000 0.000 0.000 0.000
R/X: 0.000 Ik"(kA): 0.000
Ip(kA): 0.001 Ik(kA): 0.000
TIME (Cycles) 0.5 2.0 5.0 12.5

========================================================================================
Ib(slg)(Asym. RMS) (kA) 0.000 0.000 0.000 0.000
Ib(slg)(Sym. RMS) (kA) 0.000 0.000 0.000 0.000
iDC(slg)(kA) 0.001 0.001 0.001 0.001
Ib(Asym)/Ib(Sym) 1.780 2.036 2.910 6.499
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9 APPENDIX A: DRAWINGS
9.1 600V Single-Line Diagram

GEN2
GEN1 GEN3 GEN4
1750 kVA
1750 kVA 1750 kVA 1750 kVA
X"d 0.1770 pu
X"d 0.1770 pu Ik" 10.7 kA 3P X"d 0.1770 pu X"d 0.1770 pu
Ik" 10.7 kA 3P Ik" 10.7 kA 3P Ik" 10.7 kA 3P
CBL-GEN1 CBL-GEN2 CBL-GEN3 CBL-GEN4
BUS-MAIN
GEN1 CB GEN2 CB GEN3 CB GEN4 CB 600 V, 60 Hz, 3 Wire, 3 Pole
75 kA 75 kA 75 kA
75 kA Braced for 100 kA
Ik" 45.5 kA 3P
Ip 118.7 kA 3P
FB02
CB-INC1 FUSE- TD AUX 75 kA
75 kA FB01
200 kA
80 kA
CB-INC2
75 kA
CBL-FB02
CBL-FB01 DSW
100 kA
CBL-CBINC1
CBL-CB INC2
P CBL-DSW
DIST XFMER
P
S 112.5 kVA MCC XFMER
Z% 4.99 % S 1000.0 kVA
Z% 5.75 %
REACTOR-INC/REC1 CBL- DIST XFMR REACTOR-INC/REC2
BUS-DIST
208 V, 60 Hz, 4 Wire, 4 Pole
LIGHTING PANEL Braced for 10 kA CBL-MCC XFMR FUSE- INC/REC 2
FUSE- INC/REC 1 TOP DRIVE AUX
Ik" 6.3 kA 3P 200 kA
200 kA Ip 12.5 kA 3P
BUS-MCC
480 V, 60Hz, 3 Wire, 3 Pole
Braced for 42 kA
Ik" 20.0 kA 3P
DSW-1 Ip 45.8 kA 3P
75 kA DSW-2
75 kA
REST OF MCC A
LOAD1
LOAD2
1000 kVA
X"d 0.2500 pu
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System Circuit Breaker
Coordination Study
SYSTEM CIRCUIT BREAKER

COORDINATION STUDY REPORT

information which belongs to National Oilwell Varco; it is 11000 Corporate Center Dr.
of National Oilwell Varco. Reproduction, in whole or in part; Suite # 200
MAIN TAG NUMBER DISCIPLINE or use of this design or distribution of this information to Houston, TX 77041
others is not permitted without the express written consent Phone + 281-854-0400
of National Oilwell Varco. This document is to be returned
CLIENT PO NUMBER to National Oilwell Varco upon request and in any event Fax + 281-854-0607
upon completion of the use for which it was loaned.
10621770-REP 02
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Revision 02
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REVISION HISTORY

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Revision 02
Page 3
TABLE OF CONTENTS
1 GENERAL ......................................................................................................................... 4
1.1 Purpose .................................................................................................................. 4
1.2 Scope ..................................................................................................................... 4
1.3 Responsibility.......................................................................................................... 4
2 INTRODUCTION ............................................................................................................... 5
3 SINGLE LINE DIAGRAM.................................................................................................. 6
4 CIRCUIT BREAKER TRIP SETTINGS ............................................................................. 6
5 TCC CURVES ................................................................................................................... 7
5.1 Generator CB and Generator ................................................................................. 7
5.2 Generator CB and Top Drive Fuse ......................................................................... 8
5.3 Generator CB, Incomer / Rectifier 1, 2.................................................................... 9
5.4 Generator CB, DIST XFMER, FB01 ..................................................................... 10
5.5 Generator CB, MCC XFMER, FB02 ..................................................................... 11
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Revision 02
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1 GENERAL
1.1 Purpose
The purpose of this document is to provide the circuit breaker trip settings.
1.2 Scope
The scope of the circuit breaker trip settings include branch feeder circuit breakers
provided as part of the power system.
1.3 Responsibility

Commissioning Team.
Document Control.
Prior to any work starting on this procedure, the responsible engineer will ensure that the
print-out copy available at site has the latest revision number and contains the latest
updated information.
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Revision 02
Page 5
2 INTRODUCTION
The coordination study contained in this document demonstrates practical trip settings for
the coordination of protective devices in the power system.
Power Tools for Windows (PTW) was used to carry out the breaker coordination study for
the power system in this project. PTW is capable of trending and organizing protective
device coordination for wide arrays bus and circuit arrangements.
Ref Reference
Man Manufacturer
LTD Long Time Delay
LTPU Long Time Pick-Up
STPU Short Time Pick-Up
STD Short Time Delay
INST Instantaneous setting
CB Circuit Breaker
GEN Generator
FDR Feeder Breaker
XFMR Transformer
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Revision 02
Page 6
3 SINGLE LINE DIAGRAM

4 CIRCUIT BREAKER TRIP SETTINGS
Settings
Trip Unit Model Frame LTPU STPU INST
LTPU LTD STPU STD-I2T INST
(A) (A) (A)
0.2
CB-GEN1 EMAX, PR121/P E3S-A 2000 0.85 1700 12 1.5 3000 9 18000
(I^2t In)
0.85 1700 12 1.5 0.2 18000
CB-GEN2 EMAX, PR121/P E3S-A 2000 3000 9
(I^2t In)
0.85 1700 12 1.5 0.2 18000
(I^2t In)
0.85 1700 12 1.5 0.2 18000
(I^2t In)
0.1
FB01 4,TMA T4V 250 0.44 110 3 1 250 5.5 1375
(I^2t In)
0.2
FB02 EMAX, PR121/P E3S 1250 0.775 968 12 1.5 1875 8 10000
(I^2t In)
0.1
CB-INC1 EMAX, PR121/P E3S 2500 0.85 2125 3 1 2500 2 5000
(I^2t Out)
0.1
CB-INC2 EMAX, PR121/P E3S 2500 0.85 2125 3 1 2500 2 5000
(I^2t Out)
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Revision 02
Page 7
5 TCC CURVES
5.1 Generator CB and Generator
CURRENT IN AMPERES
1000
GEN1
GEN1 CB
ABB
EMAX, PR121
E3S-A
Trip 2000.0 A
Plug 2000.0 A
Settings Phase
LTPU 0.85 (1700A)
100 LTD 12
STPU 1.5 (3000A)
STD-I2T 0.2 (I^2t In)
INST 9 (18000A)
Gen SC
TIME IN SECONDS
10
1 GEN1
0.10
0.01
10 100 1K 10K 100K 1M
GEN, CBGEN.tcc Ref. Voltage: 600V Current in Amps x 1 InitSym 3P
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Revision 02
Page 8
5.2 Generator CB and Top Drive Fuse
CURRENT IN AMPERES
1000
FUSE- TD AUX
100
Name FUSE- TD AUX
ManufacturerGOULD SHAWMUT
Type AJT, 600V Class J
Frame/Model AJT
Trip 60.0 A
TIME IN SECONDS
10
GEN1 CB
Name GEN1 CB
ManufacturerABB
Type EMAX, PR121
1 Frame/Model E3S-A
Trip 2000.0 A
Plug 2000.0 A
Settings Phase
LTPU 0.85 (1700A)
LTD 12
STPU 1.5 (3000A)
STD-I2T 0.2 (I^2t In)
INST 9 (18000A)
0.10
0.01
10 100 1K 10K 100K 1M
FUSE-TD AUX' CBGEN.tcc Ref. Voltage: 600V Current in Amps x 1 InitSym 3P
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Revision 02
Page 9
5.3 Generator CB, Incomer / Rectifier 1, 2
CURRENT IN AMPERES
1000
100
TIME IN SECONDS
10
CB-INC1 GEN1 CB
ABB ABB
EMAX IEC EMAX, PR121
E3S E3S-A
Trip 2500.0 A Trip 2000.0 A
Plug 2500.0 A Plug 2000.0 A
1 Settings Phase Settings Phase
LTPU 0,85 (2125A) LTPU 0.85 (1700A)
LTD 3 LTD 12
STPU 1 (2500A) STPU 1.5 (3000A)
STD-I2T 0,1 (I^2t Out) STD-I2T 0.2 (I^2t In)
INST 2 (5000A) INST 9 (18000A)
0.10
0.01
10 100 1K 10K 100K 1M
CB-INC1, CBGEN.tcc Ref. Voltage: 600V Current in Amps x 1 InitSym 3P
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Revision 02
Page 10
5.4 Generator CB, DIST XFMER, FB01
CURRENT IN AMPERES
1000
DIST XFMER
100
DIST XFMER
TIME IN SECONDS
GEN1 CB
10
ABB
EMAX, PR121
E3S-A
Trip 2000.0 A
Plug 2000.0 A
Settings Phase
LTPU 0.85 (1700A)
FB01 LTD 12
ABB STPU 1.5 (3000A)
TMAX, PR221DS STD-I2T 0.2 (I^2t In)
T4V INST 9 (18000A)
1 Trip 250.0 A
Settings Phase
LTPU 0.44 (110A)
LTD 3
STPU 1 (250A)
STD-I2T 0,1 (I^2t In)
INST 5.5 (1375A)
TX Inrush
0.10
0.01
10 100 1K 10K 100K 1M
CBGEN, FB01,DIST XFER.tcc Ref. Voltage: 600V Current in Amps x 1 InitSym 3P
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Revision 02
Page 11
5.5 Generator CB, MCC XFMER, FB02
CURRENT IN AMPERES
1000
MCC XFMER
100
MCC XFMER
TIME IN SECONDS
10
FB02
Name FB02 GEN1 CB

1 ManufacturerABB
Type EMAX IEC Name GEN1 CB
Frame/Model E3S ManufacturerABB
Trip 1250.0 A Type EMAX, PR121
Plug 1250.0 A Frame/Model E3S-A
Settings Phase Trip 2000.0 A
LTPU 0,775 (968.75A) Plug 2000.0 A
LTD 12 Settings Phase
STPU 1,5 (1875A) LTPU 0.85 (1700A)
STD-I2T 0,2 (I^2t In) LTD 12
INST 8 (10000A) STPU 1.5 (3000A)
TX Inrush STD-I2T 0.2 (I^2t In)
0.10 INST 9 (18000A)
0.01
10 100 1K 10K 100K 1M
CBGEN, FB02, MCC XFMER.tcc Ref. Voltage: 600V Current in Amps x 1 InitSym 3P
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Revision 02
Page 12

GEN2
GEN1 GEN3 GEN4
600 V, 1750 kVA
600 V, 1750 kVA 600 V, 1750 kVA 600 V, 1750 kVA

3-1/C 535 AWG/kcmil 3-1/C 535 AWG/kcmil 3-1/C 535 AWG/kcmil 3-1/C 535 AWG/kcmil
3 per phase 3 per phase 3 per phase 3 per phase
BUS-MAIN
GEN1 CB GEN2 CB GEN3 CB GEN4 CB
ABB ABB ABB 600 V, 60 Hz, 3 Wire, 3 Pole
ABB E3S-A 2000 A E3S-A 2000 A E3S-A 2000 A (3) 1/4" x 6" Cu Bus, 4000 A
E3S-A 2000 A Braced for 100 kA
75 kA 75 kA 75 kA
75 kA
FB02
CB-INC1 ABB
ABB FB01 FUSE- TD AUX E3S 1250 A
E3S 2500 A ABB 75 kA
T4V 250 A GOULD SHAWMUT CB-INC2
75 kA AJT 60 A ABB
80 kA
200 kA CBL-FB02 E3S 2500 A
CBL-FB01 DSW 3-1/C 535 AWG/kcmil 75 kA
3/C 1 AWG/kcmil ABB 2 per phase
CBL-CBINC1 1 per phase T4V 80 A
3-1/C 535 AWG/kcmil 100 kA CBL-CB INC2
4 per phase P CBL-DSW 3-1/C 535 AWG/kcmil
DIST XFMER 3-1/C 6 AWG/kcmil 4 per phase
P
S 112.5 kVA 1 per phase MCC XFMER
600 : 208 V S 1000.0 kVA
600 : 480 V
CBL- DIST XFMR
REACTOR-INC/REC1 REACTOR-INC/REC2
3-1/C 313 AWG/kcmil
2200 A 1 per phase 2200 A
BUS-DIST
208 V, 60 Hz, 4 Wire, 4 Pole
LIGHTING PANEL 400 A CBL-MCC XFMR FUSE- INC/REC 2
FUSE- INC/REC 1 TOP DRIVE AUX 3-1/C AWG/kcmil
Braced for 10 kA 2 per phase BUSSMANN
BUSSMANN 208 V, 112.5 kVA 600 V, 62.0 kVA
170M 1600 A
170M 1600 A 200 kA
200 kA
BUS-MCC
480 V, 60Hz, 3 Wire, 3 Pole
1200 A
Braced for 42 kA
DSW-1
ABB DSW-2
E3S 2500 A ABB
75 kA E3S 2500 A
75 kA
REST OF MCC A
LOAD1
600 V, 2196.5 Amps LOAD2
480 V, 1000.0 kVA
600 V, 2196.5 Amps
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Heat Loss Report
NOV Ideal Galena Rig 135

VFD System

Ideal Rig 135 J258434 NOV IDEAL GALENA RIG 135
G10 6 This document contains proprietary and/or confidential
REMARKS information of National Oilwell Varco (NOV). It is loaned for National Oilwell Varco
MAIN TAG NUMBER DISCIPLINE
accordance with the terms and conditions agreed upon with
NOV. Any use, reproduction, or disclosure beyond the terms
11000 Corporate Centre Drive
CLIENT PO NUMBER and conditions of the release is prohibited without the express Suite 200
written consent of NOV. The burden of proof that NOV Houston, Texas 77041
CLIENT DOCUMENT NUMBER
consent has been issued within the provisions of this U.S.A
paragraph lies with the recipient. This document is to be
returned to NOV or its destruction certified upon request by
NOV and in any event upon completion of the use for which it Phone +1-281-854-0400
was loaned. Except for the limited purposes agreed upon Fax +1-281-854-0607
between NOV and the recipient, no licenses or other rights are
granted or conferred upon recipient, expressly, implied or
otherwise, under any of NOV’s patents, trademarks, trade
secrets, copyrights, or other intellectual property rights. All
rights pertaining to this document and its contents are
expressly reserved and retained by NOV. ©National Oilwell
Varco, all rights reserved.
DOCUMENT NUMBER REV
10620338-REP 02
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Revision 02
Page 2
REVISION HISTORY

01 25.04.2012 For Information JAR BD JAR
CHANGE DESCRIPTION
Rev Change Description

01 Initial Release
02 Change the Rig ID from 137 to 135
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Revision 02
Page 3
TABLE OF CONTENTS
1 INTRODUCTION ............................................................................................................... 4
2 PURPOSE ......................................................................................................................... 4
3 EQUIPMENT DATA .......................................................................................................... 4
3.1 System .................................................................................................................... 4
3.2 Generator/Feeder Line-up ...................................................................................... 4
3.2.1 AC Main Bus ............................................................................................... 4
3.3 AC Drive Line-Up (Air Cool) .................................................................................... 4
3.3.1 DC Main Bus ............................................................................................... 5
3.3.2 AC Drive Utilization Factor for Inverter ........................................................ 5
3.4 Motor Control Center .............................................................................................. 5
4 CONVERSION TABLE ..................................................................................................... 5
5 CALCULATED HEAT LOSSES........................................................................................ 5
6 CONCLUSION .................................................................................................................. 6
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Revision 02
Page 4
1 INTRODUCTION
All electrical equipment produces heat, which must be removed to prevent the equipment
temperature from rising to an unacceptable level. Sizing a cooling system requires an
understanding of the amount of heat produced by the equipment contained in the enclosed
space, along with the heat produced by other heat sources typically encountered.
2 PURPOSE
The purpose of this document is to provide estimated heat losses generated by National
Oilwell Varco equipment under normal operating conditions to allow for proper sizing of the
air conditioning system.
3 EQUIPMENT DATA
3.1 System
Voltage (VAC) 600

Frequency (HZ) 60
3.2 Generator/Feeder Line-up
Number of Cubicles 4
Number of Circuit Breakers 6
Circuit Breakers (Fixed/Drawout) Fixed
3.2.1 AC Main Bus
Bus Size 6” x 0.25”

Number of Bars per Phase 3
3.3 AC Drive Line-Up (Air Cooled)
Number of Incomer/Rectifier Cubicle 2

Number of Inverter Cubicles 5
Number of Chopper Cubicles 1
Number of Assignment Cubicles 0
Circuit Breakers (Fixed/Drawout) Fixed
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Revision 02
Page 5
3.3.1 DC Main Bus
Bus Size 6” x 0.25”

Number of Bars per Phase 2
3.3.2 AC Drive Utilization Factor for Inverter
Mud Pumps 50%

Drawworks 10%
Top Drive 50%
3.4 Motor Control Center
MCC ID # of Sections
MCC #1 10
4 CONVERSION TABLE
In North America, specification for power and cooling capability are still often provided in
the legacy BTU and Tons term. For this reason, the following conversions are provided to
assist the reader.
Given a value in Multiply by To Get

BTU per Hour 0.293 Watts
Watts 3.41 BTU per Hour
Tons 3,530 Watts
Watts 0.000283 Tons
5 CALCULATED HEAT LOSSES
Generator Losses (Watts) 2,175

AC Drive Losses (Watts) 63,358
Motor Control Center Losses (Watts) 3,080
House Losses (Watts) 7,250
Total Loss (Watts) 75,863

Total refrigerate tons required (Tons) 21.4
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Revision 02
Page 6
6 CONCLUSION
National Oilwell Varco supplied equipment will require 21 Tons of air conditioning to
operate at 40C ambient rating.
The air conditioning system should be sized such that it can maintain a maximum of 40C
for National Oilwell Varco supplied equipment plus any other equipment that might reside in
the VFD House.
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System Harmonic Distortion
Study
SYSTEM HARMONIC DISTORTION

STUDY REPORT

REMARKS purposes only and remains the property of National Oilwell.
Reproduction, in whole or in part; or use of this design or Suite # 200
10621775-REP 02
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Revision 02
Page 2
REVISION HISTORY

01 27.04.2012 First Issue JAR RA JAR
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Revision 02
Page 3
TABLE OF CONTENTS
1 GENERAL ......................................................................................................................... 4
1.1 Purpose .................................................................................................................. 4
1.2 Scope ..................................................................................................................... 4
1.3 Responsibility.......................................................................................................... 4
2 INTRODUCTION ............................................................................................................... 5
3 SINGLE LINE DIAGRAMS ............................................................................................... 6
4 INPUT DATA .................................................................................................................... 6
4.2 Transformer Input Data ........................................................................................... 6
4.3 Motor Input Data and Load Schedule ..................................................................... 7
4.4 Current Distortion Models ....................................................................................... 8
5 STUDY CRITERIA AND METHODOLOGY ...................................................................... 9
6 SIMULATION RESULTS ................................................................................................ 10
6.1 600V Bus Distortion Plots ..................................................................................... 10
6.2 480V Bus Distortion Plots ..................................................................................... 11
6.3 208Y120 V Bus Distortion Plots ............................................................................ 12
6.4 Summary .............................................................................................................. 13
7 SIMULATION RESULTS ................................................................................................ 13
8 PTW REPORT ................................................................................................................ 14
9 APPENDIX: DRAWINGS ............................................................................................... 29
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Revision 02
Page 4
1 GENERAL
1.1 Purpose
The purpose of this document is to provide harmonic distortion information for the electrical
power system.
1.2 Scope
The Scope of this study covers the expected levels of harmonic distortion during normal
operating conditions.
1.3 Responsibility

Commissioning Team.
Document Control.
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Revision 02
Page 5
2 INTRODUCTION
This document explains the methodology and results for the expected harmonic current
and voltage distortion on the electrical power system. The methods and calculations used
to generate this report are based on information provided to NOV by the manufacturers
about the major system components. The criteria for this study are based on IEEE-519
(1992 and 1996) guidelines and project specifications. The simulations are based on
maximum utilization of the power system under maximum operating conditions. Utilization,
operating assumptions, and input data are outlined in section 4 of this report. Results are
summarized, and the complete report is included at the end of this document.
V_THD% Per unit or percent harmonic voltage distortion
I_THD% Per unit or percent harmonic current distortion
V_RMS RMS voltage – calculated on each bus
TIF Telephone Influence Factor
I_RMS RMS current – calculated on each bus
BUS-MCC 480V MCC Bus
p.u. Per Unit
RMS Root Mean Square
ms Millisecond
FFT Fast Fourier Transform
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Page 6
3 SINGLE LINE DIAGRAMS
4 INPUT DATA
input data

Component
GEN1 1750 1225 600 0.1770 0.146 0.012 2.112 0.314
GEN2 1750 1225 600 0.1770 0.146 0.012 2.112 0.314
GEN3 1750 1225 600 0.1770 0.146 0.012 2.112 0.314
GEN3 1750 1225 600 0.1770 0.146 0.012 2.112 0.314

data.
Pri Sec
Type (kVA) (%) (%) (%)
(V) (V)
MCC XFMER Delta/Delta 1000 600 480 5.7112 0.99 5.66 5.75
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Revision 02
Page 7
4.3 Motor Input Data and Load Schedule
each respectively. Detailed information about these equivalent motors can be found in the
full PTW report. Non-linear loads, e.g. SCRs and VFDs are all modelled as general, non-
motor, constant KVA loads. The load schedules are shown in the Table 4-3
TABLE 4-3 LOAD SCHEDULE

CONNECTED LOAD UTILIZATION
BUS LOAD NAME VOLTAGE LOAD [KVA] FACTOR [KVA]
BUS-MAIN TOP DRIVE 600 759.8 80% 607.8
BUS-MAIN DW 600 1488.5 10% 148.8
BUS-MAIN MP1 600 1211.3 80% 969.1
BUS-MAIN MP2 600 1211.3 80% 969.1
BUS-MAIN MP3 600 1211.3 80% 969.1
BUS-DIST DIST LOAD 208 112.5 80% 90
BUS-MCC MCC A LOAD 480 1000 75% 750
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Page 8
4.4 Current Distortion Models
Current distortion tables are derived from the PSIM simulations. These are shown below
for reference. In generating these, it is assumed there are no pre-existing harmonics and
that all loading across phases is equally balanced.
INVERTER CURRENT DISTORTION
Harmonic P.U.
Order Magnitude
1 100.00%
5 26.39%
7 7.63%
11 4.95%
13 3.28%
17 1.57%
19 1.47%
23 0.93%
25 0.73%
29 0.63%
31 0.53%
35 0.39%
37 0.37%
41 0.29%
43 0.25%
47 0.23%
49 0.21%
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Revision 01
Page 9
5 STUDY CRITERIA AND METHODOLOGY
To generate the harmonics report, 6 pulse rectifier models were constructed to determine the
characteristic harmonic distortion from a single VFD.
Current distortion for a PWM VFD is a function of both commutating reactance (source
reactance), DC bus capacitance, and loading, while the SCR current distortion is a function of the
source reactance, DC side inductance (motor inductance), and load. The DC bus capacitance is
simply the capacitance of a single inverter.
The Important considerations;

1. No pre-existing triplen harmonic levels are assumed
2. Exact Load sharing in parallel rectifiers is assumed and all transformers and system phases
are evenly loaded
With the foregoing assumptions, we include only odd harmonics in the 6 pulse harmonic source
models. Therefore, per unit current distortion for h = kq+ 1 harmonics up to the 49th are reported,
where k=n, 1, 2, 3… and q = 6.
Finally, the HiWave program module in PTW is then used to perform the harmonic system
analysis.
The VFD rectifiers are connected to the system bus via a circuit breaker
PTW then reports the total harmonic voltage distortion present on all buses, by injecting the
resultant currents throughout the distribution network. Included in the report are the Telephone
Influence Factor, the Total Harmonic Voltage Distortion, and RMS voltage at each bus.
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Revision 01
Page 10
6 SIMULATION RESULTS
6.1 600V Bus Distortion Plots
600V Main Bus Voltage Distortion
600V Main Bus A Voltage Spectrum
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Page 11
6.2 480V Bus Distortion Plots
480 V Bus Voltage Distortion
480 V Bus Voltage Spectrum
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Page 12
6.3 208Y120 V Bus Distortion Plots
208Y120V Bus Voltage Distortion
208Y120V Bus Voltage Spectrum
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Revision 01
Page 13
6.4 Summary
The following table summarizes the distortion levels for the system.
BUS NAME VOLTAGE VTHD (%) V_RMS (V)

BUS-MAIN 600 19.78 610.05
BUS-MCC 480 16.87 457.33
BUS-DIST 208 19.19 201.83
7 SIMULATION RESULTS
The harmonic distortion for this system falls within reasonable levels for a predominantly
6 pulse system and corresponds to theoretical expectations for a 6 pulse design.
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Revision 01
Page 14
8 PTW REPORT
Apr 27, 2012 10:24:04 Page 1
------------------------------------------------------------------------------
------------------------------------------------------------------------------
OUTPUT DATA REPORT
COPYRIGHT SKM SYSTEMS ANALYSIS, INC. 1995-2009
------------------------------------------------------------------------------
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Revision 01
Page 15
Apr 27, 2012 10:24:04 Page 2
⁄ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒø
≥ S T U D Y C R I T E R I A ≥
¿ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒŸ
Studies Selected To Run:

Load Flow: Yes
Frequency Scan: Yes
Harmonic Distortion: Yes
Load Flow Study Setup Options

Utility Impedance: Yes
Transformer Phase Shift: Yes
Solution Method: Exact
Load Specification: Connected Load
Generation Acceleration Factor: 1.00
Load Acceleration Factor: 1.00
Bus Voltage Drop: 5.00
Branch Voltage Drop: 3.00
HI_WAVE Study Setup Options

Fundamental Frequency: 60 Hz
Max. Harmonic Order: 50
Include Triplet Harmonics Path (Static Load): No
Include Triplet Harmonics Path (Ind. Motor): No
Modify Motor Z by Load Factor (Ind. Motor): Yes
Modify Load Z by Load Factor (Static Load): Yes
HI_WAVE Study Setup Options for Frequency Scan

Scan Impedance Option: Scan Self Impedance
Use Positive Sequence Network: Yes
Use Negative Sequence Network: Yes
Use Zero Sequence Network: No
Model Transformer Tap: Yes
Model Transformer Phase Shift: Yes
Report Bus Equivalent Impedance: No
Number of Scan Steps Per Order: 1
HI_WAVE Study Setup Options for Distortion

Use Positive Sequence Network: Yes
Use Negative Sequence Network: Yes
Use Zero Sequence Network: Yes
Model Transformer Tap: Yes
Model Transformer Phase Shift: Yes
Fundamental Solution: Use Load Flow Result
Report Option: All Distortions and Violations
Current Limits: Selected PCC, Based on 1996 Std Current Distortion Limit Table 3.2
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Revision 01
Page 16
Apr 27, 2012 10:24:04 Page 3
⁄ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒø
≥ LOADS AND MOTORS WITH HARMONIC SOURCE MODELS ≥
∆ÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕμ
≥ Bus Name ≥ Voltage ≥ Component Name ≥ LF Current≥ Harmonic Library ≥
√ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¥
≥BUS-0060 ≥ 600≥ LOAD1 ≥ 2196.5≥ NOV Drillforce Incomer/Rectifier ≥
≥BUS-0061 ≥ 600≥ LOAD2 ≥ 2196.5≥ NOV Drillforce Incomer/Rectifier ≥
¿ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒŸ
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Revision 01
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Apr 27, 2012 10:24:04 Page 4
⁄ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒø
≥ HARMONIC SOURCE ≥
∆ÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕμ
≥ NOV Drillforce Incomer/Rect≥
√ƒƒƒƒƒƒ¬ƒƒƒƒƒƒƒƒƒƒ¬ƒƒƒƒƒƒƒƒƒƒ¥
≥ Order≥ Magnitude≥ Angle ≥
≥ ≥ (%)≥ (Degrees)≥
√ƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒ¥
≥ 1 ≥ 100.000≥ 0.00≥
≥ 5 ≥ 29.400≥ 0.00≥
≥ 7 ≥ 8.600≥ 0.00≥
≥ 11 ≥ 5.000≥ 0.00≥
≥ 13 ≥ 3.300≥ 0.00≥
≥ 17 ≥ 1.600≥ 0.00≥
≥ 19 ≥ 1.500≥ 0.00≥
≥ 23 ≥ 0.900≥ 0.00≥
≥ 25 ≥ 0.700≥ 0.00≥
≥ 29 ≥ 0.600≥ 0.00≥
≥ 31 ≥ 0.500≥ 0.00≥
≥ 35 ≥ 0.400≥ 0.00≥
≥ 37 ≥ 0.400≥ 0.00≥
≥ 41 ≥ 0.300≥ 0.00≥
≥ 43 ≥ 0.300≥ 0.00≥
≥ 47 ≥ 0.200≥ 0.00≥
≥ 49 ≥ 0.200≥ 0.00≥
¿ƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒŸ
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⁄ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒø
≥ H A R M O N I C S O U R C E I N D E X T A B L E ≥
∆ÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕμ
≥ HARMONIC SOURCES HAVE BEEN FOUND AND INJECTED FOR EACH OF ≥
≥ THE FOLLOWING HARMONIC ORDERS ≥
√ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¥
≥ 5 7 11 13 17 19 23 25 29 31 35 37 ≥
≥ 41 43 47 49 ≥
¿ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒŸ
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⁄ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒø
≥ P A S S I V E F I L T E R D A T A ≥
∆ÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕ—ÕÕÕ—ÕÕÕÀÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕμ
≥ Filter ≥ Bus ≥ Bus ≥ Rated ≥Connect≥ Filter ≥Capacitor≥Tuned≥ ≥ ∫ R ≥ L ≥ C ≥
≥ Name ≥ Name ≥ Voltage ≥ Voltage ≥ ≥ Type ≥ KVAR ≥Order≥ Q ≥ M ∫ (Í) ≥ (H) ≥ (ÊF) ≥
√ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒ≈ƒƒƒ≈ƒƒƒ◊ƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒ¥
≥ NO FILTER ≥ ≥ ≥ ≥ ≥ ≥ ≥ ≥ ≥ ∫ ≥ ≥ ≥
¿ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒ¡ƒƒƒ¡ƒƒƒ–ƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒŸ
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⁄ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒø
≥ U L T I L I T Y , G E N E R A T O R A N D M O T O R D A T A ≥
∆ÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÀÕÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕÕÕμ
≥ Component ≥ Component ≥ Bus ≥ Bus ≥ Base ≥ Base ∫ R1(pu) ≥ X1(pu) ≥
≥ Name ≥ Type ≥ Name ≥ Voltage ≥ Voltage ≥ KVA ∫ R2 ≥ X2 ≥
≥ ≥ ≥ ≥ ≥ ≥ ∫ R0 ≥ X0 ≥
√ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒ◊ƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒƒ¥
≥GEN1 ≥SYNCH GENERATOR≥BUS-GEN1STABS ≥ 600≥ 600≥ 0∫ 0.4023≥ 10.1143≥
≥ ≥ ≥ ≥ ≥ ≥ ∫ 0.4023≥ 10.1143≥
≥ ≥ ≥ ≥ ≥ ≥ ∫500000000.00≥500000000.00≥
≥GEN2 ≥SYNCH GENERATOR≥BUS-GEN2STAB ≥ 600≥ 600≥ 0∫ 0.4023≥ 10.1143≥
≥ ≥ ≥ ≥ ≥ ≥ ∫ 0.4023≥ 10.1143≥
≥ ≥ ≥ ≥ ≥ ≥ ∫500000000.00≥500000000.00≥
≥GEN3 ≥SYNCH GENERATOR≥BUS-GEN3STAB ≥ 600≥ 600≥ 0∫ 0.4023≥ 10.1143≥
≥ ≥ ≥ ≥ ≥ ≥ ∫ 0.4023≥ 10.1143≥
≥ ≥ ≥ ≥ ≥ ≥ ∫500000000.00≥500000000.00≥
≥GEN4 ≥SYNCH GENERATOR≥BUS-GEN3STAB0 ≥ 600≥ 600≥ 0∫ 0.4023≥ 10.1143≥
≥ ≥ ≥ ≥ ≥ ≥ ∫ 0.4023≥ 10.1143≥
≥ ≥ ≥ ≥ ≥ ≥ ∫500000000.00≥500000000.00≥
¿ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒ–ƒƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒƒƒŸ
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⁄ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒø
≥ T O T A L V O L T A G E D I S T O R T I O N ≥
∆ÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕÕÕÕÕμ
≥ Bus Name ≥ Voltage ≥ V_RMS(V) ≥ V_TIF ≥ V_THD(%) ≥ IEEE-519 ≥
√ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¥
≥BUS-0019 ≥ 600≥ 608.24≥ 508.1928≥ 19.7270 ≥ ≥
≥BUS-0020 ≥ 480≥ 459.38≥ 439.7352≥ 16.9849 ≥ ≥
≥BUS-0021 ≥ 600≥ 607.48≥ 511.5195≥ 19.8567 ≥ ≥
≥BUS-0041 ≥ 600≥ 609.78≥ 511.7813≥ 19.8729 ≥ ≥
≥BUS-0042 ≥ 600≥ 609.78≥ 511.7813≥ 19.8729 ≥ ≥
≥BUS-0060 ≥ 600≥ 609.61≥ 513.6042≥ 19.9466 ≥ ≥
≥BUS-0061 ≥ 600≥ 609.61≥ 513.6042≥ 19.9466 ≥ ≥
≥BUS-DIST ≥ 208≥ 201.83≥ 493.8905≥ 19.1887>≥ 5.0≥
≥BUS-GEN1STABS ≥ 600≥ 611.31≥ 502.6601≥ 19.5040 ≥ ≥
≥BUS-GEN2STAB ≥ 600≥ 611.31≥ 502.6601≥ 19.5040 ≥ ≥
≥BUS-GEN3STAB ≥ 600≥ 611.31≥ 502.6601≥ 19.5040 ≥ ≥
≥BUS-GEN3STAB0 ≥ 600≥ 611.31≥ 502.6601≥ 19.5040 ≥ ≥
≥BUS-MAIN ≥ 600≥ 610.05≥ 509.6085≥ 19.7848>≥ 5.0≥
≥BUS-MCC ≥ 480≥ 457.33≥ 436.8825≥ 16.8708>≥ 5.0≥
≥BUS-XFMR2PRI ≥ 600≥ 609.75≥ 509.7494≥ 19.7901 ≥ ≥
≥BUS-XFMR2SEC ≥ 208≥ 202.14≥ 493.6947≥ 19.1833 ≥ ≥
¿ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒƒƒƒƒŸ
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⁄ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒø
≥ V O L T A G E D I S T O R T I O N S U M M A R Y ≥
∆ÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕÕÕÕÕμ
≥ Bus Name ≥ Voltage ≥ V_RMS(V) ≥ V_TIF ≥ V_THD(%) ≥ IEEE-519 ≥
√ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¥
≥BUS-DIST ≥ 208≥ 201.83≥ 493.8905≥ 19.1887>≥ 5.0≥
≥BUS-MAIN ≥ 600≥ 610.05≥ 509.6085≥ 19.7848>≥ 5.0≥
≥BUS-MCC ≥ 480≥ 457.33≥ 436.8825≥ 16.8708>≥ 5.0≥
¿ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒƒƒƒƒŸ
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⁄ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒø
≥ T O T A L C U R R E N T D I S T O R T I O N ≥
∆ÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕ—ÕÕÕÕÕÕÕÕÕÕμ
≥ Deicve Name ≥ Bus Name ≥ Voltage ≥ I_RMS(A) ≥ kWLoss ≥ kVARLoss ≥ IT ≥ K ≥ I_THD(%) ≥ IEEE-519 ≥
≥ ≥ From/To ≥ From/To ≥ ≥ Tot/Harm ≥ Tot/Harm ≥ ≥ ≥ ≥ ≥
√ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒ¥
≥GEN1 ≥BUS-GEN1STABS ≥ 600≥ 1432.47≥ 0.833≥ 60.163≥ 248425.72≥ 2.63≥ 22.62 ≥ ≥
≥ ≥ ≥ 600≥ ≥ 0.833≥ 60.163≥ ≥ ≥ ≥ ≥
≥GEN2 ≥BUS-GEN2STAB ≥ 600≥ 1432.47≥ 0.833≥ 60.163≥ 248425.72≥ 2.63≥ 22.62 ≥ ≥
≥ ≥ ≥ 600≥ ≥ 0.833≥ 60.163≥ ≥ ≥ ≥ ≥
≥GEN3 ≥BUS-GEN3STAB ≥ 600≥ 1432.47≥ 0.833≥ 60.163≥ 248425.72≥ 2.63≥ 22.62 ≥ ≥
≥ ≥ ≥ 600≥ ≥ 0.833≥ 60.163≥ ≥ ≥ ≥ ≥
≥GEN4 ≥BUS-GEN3STAB0 ≥ 600≥ 1432.47≥ 0.833≥ 60.163≥ 248425.72≥ 2.63≥ 22.62 ≥ ≥
≥ ≥ ≥ 600≥ ≥ 0.833≥ 60.163≥ ≥ ≥ ≥ ≥
≥MCC XFMER ≥BUS-0019 ≥ 600≥ 1029.47≥ 11.457≥ 67.809≥ 81688.63≥ 1.34≥ 10.14 ≥ ≥
≥ ≥BUS-0020 ≥ 480≥ ≥ 0.222≥ 3.641≥ ≥ ≥ ≥ ≥
≥CBL-MCC XFMR ≥BUS-0020 ≥ 480≥ 1286.84≥ 2.991≥ 3.300≥ 102110.77≥ 1.34≥ 10.14>≥ 8.0≥
≥ ≥BUS-MCC ≥ 480≥ ≥ 0.053≥ 0.177≥ ≥ ≥ ≥ ≥
≥REACTOR-INC/REC1≥BUS-0041 ≥ 600≥ 2301.77≥ 0.572≥ 1.245≥ 541169.19≥ 3.99≥ 31.33 ≥ ≥
≥ ≥BUS-0060 ≥ 600≥ ≥ 0.051≥ 0.437≥ ≥ ≥ ≥ ≥
≥REACTOR-INC/REC2≥BUS-0042 ≥ 600≥ 2301.77≥ 0.572≥ 1.245≥ 541169.19≥ 3.99≥ 31.33 ≥ ≥
≥ ≥BUS-0061 ≥ 600≥ ≥ 0.051≥ 0.437≥ ≥ ≥ ≥ ≥
≥CBL-GEN1 ≥BUS-GEN1STABS ≥ 600≥ 1432.47≥ 3.052≥ 3.204≥ 248425.72≥ 2.63≥ 22.62>≥ 8.0≥
≥ ≥BUS-MAIN ≥ 600≥ ≥ 0.231≥ 0.705≥ ≥ ≥ ≥ ≥
≥CBL-GEN2 ≥BUS-GEN2STAB ≥ 600≥ 1432.47≥ 3.052≥ 3.204≥ 248425.72≥ 2.63≥ 22.62>≥ 8.0≥
≥ ≥BUS-MAIN ≥ 600≥ ≥ 0.231≥ 0.705≥ ≥ ≥ ≥ ≥
≥ ≥BUS-MAIN ≥ 600≥ ≥ 0.231≥ 0.705≥ ≥ ≥ ≥ ≥
≥CBL-GEN4 ≥BUS-GEN3STAB0 ≥ 600≥ 1432.47≥ 3.052≥ 3.204≥ 248425.72≥ 2.63≥ 22.62>≥ 8.0≥
≥ ≥BUS-MAIN ≥ 600≥ ≥ 0.231≥ 0.705≥ ≥ ≥ ≥ ≥
≥CBL-FB02 ≥BUS-MAIN ≥ 600≥ 1029.47≥ 2.311≥ 2.128≥ 81688.63≥ 1.34≥ 10.14 ≥ 12.0≥
≥ ≥BUS-0019 ≥ 600≥ ≥ 0.037≥ 0.114≥ ≥ ≥ ≥ ≥
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≥ T O T A L C U R R E N T D I S T O R T I O N ≥
≥CBL-DSW ≥BUS-MAIN ≥ 600≥ 60.16≥ 0.326≥ 0.017≥ 2608.04≥ 1.10≥ 5.38 ≥ 20.0≥
≥ ≥BUS-0021 ≥ 600≥ ≥ 0.001≥ 0.000≥ ≥ ≥ ≥ ≥
≥CBL-CBINC1 ≥BUS-MAIN ≥ 600≥ 2301.77≥ 1.420≥ 1.428≥ 541169.19≥ 3.99≥ 31.33>≥ 8.0≥
≥ ≥BUS-0041 ≥ 600≥ ≥ 0.374≥ 0.502≥ ≥ ≥ ≥ ≥
≥CBL-CB INC2 ≥BUS-MAIN ≥ 600≥ 2301.77≥ 1.420≥ 1.428≥ 541169.19≥ 3.99≥ 31.33>≥ 8.0≥
≥ ≥BUS-0042 ≥ 600≥ ≥ 0.374≥ 0.502≥ ≥ ≥ ≥ ≥
≥CBL-FB01 ≥BUS-MAIN ≥ 600≥ 113.73≥ 0.062≥ 0.017≥ 4380.75≥ 1.08≥ 4.79 ≥ 15.0≥
≥ ≥BUS-XFMR2PRI ≥ 600≥ ≥ 0.000≥ 0.000≥ ≥ ≥ ≥ ≥
≥DIST XFMER ≥BUS-XFMR2PRI ≥ 600≥ 113.73≥ 1.755≥ 6.010≥ 4380.75≥ 1.08≥ 4.79 ≥ ≥
≥ ≥BUS-XFMR2SEC ≥ 208≥ ≥ 0.008≥ 0.076≥ ≥ ≥ ≥ ≥
≥CBL- DIST XFMR ≥BUS-XFMR2SEC ≥ 208≥ 328.07≥ 0.160≥ 0.084≥ 12636.77≥ 1.08≥ 4.79 ≥ 5.0≥
≥ ≥BUS-DIST ≥ 208≥ ≥ 0.001≥ 0.001≥ ≥ ≥ ≥ ≥
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⁄ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒø
≥ T O T A L S Y S T E M P O W E R L O S S E S ≥
≥ Harmonic Losses Total RMS Losses ≥
≥ P(kW) Q{kVAR) P(kW) Q(kVAR) ≥
≥ 61.91 254.92 95.07 343.74 ≥
¿ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒŸ
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≥ C U R R E N T D I S T O R T I O N S U M M A R Y ≥
≥CBL-MCC XFMR ≥BUS-0020 ≥ 480≥ 1286.84≥ 2.991≥ 3.300≥ 102110.77≥ 1.34≥ 10.14>≥ 8.0≥
≥ ≥BUS-MCC ≥ 480≥ ≥ 0.053≥ 0.177≥ ≥ ≥ ≥ ≥
≥CBL-GEN1 ≥BUS-GEN1STABS ≥ 600≥ 1432.47≥ 3.052≥ 3.204≥ 248425.72≥ 2.63≥ 22.62>≥ 8.0≥
≥ ≥BUS-MAIN ≥ 600≥ ≥ 0.231≥ 0.705≥ ≥ ≥ ≥ ≥
≥ ≥BUS-MAIN ≥ 600≥ ≥ 0.231≥ 0.705≥ ≥ ≥ ≥ ≥
≥ ≥BUS-MAIN ≥ 600≥ ≥ 0.231≥ 0.705≥ ≥ ≥ ≥ ≥
≥CBL-GEN4 ≥BUS-GEN3STAB0 ≥ 600≥ 1432.47≥ 3.052≥ 3.204≥ 248425.72≥ 2.63≥ 22.62>≥ 8.0≥
≥ ≥BUS-MAIN ≥ 600≥ ≥ 0.231≥ 0.705≥ ≥ ≥ ≥ ≥
≥CBL-CBINC1 ≥BUS-MAIN ≥ 600≥ 2301.77≥ 1.420≥ 1.428≥ 541169.19≥ 3.99≥ 31.33>≥ 8.0≥
≥ ≥BUS-0041 ≥ 600≥ ≥ 0.374≥ 0.502≥ ≥ ≥ ≥ ≥
≥CBL-CB INC2 ≥BUS-MAIN ≥ 600≥ 2301.77≥ 1.420≥ 1.428≥ 541169.19≥ 3.99≥ 31.33>≥ 8.0≥
≥ ≥BUS-0042 ≥ 600≥ ≥ 0.374≥ 0.502≥ ≥ ≥ ≥ ≥
¿ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒŸ
⁄ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒø
≥ T O T A L S Y S T E M P O W E R L O S S E S ≥
≥ Harmonic Losses Total RMS Losses ≥
≥ P(kW) Q{kVAR) P(kW) Q(kVAR) ≥
≥ 61.91 254.92 95.07 343.74 ≥
¿ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒŸ
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⁄ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒø
≥ HARMONIC VOLTAGE SPECTRUM REPORT ≥
∆ÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕÕμ
≥ Bus: BUS-DIST (208V) ≥
√ƒƒƒƒƒƒƒƒƒƒ¬ƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¬ƒƒƒƒƒƒƒƒƒ¬ƒƒƒƒƒƒƒƒƒƒ¬ƒƒƒƒƒƒƒƒƒƒ¥
≥ Harmonic ≥ Harmonic ≥ Phase ≥Distortion≥ IEEE-519 ≥
≥ Order ≥ Voltages ≥ Angle ≥ Percent≥ Limit ≥
√ƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒ≈ƒƒƒƒƒƒƒƒƒƒ¥
≥ 1 ≥ 198.210≥ -31.76≥ ≥ ≥
≥ 5 ≥ 30.419≥ 70.40≥ 15.347≥> 3.000≥
≥ 7 ≥ 12.436≥ -80.31≥ 6.274≥> 3.000≥
≥ 11 ≥ 11.350≥ 157.84≥ 5.726≥> 3.000≥
≥ 13 ≥ 8.851≥ 6.83≥ 4.466≥> 3.000≥
≥ 17 ≥ 5.611≥ -115.27≥ 2.831≥ 3.000≥
≥ 19 ≥ 5.879≥ 93.65≥ 2.966≥ 3.000≥
≥ 23 ≥ 4.270≥ -28.55≥ 2.154≥ 3.000≥
≥ 25 ≥ 3.610≥ -179.65≥ 1.821≥ 3.000≥
≥ 29 ≥ 3.589≥ 58.13≥ 1.811≥ 3.000≥
≥ 31 ≥ 3.197≥ -92.98≥ 1.613≥ 3.000≥
≥ 35 ≥ 2.888≥ 144.79≥ 1.457≥ 3.000≥
≥ 37 ≥ 3.053≥ -6.33≥ 1.540≥ 3.000≥
≥ 41 ≥ 2.537≥ -128.57≥ 1.280≥ 3.000≥
≥ 43 ≥ 2.661≥ 80.31≥ 1.342≥ 3.000≥
≥ 47 ≥ 1.939≥ -41.94≥ 0.978≥ 3.000≥
≥ 49 ≥ 2.021≥ 166.94≥ 1.020≥ 3.000≥
√ƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒ¡ƒƒƒƒƒƒƒƒƒƒ¥
≥ Voltage: 208.0 V_RMS: 201.83 V_THD(%): 19.19 >≥
≥ IEEE-519 LIMIT (THD%): 5.0 ≥
¿ƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒƒŸ
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≥ Bus: BUS-MAIN (600V) ≥
≥ 1 ≥ 598.447≥ 0.01≥ ≥ ≥
≥ 5 ≥ 94.621≥ 40.97≥ 15.811≥> 3.000≥
≥ 7 ≥ 38.740≥ -49.94≥ 6.473≥> 3.000≥
≥ 11 ≥ 35.388≥ 128.00≥ 5.913≥> 3.000≥
≥ 13 ≥ 27.601≥ 36.92≥ 4.612≥> 3.000≥
≥ 17 ≥ 17.500≥ -145.27≥ 2.924≥ 3.000≥
≥ 19 ≥ 18.336≥ 123.62≥ 3.064≥> 3.000≥
≥ 23 ≥ 13.317≥ -58.62≥ 2.225≥ 3.000≥
≥ 25 ≥ 11.259≥ -149.74≥ 1.881≥ 3.000≥
≥ 29 ≥ 11.194≥ 28.01≥ 1.871≥ 3.000≥
≥ 31 ≥ 9.972≥ -63.12≥ 1.666≥ 3.000≥
≥ 35 ≥ 9.007≥ 114.63≥ 1.505≥ 3.000≥
≥ 37 ≥ 9.521≥ 23.51≥ 1.591≥ 3.000≥
≥ 41 ≥ 7.913≥ -158.75≥ 1.322≥ 3.000≥
≥ 43 ≥ 8.299≥ 110.13≥ 1.387≥ 3.000≥
≥ 47 ≥ 6.047≥ -72.13≥ 1.011≥ 3.000≥
≥ 49 ≥ 6.305≥ -163.26≥ 1.054≥ 3.000≥
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≥ Bus: BUS-MCC (480V) ≥
≥ 1 ≥ 450.959≥ -1.97≥ ≥ ≥
≥ 5 ≥ 60.796≥ 41.69≥ 13.481≥> 3.000≥
≥ 7 ≥ 24.894≥ -49.31≥ 5.520≥> 3.000≥
≥ 11 ≥ 22.742≥ 128.55≥ 5.043≥> 3.000≥
≥ 13 ≥ 17.738≥ 37.45≥ 3.933≥> 3.000≥
≥ 17 ≥ 11.247≥ -144.78≥ 2.494≥ 3.000≥
≥ 19 ≥ 11.784≥ 124.11≥ 2.613≥ 3.000≥
≥ 23 ≥ 8.559≥ -58.13≥ 1.898≥ 3.000≥
≥ 25 ≥ 7.236≥ -149.25≥ 1.605≥ 3.000≥
≥ 29 ≥ 7.194≥ 28.50≥ 1.595≥ 3.000≥
≥ 31 ≥ 6.409≥ -62.63≥ 1.421≥ 3.000≥
≥ 35 ≥ 5.789≥ 115.12≥ 1.284≥ 3.000≥
≥ 37 ≥ 6.119≥ 24.00≥ 1.357≥ 3.000≥
≥ 41 ≥ 5.086≥ -158.26≥ 1.128≥ 3.000≥
≥ 43 ≥ 5.334≥ 110.62≥ 1.183≥ 3.000≥
≥ 47 ≥ 3.887≥ -71.64≥ 0.862≥ 3.000≥
≥ 49 ≥ 4.052≥ -162.76≥ 0.899≥ 3.000≥
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9 APPENDIX: DRAWINGS

GEN2
GEN1 GEN3 GEN4
1750 kVA Gen
1750 kVA Gen 1452 kVA 1750 kVA Gen 1750 kVA Gen
1452 kVA 1452 kVA 1452 kVA

1397 Amps 1397 Amps 1397 Amps 1397 Amps
65% of Rated 65% of Rated 65% of Rated 65% of Rated
0.3% Volt Drop 0.3% Volt Drop 0.3% Volt Drop 0.3% Volt Drop
BUS-MAIN
GEN1 CB GEN2 CB GEN3 CB GEN4 CB LF Voltage 598 V
Volt Drop 0.3 %
FB02
CB-INC1 FB01 FUSE- TD AUX
CB-INC2
CBL-FB02
CBL-FB01 DSW 1024 Amps
114 Amps 72% of Rated
CBL-CBINC1 76% of Rated 0.3% Volt Drop
2197 Amps 0.0% Volt Drop CBL-CB INC2
77% of Rated P CBL-DSW 2197 Amps
0.1% Volt Drop DIST XFMER 60 Amps 77% of Rated
P
S 112.5 kVA Rated 55% of Rated MCC XFMER 0.1% Volt Drop
117.7 kVA 0.4% Volt Drop S 1000.0 kVA Rated
4.2% Volt Drop 1058.6 kVA
CBL- DIST XFMR 5.1% Volt Drop
328 Amps
64% of Rated
0.1% Volt Drop
BUS-DIST
LF Voltage 198 V
LIGHTING PANEL Volt Drop 4.7 % CBL-MCC XFMR FUSE- INC/REC 2
FUSE- INC/REC 1 TOP DRIVE AUX 1280 Amps
328 A 60 A 77% of Rated
0.80x FL 0.80x FL 0.4% Volt Drop
BUS-MCC
LF Voltage 451 V
Volt Drop 6.1 %
DSW-1
DSW-2
REST OF MCC A
LOAD1
2197 A LOAD2
1.00x FL 1280 A
0.75x FL 2197 A
1.00x FL
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System Load Flow Study
SYSTEM LOAD FLOW STUDY REPORT

REMARKS purposes only and remains the property of National Oilwell Varco.
Reproduction, in whole or in part; or use of this design or Suite # 200
10621765-REP 02
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REVISION HISTORY

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TABLE OF CONTENTS
1 GENERAL......................................................................................................................... 4
1.1 Purpose .................................................................................................................. 4
1.2 Scope ..................................................................................................................... 4
1.3 Responsibility ......................................................................................................... 4
2 INTRODUCTION ............................................................................................................... 5
3 SINGLE LINE DIAGRAM.................................................................................................. 6
4 INPUT DATA .................................................................................................................... 6
4.2 Transformer Input Data........................................................................................... 6
4.3 Motor Input Data and Load Schedule ..................................................................... 7
5 STUDY CRITERIA ............................................................................................................ 7
6 LOAD FLOW SIMULATION RESULTS............................................................................ 8
6.1 Load Flow Under Normal Operation ....................................................................... 8
7 CONCLUSIONS ................................................................................................................ 9
8 PTW REPORT ................................................................................................................ 10
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1 GENERAL
1.1 Purpose
The purpose of this document is to provide load flow information for the electrical power
system.
1.2 Scope
The Scope of this study covers the loads on the power system during normal operating
conditions.
1.3 Responsibility

Commissioning Team.
Document Control.
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2 INTRODUCTION
The purpose of these load flow simulations is to verify switchgear design and voltage drops
throughout the power distribution network. In performing this study, the system model is
loaded so that maximum kVA is drawn from the rig generators. Load schedules for
consumers are provided in the following sections. Voltage drops are calculated for system
distribution buses assuming there is nominal cable impedance. These represent the worst
case voltages for rig operations so that rig installation and commissioning may use the
projected voltage drops and adjust transformer taps or cable cross sections according to
the results in this report.
SKM, Power Tools for Windows (PTW), was used to perform the load flow simulations.
Details regarding the mathematical algorithm utilized for the simulation may be found in the
SKM complete reports provided at the end of this document.
BUS-MCC A 480V MCC A Bus
BUS-MCC B 480V MCC B Bus
BUS-DRILLING Drilling Bus
Ik” Initial symmetrical short circuit current (rms)
Ik Steady-state short circuit current (rms)
ip Peak short circuit current
Ib Symmetrical short circuit breaking current (rms) voltage
rms Root Mean Square
ms Millisecond
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3 SINGLE LINE DIAGRAM
4 INPUT DATA

input data.

Component
GEN1 1750 1225 600 0.1770 0.146 0.012 2.112 0.314
GEN2 1750 1225 600 0.1770 0.146 0.012 2.112 0.314
GEN3 1750 1225 600 0.1770 0.146 0.012 2.112 0.314
GEN4 1750 1225 600 0.1770 0.146 0.012 2.112 0.314
data.
Pri Sec
Type (kVA) (%) (%) (%)
(V) (V)
MCCB XFMER Delta/Delta 1000 600 480 5.7112 0.99 5.66 5.75
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4.3 Motor Input Data and Load Schedule
each respectively. Detailed information about these equivalent motors can be found in the
full PTW report. Non-linear loads, e.g. SCRs and VFDs are all modelled as general, non-
motor, constant KVA loads. The load schedules are shown in the Table 4-3
TABLE 4-3 LOAD SCHEDULE

CONNECTED LOAD UTILIZATION
BUS LOAD NAME VOLTAGE LOAD [KVA] FACTOR [KVA]
BUS-MAIN TOP DRIVE 600 956 80% 764
BUS-MAIN RT 600 497.3 60% 298.38
BUS-MAIN DWB 600 1429.8 10% 142.98
BUS-MAIN DWA 600 1429.8 10% 142.98
BUS-MAIN MP1 600 1332.1 80% 1065.68
BUS-MAIN MP2 600 1332.1 80% 1065.68
BUS-MAIN MP3 600 1332.1 80% 1065.68
BUS-DIST DIST LOAD 208 112.5 80% 90
BUS-MCC A MCC A LOAD 480 1000 75% 750
5 STUDY CRITERIA
For the load flow study, 100% kVA demand on the generators was calculated, and
utilization factors were adjusted on the consumers for simulation purposes. According to
the input data, maximum generator output is 7 MVA.
Voltage regulation is controlled based on measurements taken at the line side of the
breaker, so internal generator impedance is ignored for voltage drop calculations. Hence,
the 600V main bus will show a drop of approximately 0%, and all voltage drops throughout
the system are then with respect to the main bus. The PTW test criteria selected was 5%
for a bus voltage drop and 3% for a branch voltage drop. These values are arbitrarily
assigned since there is no project specification for a pass/fail.
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6 LOAD FLOW SIMULATION RESULTS

The following section contains the simulation results for the report. The same results can
be found graphically in the single line diagram of APPENDIX A.
6.1 Load Flow Under Normal Operation

The following report is generated for the case in which all Circuit Breakers and Feeder
Breakers are closed.
SWING GENERATOR
Source In/Out Service kW kVAR VD%
GEN1 In 1225 1249.8 0.00
GEN2 In 1225 1249.8 0.00
GEN3 In 1225 1249.8 0.00
GEN4 In 1225 1249.8 0.00
GEN5 In 1225 1249.8 0.00
BUSES
Bus Name In/Out Design LF Volts VD%
Service Volts
BUS-MAIN In 600 598.55 0.24
BUS-MCC A In 480 460.14 4.14
BUS-DIST In 208 200.17 3.76
BRANCH CURRENTS
Branch Name In/Out Service Amps Rating VD%
CBL-DSW In 48.01 50.01 0.35
CBL-CBINC1 In 2196.50 87.16 0.06
CBL-CBINC2 In 2196.50 87.16 0.06
CBL-GEN1 In 1321.30 69.91 0.24
CBL-GEN2 In 1321.30 69.91 0.24
CBL-GEN3 In 1321.30 69.91 0.24
CBL-GEN4 In 1321.30 69.91 0.24
CBL-DIST XFMR In 259.58 57.05 0.12
CBL-MCC XFMR In 944.68 64.62 0.30
CBL-FB01 In 89.99 59.99 0.04
CBL-FB02 In 755.75 59.98 0.21
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7 CONCLUSIONS
This report has adequately analyzed the power system load flow for normal operation.
Voltage drops at each bus are in agreement with transformer impedances according to load
current, although they fall outside of the selected voltage drop criteria for the PTW
simulation. As stated previously, the bus voltage test criteria was arbitrarily assigned, and
it is important to bear in mind that reported voltage drops are simply a function of the loop
impedance and load current, and this study accurately reports this relationship. Given the
reported voltage drops, the system designers can use the predicted voltage drop
information in this report with actual installation details about cable lengths and cross
section to determine approximate terminal voltages of the rig equipment. Finally, the
ampacity levels on each piece of equipment indicate they are within their rated capacity,
and that generation of the rig is sufficient to supply a typical drilling program.
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8 PTW REPORT
Apr 26, 2012 09:22:18
------------------------------------------------------------------------------
------------------------------------------------------------------------------
LOAD FLOW AND VOLTAGE DROP ANALYSIS REPORT
COPYRIGHT SKM SYSTEMS ANALYSIS, INC. 1995-2009
------------------------------------------------------------------------------
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*** SOLUTION COMMENTS ***

=========================
SOLUTION PARAMETERS
BRANCH VOLTAGE CRITERIA : 3.00 %

BUS VOLTAGE CRITERIA : 5.00 %
ACCELERATION FACTOR FOR 'PV' GENERATORS : 1.00

ACCELERATION FACTOR FOR CONSTANT KVA LOADS: 1.00
EXACT(ITERATIVE) SOLUTION : YES
UTILITY IMPEDANCE : NO
TRANSFORMER PHASE SHIFT : NO
ALL PU VALUES ARE EXPRESSED ON A 100 MVA BASE
LOAD FLOW IS BASED ON DIRECTLY CONNECTED LOADS.

AND WITH APPLIED FIRST LEVEL DEMAND OR LOAD FACTORS.
LOAD ANALYSIS INCLUDES ALL LOADS.
<<PERCENT VOLTAGE DROPS ARE BASED ON NOMINAL DESIGN VOLTAGES>>
SWING GENERATORS
SOURCE NAME VOLTAGE ANGLE
================================
GEN1 1.000 0.00
GEN2 1.000 0.00
GEN3 1.000 0.00
GEN4 1.000 0.00
LARGEST LOAD: 2282.67 KVA

CONVERGENCE CRITERIA: 0.114 KVA
LARGEST BUS MISMATCH BUS-MCC 60.809 KVA
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BALANCED VOLTAGE DROP AND LOAD FLOW ANALYSIS (SWING GENERATORS)

*****************************************************************************
SOURCE VOLTAGE ANGLE KW KVAR VD% (UTILITY IMPEDANCE)
GEN1 1.000 0.00 961.24 980.57 Gen Z Ignored

GEN2 1.000 0.00 961.24 980.57 Gen Z Ignored
GEN3 1.000 0.00 961.24 980.57 Gen Z Ignored
GEN4 1.000 0.00 961.24 980.57 Gen Z Ignored
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BALANCED VOLTAGE DROP AND LOAD FLOW ANALYSIS

*****************************************************************************
VOLTAGE EFFECT ON LOADS MODELED
VOLTAGE DROP CRITERIA: BRANCH = 3.00 % BUS = 5.00
==== BUS: BUS-DIST DESIGN VOLTS: 208 BUS VOLTS: 200 %VD: 3.76
========================= PU BUS VOLTAGE: 0.962 ANGLE: -1.4 DEGREES
NET BRANCH DIVERSITY LOAD: 72.0 KW 54.0 KVAR
LOAD FROM: BUS-XFMR2SEC CBL- DIST XFMR FEEDER AMPS: 259.5 VOLTAGE DROP: 0. %VD: 0.12
PROJECTED POWER FLOW: 72.0 KW 54.0 KVAR 90.0 KVA PF:0.80 LAGGING
LOSSES THRU FEEDER: 0.1 KW 0.1 KVAR 0.1 KVA
==== BUS: BUS-MAIN DESIGN VOLTS: 600 BUS VOLTS: 599 %VD: 0.24
========================= PU BUS VOLTAGE: 0.998 ANGLE: 0.0 DEGREES
LOAD FROM: BUS-GEN1STABS CBL-GEN1 FEEDER AMPS:1321.2 VOLTAGE DROP: 1. %VD: 0.24
LOAD FROM: BUS-GEN2STAB CBL-GEN2 FEEDER AMPS:1321.2 VOLTAGE DROP: 1. %VD: 0.24
LOAD FROM: BUS-GEN3STAB CBL-GEN3 FEEDER AMPS:1321.2 VOLTAGE DROP: 1. %VD: 0.24
LOAD TO: BUS-XFMR2PRI CBL-FB01 FEEDER AMPS: 89.9 VOLTAGE DROP: 0. %VD: 0.04
LOAD TO: BUS-0019 CBL-FB02 FEEDER AMPS: 755.7 VOLTAGE DROP: 1. %VD: 0.21
LOAD TO: BUS-0021 CBL-DSW FEEDER AMPS: 48.0 VOLTAGE DROP: 2. %VD: 0.35
LOAD TO: BUS-0041 CBL-CBINC1 FEEDER AMPS:2196.5 VOLTAGE DROP: 0. %VD: 0.06
LOAD TO: BUS-0042 CBL-CB INC2 FEEDER AMPS:2196.5 VOLTAGE DROP: 0. %VD: 0.06
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BALANCED VOLTAGE DROP AND LOAD FLOW ANALYSIS

*****************************************************************************
VOLTAGE EFFECT ON LOADS MODELED
VOLTAGE DROP CRITERIA: BRANCH = 3.00 % BUS = 5.00
LOAD FROM: BUS-GEN3STAB0 CBL-GEN4 FEEDER AMPS:1321.2 VOLTAGE DROP: 1. %VD: 0.24
==== BUS: BUS-MCC DESIGN VOLTS: 480 BUS VOLTS: 458 %VD: 4.51
========================= PU BUS VOLTAGE: 0.955 ANGLE: -1.5 DEGREES
NET BRANCH DIVERSITY LOAD: 525.0 KW 535.6 KVAR
LOAD FROM: BUS-0020 CBL-MCC XFMR FEEDER AMPS: 944.6 VOLTAGE DROP: 1. %VD: 0.30
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BALANCED VOLTAGE DROP AND LOAD FLOW BUS DATA SUMMARY

*****************************************************************************
BUS NAME BASE VOLT PU VOLT BUS NAME BASE VOLT PU VOLT
BUS-0019 600.00 0.9955 BUS-0020 480.00 0.9579
BUS-0021 600.00 0.9941 BUS-0041 600.00 0.9969
BUS-0042 600.00 0.9969 BUS-0060 600.00 0.9965
BUS-0061 600.00 0.9965 BUS-DIST 208.00 0.9624
BUS-GEN1STABS 600.00 1.0000 BUS-GEN2STAB 600.00 1.0000
BUS-GEN3STAB 600.00 1.0000 BUS-GEN3STAB0 600.00 1.0000
BUS-MAIN 600.00 0.9976 BUS-MCC 480.00 0.9549
BUS-XFMR2PRI 600.00 0.9972 BUS-XFMR2SEC 208.00 0.9636
BALANCED VOLTAGE DROP AND LOAD FLOW BRANCH DATA SUMMARY

*****************************************************************************
FROM NAME TO NAME TYPE VD% AMPS KVA RATING%

BUS-0019 BUS-0020 TX2 3.75 755.75 781.82 78.18
BUS-0020 BUS-MCC FDR 0.30 944.68 752.33 64.62
BUS-0041 BUS-0060 FDR 0.04 2196.50 2275.69 99.84
BUS-0042 BUS-0061 FDR 0.04 2196.50 2275.69 99.84
BUS-GEN1STABS BUS-MAIN FDR 0.24 1321.30 1373.13 69.91
BUS-GEN2STAB BUS-MAIN FDR 0.24 1321.30 1373.13 69.91
BUS-GEN3STAB BUS-MAIN FDR 0.24 1321.30 1373.13 69.91
BUS-GEN3STAB0 BUS-MAIN FDR 0.24 1321.30 1373.13 69.91
BUS-MAIN BUS-XFMR2PRI FDR 0.04 89.99 93.29 59.99
BUS-MAIN BUS-0019 FDR 0.21 755.75 783.47 59.98
BUS-MAIN BUS-0021 FDR 0.35 48.01 49.77 50.01
BUS-MAIN BUS-0041 FDR 0.06 2196.50 2277.08 87.16
BUS-MAIN BUS-0042 FDR 0.06 2196.50 2277.08 87.16
BUS-XFMR2PRI BUS-XFMR2SEC TX2 3.36 89.99 93.25 82.89
BUS-XFMR2SEC BUS-DIST FDR 0.12 259.58 90.11 57.05
NOTE: FDR RATING% = % AMPS RATING BASED ON LIBRARY FLA OR BRANCH INPUT FLA
TX2 RATING% = % KVA RATING BASED ON TRANSFORMER FL KVA
16 BUSES
*** T O T A L S Y S T E M L O S S E S ***
24. KW 54. KVAR
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Revision 02
Page 16

GEN2
GEN1 GEN3 GEN4
1750 kVA Gen
1750 kVA Gen 1750 kVA Gen 1750 kVA Gen
1373 kVA
1373 kVA 1373 kVA 1373 kVA

1321 Amps 1321 Amps 1321 Amps 1321 Amps
62% of Rated 62% of Rated 62% of Rated 62% of Rated
0.2% Volt Drop 0.2% Volt Drop 0.2% Volt Drop 0.2% Volt Drop
BUS-MAIN
GEN1 CB GEN2 CB GEN3 CB GEN4 CB
LF Voltage 599 V
Volt Drop 0.2 %
FB02
CB-INC1 FUSE- TD AUX
FB01
CB-INC2
CBL-FB02
CBL-FB01 DSW 756 Amps
90 Amps 53% of Rated
CBL-CBINC1 60% of Rated 0.2% Volt Drop
2197 Amps 0.0% Volt Drop CBL-CB INC2
77% of Rated P CBL-DSW 2197 Amps
0.1% Volt Drop DIST XFMER 48 Amps 77% of Rated
P
S 112.5 kVA Rated 44% of Rated MCC XFMER 0.1% Volt Drop
93.3 kVA 0.3% Volt Drop S 1000.0 kVA Rated
3.4% Volt Drop 781.8 kVA
CBL- DIST XFMR 3.8% Volt Drop
260 Amps
50% of Rated
0.1% Volt Drop
BUS-DIST
LF Voltage 200 V
CBL-MCC XFMR
LIGHTING PANEL Volt Drop 3.8 % FUSE- INC/REC 2
FUSE- INC/REC 1 TOP DRIVE AUX 945 Amps
260 A 48 A 57% of Rated
0.80x FL 0.80x FL 0.3% Volt Drop
BUS-MCC
LF Voltage 458 V
Volt Drop 4.5 %
DSW-1
DSW-2
REST OF MCC A
LOAD1
2197 A LOAD2
945 A
1.00x FL 2197 A
0.75x FL
1.00x FL
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FINAL DOCUMENTATION
Ideal Rig 135
Chapter 7.0
Controls & Instrumentation
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FINAL DOCUMENTATION
Ideal Rig 135
Section 7.1
Amphion
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Amphion Integrated System
FINAL DOCUMENTATION
User Manual
Ideal Rig 135
Customer

Rig/Hull
IR 135 11000 Corporate Centre Drive.
Project Manager
N/A Houston, Texas 77041
Purchase Order Number
USA
GPK1000451
Serial Number Phone: (281) 854-0400
N/A
Project Number
FAX: (281) 854-0607
8375
Document Number Rev
10707386-FDD 03
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Document number 10707386-FDD
Revision 03
Page 2
REVISION HISTORY
03 22.01.2014 Reissued for information VNB KM RM

02 03.12.2013 Reissued for information VNB KM RM
01 03.01.2013 Final Documentation VNB KM RM
CHANGE DESCRIPTION

01 Initial Release
02 Documentation updated; As Commissioned
03 Corrected Rig name
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P.O. Number: GPK1000451 Page: i of ii
Table of Contents
different binders as necessary to adequately document the equipment presented.

Ideal Rig 135
Amphion Integrated System
Chapter 1 Installation, Operation & Maintenance
Operation and Maintenance ........................................................................................... 1.1

Operation & Maintenance
Spare Parts ...................................................................................................................... 1.2

Spares List – Commissioning/ Operating
Chapter 2 Technical Document & Drawing Package
General Drawings ........................................................................................................... 2.1

Assembly Drawing
Interface and Connection Drawing
System Diagram & Specifications ................................................................................. 2.2

Electrical Single Line Diagram
Cause & Effect Chart
Network Topology Diagram
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P.O. Number: GPK1000451 Page: ii of ii
Electrical/Instrument ....................................................................................................... 2.3

Electrical Block Diagram
Electrical Interconnect/ Termination Diagram
Electrical Cable Index
Hazardous Area Equipment Index
Input / Output Map
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FINAL DOCUMENTATION
Amphion Manual
Chapter 1
Installation, Operation &
Maintenance
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FINAL DOCUMENTATION
Amphion Manual
Section 1.1
Operation and Maintenance
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CHAPTER 1 INDEX 1.1
Installation, Operation & Maintenance

8375 Operation & Maintenance
DOCUMENT NUMBER REV
10707840-IDX 02
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1.1 OPERATION & MAINTENANCE
AMPHION OPERATOR’S GUIDE 10869384-MAN 01 N04
AMPHION TOOL CONTROLLER D811001117-MAN-001 02 N04
AMPHION TECHNICAL REF (STD) D811000238-MAN-001 04 N04
SERVICE CENTER DIRECTORY D811001337-DAS-001 04 N04
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Amphion™
Operator’s Guide
Pemex 1381
Pemex 1381(Ideal Rig 135) Amphion Operator’s Guide
This document contains proprietary and confidential

information which is the property of National Oilwell Varco,
L.P., its affiliates or subsidiaries (all collectively referred to
hereinafter as "NOV"). It is loaned for limited purposes only National Oilwell Varco
and remains the property of NOV. Reproduction, in whole or in RIG SOLUTIONS
part, or use of this design or distribution of this information to
others is not permitted without the express written consent of
11000 Corporate Centre Drive
NOV. This document is to be returned to NOV upon request or Houston, TX 77041
upon completion of the use for which it was loaned. This
document and the information contained and represented
herein is the copyrighted property of NOV.
Document Number Rev.
10869384-MAN 01
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Form D811001123-GEN-001/06
10869384-MAN
Revision 01
Revision History
Andrew
Ami Sarah
01 23.10.2013 First Issue Hastings Sobreira
Robinson-
Powell
Change Description
01 First Issue
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10869384-MAN
Revision 01
Page i of x
Table of Contents
Chapter 1: General Information

Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Chapter 2: Amphion Overview

Main Features and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Workstation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Touchscreen Computers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Workstation Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Left Control Panel Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Right Control Panel Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Joysticks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Main Menu Navigation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Alarms and Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Operator Tool Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
(This Tool) Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Back or Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Operator Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Operator Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Keypads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Utility Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Choose Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Choose Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Language Translation Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Add . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Clean Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Service Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Common Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
I/O Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Controller-to-Controller (C2C) Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Cyberbase Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Modbus Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Profibus Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
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Step 7 Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Screen Communication Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Tool Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
HTTP Requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Write Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Exceptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Tool Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Ownership Controls and Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Granting and Releasing Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Tool Controllers and Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Optional Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
RigSense and WITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Simple Data Acquisition (S-DAQ™) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
System 5 Data Acquisition (V-DAQ™) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Electronic Driller System™ (EDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Chapter 3: Alarms and Events

System Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Alarm Message Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Alarm and Event Sort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Alarm Acknowledgment and Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Alarm Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Alarm Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Alarm Sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Chapter 4: Cathead
Operator Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Tool Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Status Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Cathead Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Stream Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Slow Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Defining Tong Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Defining Torque Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Pull Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Cathead Tool Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Chapter 5: Chair (Workstation)

Workstation Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Tool Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Left Panel Switches and Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Ownership Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Joystick Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Chair Status Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
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Deadman Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Encoder Status Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Chair Tool Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Multi-Tool Controller (MTC) Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Emergency Stop (E-Stop) Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Joystick Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Left Joystick (Tugger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Right Joystick (Drawworks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Hookload Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Calibration Status Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Chapter 6: Drawworks
Tripping and Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Tool Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Hook Load Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Fault and Status Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Brake Pressure Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Parking Brake Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Derrick Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Block and Elevator Height Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Defining Block Travel Limit and Stop Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
High Travel Limit and Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Low Travel Limit and Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Defining the Drill Stop Point Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Defining Maximum Block Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Lowering and Hoisting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Defining Hook Load Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Defining Max Pull Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Defining Minimum Pull Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Defining Drag Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Hook Load Limit Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Defining the Drawworks Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Mode Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Max Slow Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Slow Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Slip & Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Drag and Drag limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
% Drag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
BOP Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Standpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Park Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Lowering and Hoisting Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Autodrill Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
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Activating the Electronic Driller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

Activating or De-activating Autodrill Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Defining Parameter Setpoint Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Variable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Auto Reaming Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Pull Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Hoist Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Lower Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Drilling Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Drawworks Tool Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Operator Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Auxiliary Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Drawworks Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Alarm and Fault Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Hook Load and Drum Encoder Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Alarms Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Ambient Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Motor Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Chopper/DBR Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Brake Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Brake Capacity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Capacity Test Status Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Brake Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
Drum and Block Status Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Lube Oil Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Motor/VFD Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
DW Motor/VFD Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Motor Winding Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
On Line Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Calibration Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Block and Elevator Position Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Elevator Position Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Hook Load Tare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
Hook Load Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
Standpipe Tare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
Tool Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
Drum Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
Status Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
Enable or Disable an Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Hook Load Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Status Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Enable or Disable an Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
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Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Alarm Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Abnormal Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Soft Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Category 2 Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
E-Stop (Category 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
Chapter 7: Hydraulic Power Unit (HPU)

Operator Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
HPU Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Fan Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
HPU Tool Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Chapter 8: S-DAQ™
Operator Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Hookload and Weight On Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Standpipe Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
RPM, Torque, and Tong Line Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Mud Pump Displays and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Alarm Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Digital Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
S-DAQ Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Mud Pits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Shaker Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Status Displays and Tank Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Alarm Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Suction Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Status Displays and Tank Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Alarm Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Chapter 9: Mud Pumps

Operator Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Tool Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Mud Pump Status Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Strokes Per Minute (SPM) Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Defining SPM Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Standpipe Pressure Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Defining the Pressure Limit Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Defining Group Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Starting and Pausing Mud Pump Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
IBOP Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
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Stop All Mud Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

Operator Messages and Miscellaneous Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Mud Pumps Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Mud Pumps Tool Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Auxiliary Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Status and Fault Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Manual Motor Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Mud Pump Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Drive Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Pre-Charge and Liner Wash Pump Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Motor Temperature Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Chapter 10: PipeCat™

Operator Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Tool Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Status Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Digital Feedback Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Local Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
PipeCat Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Tool On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
HPU (#1 and #2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Trough Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Trough Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Skate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Piperack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Driller and Off Driller Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Safety Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
HPU Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Radio Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Pipe Rack Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
ESD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Pipe Rack (Off Driller and Driller Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Trough Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Interlock Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
System Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Safety Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Status Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Off/On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
PipeCat Tool Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
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Chapter 11: Power Slips

Operator Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Tool Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Status Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Power Slips Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Auto Greaser Controls and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Power Slips Tool Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Chapter 12: Power System

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Operator Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Screen Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Power System Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Generators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Status Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Ground Fault Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Generator Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Drill Floor Equipment E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
Generator E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
Inverters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
Motor Status Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
Choppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10
Rectifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11
Motor Control Center (MCC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12
Power Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14
Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15
Power Capacity Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16
AC Bus Generator Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16
AC Bus Transformer Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16
System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16
Total Online Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17
DC Rectifier Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17
DC Bus Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17
Power Consumed Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18
DC Bus Consumed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18
AC Bus Consumed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18
Power Available Calculations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19
System Total Power Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19
Tool Power Available (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19
Power Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19
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Chapter 13: Rotary Table

Operator Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Tool Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Speed and Torque Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Slips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Status Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
Direction Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Brake Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Speed and Torque Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Defining the Throttle Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Zero Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Defining the Torque Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Rotary Table Tool Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
Assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
Tool Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
Rotary Table Status Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
Manual Blower Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
Fault Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
Chapter 14: Top Drive System (TDS)

Operator Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Tool Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Status Readings and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
Drill Speed and Torque Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
Status Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
Speed and Torque Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
Defining a Throttle Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
Zero Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
Defining a Drill Torque Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
Defining a Makeup Torque Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5
Defining a Spin Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5
Defining a Spin Torque Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
Direction and Mode Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
Make Up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
Break Out Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
Elevator, Torque Wrench, and IBOP Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8
Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8
Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9
IBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9
Brake Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-10
Link Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11
Link Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11
Link Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11
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Top Drive Tool Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-12

Twister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
Status Readings and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
Drill Speed and Torque Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
Status Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-16
Speed and Torque Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-16
Defining a Twister Throttle Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-16
Zero Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-16
Defining a Twister Torque Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17
Direction and Mode Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17
Twister Mode Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-18
Motor/VFD Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19
TDS Motor Status Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-20
Fault Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-21
Blower Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-21
HPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-22
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-22
Data Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-23
Assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-24
Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-25
Chapter 15: Trip Tank Pumps

Operator Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Pump Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
Trip Tank Pump Tool Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3
Chapter A: Appendix
Network Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Opening a Command Prompt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Command Descriptions and Syntax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Ping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Ping Command Switch Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
IP Config . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Tracert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Nslookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Network Address Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
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General Information 1
This section of the manual contains examples of Amphion

equipment, features, and operator interface screens, and
may or may not represent your particular rig configuration.
Conventions
This manual is intended for use by field engineering, installation, operation, and repair personnel.
Every effort has been made to ensure the accuracy of the information contained herein. National
Oilwell Varco® (NOV) will not be held liable for errors in this material, or for consequences arising
from misuse of this material.
Notes, Cautions, and Warnings

Notes, cautions, and warnings provide readers with additional information, and to advise the
reader to take specific action to protect personnel from potential injury or lethal conditions. They
may also inform the reader of actions necessary to prevent equipment damage. Please pay close
attention to these advisories.
The note symbol indicates that additional information is

provided about the current topics.
!
The caution symbol indicates that potential damage to
equipment or injury to personnel exists. Follow instructions
explicitly. Extreme care should be taken when performing
operations or procedures preceded by this caution symbol.
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The warning symbol indicates a definite risk of

equipment damage or danger to personnel. Failure to
follow safe work procedures could result in serious or
fatal injury to personnel, significant equipment
damage, or extended rig down time.
Illustrations
Illustrations (figures) provide a graphical representation of equipment components or screen
snapshots for use in identifying parts or establishing nomenclature, and may or may not be drawn
to scale.
For component information specific to your rig configuration, see the technical drawings included
with your NOV documentation.
Safety Requirements
Operators should review and follow recommendations in NOV Product Bulletins for additional
information regarding safe operation, maintenance, and inspection criteria.
Failure to follow the recommendations in NOV Product

Bulletins may result in serious or fatal injury to
personnel, significant damage to equipment, and
extended rig downtime.
Reference: See http://www.nov.com/drilling/ for the NOV Product Information Bulletins and
Safety alerts.
NOV equipment is installed and operated in a controlled drilling rig environment involving
hazardous situations. Proper maintenance is important for safe and reliable operation. Procedures
outlined in NOV manuals are the recommended methods of performing operations and
maintenance.
!
To avoid injury to personnel or equipment damage,
carefully observe requirements outlined in this section.
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General Information 1
Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on the
equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool operation,
and maintenance to ensure their safety.
!
Personnel should wear protective gear during installation,
maintenance, and certain operations.
Contact the NOV Drilling Equipment training department for more information about equipment
operation and maintenance training.
Recommended Tools
Service operations may require the use of tools designed specifically for the purpose described.
NOV recommends that only those tools specified be used when stated. Ensure that personnel and
equipment safety are not jeopardized when following service procedures or using tools not
specifically recommended by NOV.
General System Safety Practices

The equipment discussed in this manual may require or contain one or more utilities, such as
electrical, hydraulic, pneumatic, or cooling water.
!
Read and follow the guidelines below before installing
equipment or performing maintenance to avoid
endangering exposed persons or damaging equipment.
 Isolate energy sources before beginning work.

 Avoid performing maintenance or repairs while the equipment is in operation.
 Wear proper protective equipment during equipment installation, maintenance, or
repair.
Replacing Components
 Verify that all components (such as cables, hoses, etc.) are tagged and labeled
during assembly and disassembly of equipment to ensure correct installment.
 Replace failed or damaged components with NOV certified parts. Failure to do so
could result in equipment damage or injury to personnel.
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Routine Maintenance
Equipment must be maintained on a routine basis. See the service manual for maintenance
recommendations.
!
Failure to conduct routine maintenance could result in
equipment damage or injury to personnel.
Proper Use of Equipment

NOV equipment is designed for specific functions and applications, and should be used only for its
intended purpose.
Service Centers
For a directory of NOV Service Centers, see NOV document number D811001337-DAS-001, titled
"Service Center Directory." This document is located in the User Manual.
The link below provides after-hours contact information for emergencies or other equipment issues
requiring an immediate response by NOV service personnel.
http://www.nov.com/ContactUs/24HrEmergencyContacts.aspx
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Amphion Overview 2
This manual contains examples of Amphion equipment,

features, and operator interface screens, and may or may
not represent your particular rig configuration.
Main Features and Equipment

The Amphion system provides operators with control of drilling tools and processes from an
ergonomically-correct workstation. Usually located inside the driller’s cabin, the workstations offer
tool control and status information applicable to the operations being performed.
The LER and multi-tool controller (MTC) cabinets are considered safe areas for installing Amphion
components that carry no hazardous area classifications. Depending on your particular rig’s
configuration, it may contain variations of the following features and equipment:
 One or more operator workstations, equipped with touchscreens
 One or more multi-tool controller (MTC) cabinets
 Integrated operator interface application for National Oilwell Varco (NOV) and third-
party tools, systems, or processes, such as:
Alarm and Event System
Automated Drawworks System
Automated Roughneck
Bridge Racker and Tailing Arm
Casing Running Tool
Chair (Workstation) Diagnostics
Drawworks VFD Assignment Controls
Driller Auxiliaries
Fingerboard
Foxhole
Hydraulic BX Elevators
Hydraulic Cathead
Hydraulic Power Unit
Mud Pump Motor Assignment Controls
Motor Control Center (MCC)
Mud Pumps
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Ownership Overview
Pipe Racking System
Power Management System
Power Slips
Rotary Support Table
Silicon-Controlled Rectifiers (SCR)
Simple Data Acquisition (S-DAQ™) module
System 5 Data Acquisition (V-DAQ™) module
Top Drive System
Top Drive VFD Assignment Controls
Variable Frequency Drive (VFD) System
RigSense™ application, RigSense server
Zone Management System (ZMS)
 Engineering drawings
 Equipment service manuals
 Amphion tool controller service manual
 Amphion operator’s guide
 Amphion technical reference manual
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Amphion Overview 2
Operator Workstation
The workstations are the user's interface to the control network and tools. A Wrap-Around™
workstation is shown here.
Located in the driller’s cabin, each workstation may contain:
 Amphion touchscreens (four shown here)
 Joysticks (one shown here)
 Two discrete switch control panels
 One chair
500 550
400 450 600
350 650
300 700
250 750
200 800
150 850
100 900
TONG SCALE HOOK LOAD
50 X 1000 LB
O
LCD WEIGHT ON BIT 1000
X 1000 LB
Touchscreen Computers
Workstations include self-contained touchscreens that display tool control, drilling operation,
alarm, and status information. The Wrap-Around workstation can accommodate up to four
touchscreens, all with access to tools connected to the network.
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Workstation Control Panels

Joysticks are used for tools that require controlled movement, such as the drawworks or the racker.
See section titled "Joysticks" on page 2-6.
Discrete switch controls are normally dedicated to frequently-used operations (such as opening
and closing the power slips or racker jaws).
While there are many possible combinations of controls and placement of the buttons and discrete
switches, two examples of workstation control panels are presented here. Specific controls and
their placement can vary widely from one rig to the next, depending on the customer’s needs.
Left Control Panel Examples
MUD MUD
PU PU
THRO MP #1 THRO MP #1
TTLE TTLE
MUD MUD
PU
THRO MP #2 PU
THRO MP #2
TTLE TTLE
M M
U U
D D
MUD
P P
PU MUD
THRO MP #3
TTLE
U PU
THRO MP #3 U
M TTLE
M
P
P
S
S
OFF
/AUT
O
ON
OPE
N DRIL
CLO L
SE TILT
TDS
BRA
KE TDS
TDS LINK
FLO FLO
OPE AT AT
N POW OPE
CLO ER S N TDS
SE LIPS CLO LINK
DRIL SE
L OPE
TILT N
OPE CLO
N SE
CLO
SE
TDS TDS
IBOP ELE
VAT
TDS OR
LINK
R AC
TDS KER
ELE JAW
VAT
OR

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Revision Change Description

FINAL DOCUMENTATION PACKAGE

Description Chapter - Section

INTRODUCTION Title Page ........................................................ Front Matter

Overall Rig Drawings and Procedures ........................................................................... 1.0

Drilling Module ................................................................................................................. 2.0

Table of Contents (Continued)

Low Pressure Mud System.............................................................................................. 4.0

High Pressure Mud System ............................................................................................. 5.0

Power System .................................................................................................................. 6.0

Controls & Instrumentation ............................................................................................. 7.0

BOP Control System ........................................................................................................ 8.0

Air System ........................................................................................................................ 9.0

Table of Contents (Continued)

Utility System ................................................................................................................. 10.0

Safety System ................................................................................................................ 11.0

Copyrighted as an unpublished work.

All RIGHTS RESERVED

This manual is not intended as a textbook on mechanics, electronics or hydraulics. Sufficient

Introduction (Front Matter)

Chapter 1.0 thru 11.0 Major Components Detailed

Content and Accuracy of Information

Safety is Very Important

WARNING safety notes MUST be followed carefully. Failure

CAUTION safety notes are also very important and should

Basic Safety Precautions

Operating instructions tend to be general in nature to make

AREA HAZARD SAFEGUARDS

Hydraulic/Pneumatic Hydraulic or pneumatic system Avoid striking or puncture of

Lubrication/Filtration Failure to adequately maintain Institute a complete lubrication

Typical Safety Warnings and Precautions

Always use caution when inspecting equipment. Begin only

All equipment should be shut down, isolated and tagged

Do not wear loose clothing, unbuttoned shirts, shirt sleeves,

Typical Safety Warnings and Precautions (Continued)

DO NOT LEAVE ZERK FITTINGS INSTALLED ON THIS HIGH

Always use lifting equipment, supports and chains with a

Exercise extreme caution when performing maintenance on

Prior to hoisting equipment, ensure that no loose bars, tools

For your own protection, DO NOT USE SUBSTITUTE PARTS

Typical Safety Warnings and Precautions (Continued)

Leaking joints, fittings and connections should only be

When cleaning, use only approved solvents to prevent

The hydraulic tank RETURN connector MUST be connected

Typical Safety Warnings and Precautions (Continued)

Ensure the battery connection is made up to the positive or

DO NOT grip polished area with tongs or any other gripping

Application of Preventive Maintenance

Major Maintenance Types

Major Maintenance Procedure Types

• Maintaining the Rig for Daily Operations:

- Inspect all moorings, outriggers, etc. for rig stability.

- Inspect all work areas, catwalks, etc. (free and passable).

- Check all fluid levels. (day tanks, hydraulic reservoir, etc.)

- Check all batteries for connection corrosion and adequate charge.

- Ensure all controls and instrumentation are in good working order.

- Check and grease fittings and bearings (drawworks, winches, crown

- Check all safety equipment to be present and functional.

Major Maintenance Types (Continued)

Periodic Rig or Equipment Maintenance: