Drive PC tools

User manualDriveSize

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User manual

DriveSize

3AXD00000000073 Rev 1ENEFFECTIVE: 2014-03-03

© 2014 ABB Oy. All Rights Reserved

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Table of contents

Introduction to the manual 9What this chapter contains ................................................................................................. 9Applicability ........................................................................................................................ 9Compatibility ....................................................................................................................... 9Purpose of the manual........................................................................................................ 9Target audience.................................................................................................................. 9Terms and abbreviations .................................................................................................. 10

Overview of DriveSize 11What this chapter contains ............................................................................................... 11DriveSize installation instructions ..................................................................................... 11Program structure ............................................................................................................. 11DriveSize functions ........................................................................................................... 12DriveSize Help .................................................................................................................. 12

Dimensioning 13What this chapter contains ............................................................................................... 13Starting a new project ....................................................................................................... 13

Selecting a product series ......................................................................................... 14Changing project data ............................................................................................ 15Selecting ambient conditions .................................................................................. 15

Input data ......................................................................................................................... 16The main dimensioning window ........................................................................................ 16

Toolbar ...................................................................................................................... 17System configuration ................................................................................................. 18Network and transformer data ................................................................................... 19Motor input data ........................................................................................................ 20

Selecting the load type and duty cycle ................................................................... 20Entering motor speeds and loads ........................................................................... 21One-time overload at start ...................................................................................... 23Changing motor specifications ............................................................................... 24Motor selection in general and User selection ........................................................ 25

Additional derating requirements ............................................................................... 25Reinforced insulation.............................................................................................. 25Terminal boxes ...................................................................................................... 25

Inverter input data...................................................................................................... 26Entering inverter load ............................................................................................. 26Changing inverter specifications ............................................................................ 27Inverter selection in general and User selection ..................................................... 27Selecting liquid cooled inverter ............................................................................... 28

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Line supply unit input data ......................................................................................... 29Entering line supply unit load.................................................................................. 29Changing line supply unit specifications ................................................................. 29Selecting liquid cooled supply unit .......................................................................... 30

System configuration ................................................................................................. 31Names of units ....................................................................................................... 31Inserting, copying or deleting components ............................................................. 31Highlighting components ........................................................................................ 32Dragging and dropping ........................................................................................... 32Automatic track ...................................................................................................... 33

Opening a saved project ................................................................................................... 34Opening a project file ................................................................................................. 34Changing the Drive or the Directories path ................................................................ 34

Special features 35What this chapter contains ................................................................................................ 35Motor load ........................................................................................................................ 35

Custom duty cycle ..................................................................................................... 37Line supply unit load ......................................................................................................... 37Customer-specific motors ................................................................................................. 39Existing motors ................................................................................................................. 40User motors ...................................................................................................................... 40

Creating a user motors file ......................................................................................... 40Importing from a file ................................................................................................... 41Entering loadability curves ......................................................................................... 42

Importing motor loads ....................................................................................................... 42

Results 44What this chapter contains ................................................................................................ 44Dimensioning results ........................................................................................................ 44Result view ....................................................................................................................... 45

Efficiency report ......................................................................................................... 47Graph view ....................................................................................................................... 48User selection view ........................................................................................................... 49List of selected .................................................................................................................. 51

Network Check 52What this chapter contains ................................................................................................ 52Network Check view ......................................................................................................... 52

IEEE and IEC standards ............................................................................................ 53Calculating harmonics ............................................................................................... 54

Printing and saving results with Excel format 56What this chapter contains ................................................................................................ 56

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Printing the dimensioning results ...................................................................................... 56Efficiency Report .............................................................................................................. 57Network check report ........................................................................................................ 57

Product and service inquiries ..................................................................................... 58Product training ......................................................................................................... 58Providing feedback on ABB Drives manuals .............................................................. 58Document library on the Internet................................................................................ 58

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Introduction to the manual

What this chapter containsThis chapter gives basic information on the manual.

ApplicabilityThis manual applies to DriveSize (version 3.9 or later).

Note: Version-specific installation instructions for DriveSize are given in the readme file.The file contains also hardware and system requirements. Read the readme file carefullybefore installing the software.

CompatibilityDriveSize is compatible with ABB low voltage AC drives and ABB low voltage motorssuitable for the use with the drives. The software is also compatible with the ABB DCdrives and ABB direct-on-line motors if the software includes the appropriate additionalcomponents. These components have their own manuals.

Purpose of the manualThis manual instructs you to use DriveSize for selecting motors and drives.

Target audienceTo use this manual you must have basic knowledge of:· Terminology of AC drives· ABB product names· Load torque, power and speed requirements.

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10 Introduction to the manual

Terms and abbreviationsThe table below lists the terms and abbreviations which have a special meaning in theDriveSize software and this manual.

Term/Abbreviation Description

Base speed Maximum speed of the driven machinery at nominal loadtorque. Also maximum speed of constant torque range(and minimum speed of constant power range).

Base power Motor shaft power, typically, nominal load of themachinery on the motor shaft. Also used as the referencevalue for loads of the duty cycle.

Drive Frequency converter for controlling AC motors

DSU Diode supply unit

Generating The operating mode of the IGBT supply unit whenconverting power from the drive back to the AC supply.

Generator bridge The bridge of the thyristor supply unit in the regenerativemode (converts power from the drive back to the ACsupply).

IC International Cooling

IP International Protection

ISU IGBT supply unit

LC Liquid cooling

Line-up Consists of the supply unit and inverters which have acommon DC bus.

Motor bridge The bridge of the thyristor supply unit or diode supply unitin the rectifying mode (converts power from the ACsupply to the DC link of the drive).

Motoring The operating mode of the IGBT supply unit whenconverting power from the AC supply into the drive DClink.

Overload Defines the maximum required power for short durations.The power is overload in percent x base power. Theoverload in percent is normally positive, but a negativevalue means the overload has a different sign than thebase power.

One-time at start overload This overload type is allowed once, for instance, at start.Before the next start, it is assumed that the drive hascooled down to the ambient temperature.

TempRiseClass Temperature rise class of the motor.

TSU Thyristor supply unit

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Overview of DriveSize

What this chapter containsThis chapter tells you how to install and start the DriveSize program. It also providesgeneral information about using DriveSize.

DriveSize installation instructionsNote: Version-specific installation instructions for DriveSize are given in the readme file.The file contains also hardware and system requirements. Read the readme file carefullybefore installing the software.

Program structureDriveSize consists of a user interface with dimensioning functions and of productdatabases. The databases contain catalog motors and drives and the units/modules ofthe drives. Dimensioning of customer-specific motors is based on ABB Sophiè, which hasbeen developed by ABB Oy / Machines. The DriveSize installation package includes ABBSophiè.

The program follows the common user interface guidelines of Microsoft Windows.

When you select first one of the AC drive product series, the associated productdatabase opens. The dimensioning cases are called projects. You can save the selectionresults for the project into their own project file (XML file). You can then generatetechnical reports in the MS Excel format and you can attach the reports to the project anddrive documentation.

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12 Overview of DriveSize

DriveSize functionsDriveSize offers several functions for dimensioning the drive. All of the functions areavailable on the main menu bar or toolbar. This manual also describes other ways toaccess these functions.

DriveSize contains the following items for dimensioning:· Ambient conditions (There are separate functions for the conditions of drives and

motors.)· Motor temperature rise class· Motor load types available:

· Constant power· Constant torque· Constant torque and power· Squared torque (Pump/fan)

· Overload types available:· One-time at start· Simple cyclic· Multiform cyclic

· Supply unit power factor· Network harmonics calculation

· Harmonics for any inverter or supply unit· Combined harmonics

· Thermal loss calculations for motor, inverter and supply unit· Supply-unit-specific total mass flow and dissipated losses for liquid cooled multidrives· Results in numerical form· Results in graphical form (load, motor, inverter)· Selecting an alternative inverter, a motor and a line supply unit· Selecting metric units or US units· Generating reports in Excel format for saving or printing· Saving and retrieving dimensioning cases· Saved information is in XML format and can be used with other software.

DriveSize HelpThe DriveSize HTML help includes information on using the program and dimensioning adrive. You can access the DriveSize Help through the Help menu or by pressing F1. TheDriveSize Help is context sensitive and when F1 is pressed, the help automatically opensa help window associated with the active function of the program.

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Dimensioning

What this chapter containsThis chapter describes how to make dimensioning or retrieve a previously saved projectfile.

Starting a new projectYou can make a complete drive system design with DriveSize in many ways. Thefollowing list is an overview of the tasks you can perform with DriveSize. Later on you willlearn shortcuts to perform the same tasks more quickly.· Double click a product family or select one and click Open in the New project

selection (See Figure 1: New project8.6 cm).· You may enter project information. Select Project Info on the File menu. (See Figure

2: Project information).· If ambient conditions deviate from normal select Ambient Conditions on the Data

menu and set new ones. (See Figure 3: Ambient conditions).· If the network data, voltages and frequency deviate from your previous settings

change them from main window (See Figure 4: The main dimensioning window). InSystem configuration, highlight a network/transformer. (See Figure 5: Network dataand Transformer load definition).

· In System configuration, highlight the motor and enter load definitions (See Figure6: Motor load and specifications data). Let DriveSize to select the motor. If you wish tochange the motor, use the User selection functions.

· Let DriveSize to select the drive or inverter once the motor/motors are known.MultiDrive systems normally contain many inverters and motors and DriveSize is ablewith one shot select all. You can also select manually the drive or inverter.

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· For a multidrives, the dimensioning of line supply unit is done when the inverters andmotors have been defined.

Note: The supply unit type has also effect on the motors.

In System configuration, use a toolbar icon or a menu command or press Ctrl+D tocontrol the dimensioning for a selected unit. You can make dimensioning one by one(Ctrl+D) or dimension all units at same time (Ctrl+A).

Selecting a product seriesWhen you start DriveSize without a project file, the Welcome window opens. If you arestarting a new project, you must select a product series first. Figure 1: New project8.6 cmshows the Welcome window.

Figure 1: New project8.6 cm

Use Project Info on the File menu and Ambient Conditions on the Data menu if youwish to change the defaults. You can change this information later with menu commands.

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Changing project dataFigure 2: Project information shows the Project information window. Enter new projectdata in the specified text box. DriveSize saves this information when you save yourproject and includes it in your reports. Click OK to accept the project information. ClickCancel to discard the changes.

Figure 2: Project information

Selecting ambient conditionsFigure 3: Ambient conditions shows the Ambient conditions window. Type new data tothe appropriate text box to change the ambient conditions. The practical range for altitudeis between 1000 m and 4000 m.

Note: The dependency of the altitude to the loadability varies with different components.The practical range of ambient temperature is mostly from 30 °C to 50 °C. This alsovaries with the component. For example, a temperature up to 55°C is accepted forACS880 single drives and marine drives but Ex motors are not selected at all if theambient temperature exceeds 40°C.

Click OK to accept the project information. Click Cancel to discard the changes.

Figure 3: Ambient conditions

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Input dataMotors, inverters, line supply units, transformers and the network have different datainput displays. When you click an item in the System configuration field, the input datadisplay changes depending on the item you select.

The main dimensioning windowAfter opening or creating a project the main window opens. Figure 4: The maindimensioning window shows its main parts.

Figure 4: The main dimensioning window

The main window contains a title bar, a menu bar, a toolbar, the System configurationfield, the input data field and a field which displays the data that you selected. Each fieldhas a specific usage and functions.

The main dimensioning window’s title bar displays the name of the project.

The menu bar contains the DriveSize menus. Each menu contains a group of selections,each of which performs a specific function. Click on a menu to open it. You can also opena menu with key combinations. Press the Alt key plus the letter that is underlined in themenu’s title. To choose a menu selection, press the appropriate letter, or use the cursorkeys to highlight it and press ENTER.

You can also access many of DriveSize's functions from the keyboard by using keycombinations. These combinations are called shortcut keys. The shortcut key for acommand appears to the right of the command on the menus.

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ToolbarThe toolbar provides quick access to common commands in DriveSize. Toolbar buttonsperform a function just like a menu selection. To perform the function of a certain button,click the button on the toolbar.

Tip: When you move the cursor over the button, the help text for that button appearsbelow it.

Table 1: Toolbar icons

Icon Action Menu equivalent

Opens a new project. New... command under the File menu.

Opens a project. Open... command under the File menu.

Saves the project. Save... command under the File menu.

Shows the Print dialog. Print... command under the File menu.

Shows the Ambient Conditionsview.

Ambient Conditions… command under the Datamenu.

Shows the Overload Definitionsview.

Overload Definitions… command under theData menu.

Shows the Network Check view. Network Check... command under the Toolsmenu.

Dimensions the selected item. Make Dimensioning… command under theTools menu.

Shows the dimensioning Resultsview.

Dimensioning Result... command under theResult menu.

Shows the Graph view. Graphs... command under the Result menu.

Shows the Selected Unit view. List of Selected... command under the Resultmenu.

Shows the User Selection view. User Selection… command under the Toolsmenu.

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Table 2: Ambient conditions on the toolbar

Picture Meaning

Indicates the installation’s altitude. It is common to allcomponents.

Indicates the transformer’s ambient temperature.

Indicates the motor’s ambient temperature.

Indicates the drive’s ambient temperature.

System configurationThe System configuration field gives you an overview of the drive system as well as thetype designation or name of each unit in the Tree structure. Figure 4: The maindimensioning window shows an example of a multidrive tree where no selections havebeen made yet.

The Motor load, Inverter load, Line supply unit load, Network data and Transformerload view appears in the input data field depending on which drive component you selectin the System configuration field.

After you select the drive components, the catalog data for the motor, the inverter, theline supply unit or the transformer appears in the selected data field depending on whichcomponent you select in the System configuration field.

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Network and transformer dataThe primary voltage does not have effect on motor and drive choices but if you select avalue that is too high it prevents you from selecting a transformer. The default systemfrequency is 50 Hz but it changes to 60 Hz if valid. The default system frequency has adirect effect on possible secondary voltage levels as well as on the motor databases. Thelogic of DriveSize assumes that in the 60 Hz countries the standard motors are 60 Hzmotors. This limitation is not valid with the AC Drives.

Short-circuit power is essential when network harmonics are calculated. DriveSize has apractical upper limit for short-circuit power.

Figure 5: Network data and Transformer load definition shows the Network data andTransformer load dialog.

DriveSize calculates the transformer load power from the motor base powers andefficiencies and power factors. You can allow DriveSize to use these values, but inspecial cases you can use your own values.

The software includes Oil immersed and Vacuum Cast Coil Dry types of transformers.

Figure 5: Network data and Transformer load definition

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Motor input dataSelecting the load type and duty cycleDriveSize supports four load types:

A) Pump/fan load (Squared torque)

B) Constant torqueC) Constant powerD) Const. torque/power (Specifies the torque versus speed characteristics of thebase load and overloads.)

Note: ACH550 only supports type A and ACQ810 supports types A and B.

In most cases DriveSize supports the following overload types:

A) Simple cyclic

B) Multiform cyclic

C) One-time at start

Only overload type C with fixed 10 s overload time or 10 s/600 s simple cyclic overloadare allowed for Ex motors. Simple cyclic assumes that overloads have specified overloaddurations every specified cycle time.

Note: The overload is assumed to exist anywhere between the minimum speed andmaximum speed.

If you select Multiform cyclic, the Overload definitions dialog opens. You can alsoopen it on the toolbar by selecting, for example, Duty cycle. The Overload definitions areexplained in detail in chapter Special features.

Electrical braking (negative base power and/or overloads) is possible with TSU or ISU.

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Entering motor speeds and loadsThe Motor speed and Motor load input fields vary with different load types.

DriveSize does not accept gear information. If a gear is involved, convert the values tomotor speed manually or use an Excel sheet.

DriveSize does not consider dynamic torque when it accelerates inertias up and down.When remarkable dynamic torque exists, include it as short term overloads.

Base speedBase speed is the minimum mechanical speed of a motor where the base power isrequired.

Note: Use exact values for base speed. Use 1456 (not 1500) because the rated speedsof motors are also exact.

Base powerBase power is the mechanical power of a motor. This is used as the base value for alloverloads. Note that motor thermal dimensioning is based on worst 10 min RMS bydefault. For motor selection there is an option to skip RMS computing. Select Skip RMS-computing of overloads from Tools menu’s Options. You can use a round number like10 kW, 50 kW or 100 kW and type in overloads based on the base value you select. Basepower is normally positive but negative values are acceptable.

Fill in the required load that is on the shaft – not the rated power of the motor. Specify thereal required shaft power of the loading machine. In VSD applications, the motors arealways slightly derated.

Base overloadBase overload defines the maximum required power together with base power for theoverload time. The power is overload in percent x base power. Overload in percent isnormally positive but a negative value means that the overload has a different sign thanthe base power.

Min speedIf the minimum speed is too low, DriveSize selects for the motors and drives a size that islarger than necessary. In DriveSize, the minimum speed is not exactly the minimumspeed of the motor but a speed that is used without interruptions of, for example,30 minutes. DriveSize assumes that the duty cycle continues without stopping andDriveSize selects the motor and drive accordingly. If the minimum speed is critical, youcan see it from the results/graphs. The default minimum speed is 300 rpm or 400 rpm.

Max speedA maximum speed that is too high can have a negative impact on the motor size. If themaximum speed is much higher than the base speed and the overload in percent is high,the absolute maximum torque of the motor can be a limiting factor.

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Overload at max speedDue to the reasons stated above, the overload in percent at maximum speed can begiven a different – normally lower - value than the overload in percent at base speed. Thisis valid for constant power load types.

Figure 6: Motor load and specifications data

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One-time overload at startFigure 7: Motor input data shows where you select the values for One-time overload atstart.OL[%]The starting torque is OL% x base torque. The base torque is calculated from the basepower and base speed. The valid range for OL% is from 1% to 1000%.

OL time is the duration of the starting overload in seconds.

OL max speed tells DriveSize at which speed the overload ceases. Use low values. Ifthe OL maximum speed is equal to the base speed and OL% is high, the power limit ofthe inverter can force DriveSize to select a larger drive.

Figure 7: Motor input data

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Changing motor specificationsYou can adjust the specifications for the motor such as the number of motors, thepreferred motor type, frame material, IP class, IC class, temperature rise class and so on.Click the item to change a selection.

The first item in the Specifications list is the name. To display Name in Systemconfiguration, go to Tools -> Options-> Unit name. DriveSize displayes the type codesof motors.Table 3: Options for Motor Specifications

Specification Options

Name Any text or string

Motors per inverter 1...100 per inverter unit. > 1 = MultiMotor Case, a factor DriveSize considerswhen it selects an inverter. The load is given for one motor. One inverter feedsseveral motors connected in parallel.

Motor type IEC 34 catalogHXR, AMI MotorsNEMA catalogMarine motorsWater cooledPM motorsFlameproofNon-sparkingDust ignition protectionUser definedSynRM (reluctance with ACS850 and ACS880 single drive)Note that all motors are not available for all drives.

FrameMaterial Not Specified, Aluminium, Cast iron, Steel. You can limit the motor families.

Family Limits the search to one family only, such as M3BP.

Pole number Pole number can be Automatic or one of the following: 2,4,6,8,10 or 12

Efficiency Not Specified, IE1, IE2, IE3, IE4. You can limit the motor efficiency class.

Design Read more about Design from the motor user manuals.

Connection Currently ignored.

IP Class IP55, This does not impact the selection

IC Class IC411 self ventilated = cooling fan on motor shaft; means lower loadability atpartial speedsIC416 forced ventilated = separate cooling fan. Select this option for constanttorque cases where the minimum speed is very low.For large motors there are other selections available.

Max speed rule Standard = Standard maximum speeds is used.Metal fan = The higher speed limit of the metallic fan is used.Separate fan = Higher maximum speed is available when force ventilated.

Temp rise B, F or not specified. Not specified means that DriveSize will use thetemperature class given in motor catalogues.

Tmax margin 43%, 30% or 20%. Motor catalogues give rough maximum torque values andsome margin has to be provided. The margin from actual overload torque to

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Tmax must be 43%, 30% or 20%.

Motor selection in general and User selectionDriveSize usually selects the most suitable motor from the technical point of viewconsidering specification. However, sometimes you may want to select another motor. Inthese cases, you can choose an optional motor from the User selection list. Figure 20:User selection view for motor shows the alternative selections.

Additional derating requirementsTerminal box mounting and possible special winding insulation have an effect on thetemperature rise of the motor. DriveSize does not take these extra deratings into account.It is assumed that standard insulation and a top-mounted terminal box are used. If not,some extra margin must be reserved. The necessity of derating can also be a sum ofthese both items.

Reinforced insulationReinforced insulation is recommended when motor voltage is higher than 500 V. Aboutthree per cents (3%) additional derating of the continuous loadability curve is requiredwhen reinforced windings are used. Reserve at least 3% margin in DriveSize for thispurpose.

Terminal boxesTerminal boxes are mounted either on the top of the motor or on the left or right side.Availability of the terminal box mounting options depends on the type of the motor andthe motor frame size. Three per cents (3%) additional derating is needed for thecontinuous loadability curve when the terminal box is mounted on the side of the motor oron the ND end of the motor. As standard, terminal boxes are mounted on the top of themotor and extra margin is unnecessary. Reserve at least 3% margin in DriveSize for thispurpose.

Note: Check the availability of force ventilation and accessories from the motormanufacturer.

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Inverter input dataThis section describes how to enter the drive/inverter data. Figure 8: Inverter input datashows the inverter input data.

Entering inverter loadThe load of the inverter consists of the motor currents and frequencies. DriveSizecalculates the load currents based on the selected motor characteristics (power factor,efficiency, pole pairs), shaft loads, shaft speeds and motor voltage.

You can change the inverter load value by entering new currents. In this case, DriveSizeuses the currents you have given manually instead of the calculated currents. The rest ofthe data that DriveSize uses in calculation is based on the motor. If you have not selectedthe motor characteristics, DriveSize uses the default values of the software.

Figure 8: Inverter input data

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Table 4: Abbreviations used for inverter load

Abbreviation Meaning

I continuous (A) Continuous (base) current required from theinverter. If you enter this value manually and if themotor is not known, DriveSize assumes that thefrequency range is wide.

I maximum (A) Maximum current required. If you enter this valuemanually and if the motor is not known, DriveSizeassumes that the frequency range is wide.

I max start (A) Maximum current at start for the inverter.

Changing inverter specificationsYou can adjust some specifications for the inverter, such as the inverter amount, type, IPclass and pulse number towards network.

Table 5: Options for inverter specifications (ACS800 SD)

Specification Options

Name Any text or string

No.of drives Number of parallel connected inverter and motor combinations.

Type Auto selection includes ACS800 and ACS800 regenerative drivesfor all the constructions but modules and marine. You can limit thetype with the following options: ACS800, ACS880, ACS800regenerative, ACS 800 low harmonic, ACS850, ACS810.

Construction Wall-mounted only, Free standing only, Cabinet drives only,Marine drives only, Drive modules only

Cooling Air, Liquid.Note: Liquid cooling is available only for the Cabinet construction.

IP Class IP00, IP21, IP22, IP42, IP54, IP54R, IP55. Depends on Type andConstruction specifications.

Pulse 6 or 12. When the 12-pulse option is selected, the transformer mustbe of a three-winding type.

Glycol concentration 0%, 30%, 50%. For liquid cooled units only.

Liquidtemperature

25°C…45°C. For liquid cooled units only.

Inverter selection in general and User selectionDriveSize usually selects the most suitable inverter/drive from the technical point of viewconsidering specification. However, sometimes you may want to select another inverter.In these cases, you can choose an optional inverter from the User selection list. Figure20: User selection view for motor shows this screen for motors but similar screen isavailable for inverters and drives too.

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Selecting liquid cooled inverterWhen you select the liquid cooled drive option in the Cooling specification, two newspecifications Glycol concentration and Liquid temperature appear. For a multidrive,select liquid cooling for the supply unit first. The cooling method of the supply unitdetermines also cooling for all the inverters connected to that line-up.

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Line supply unit input dataThis section describes the line supply unit data input (see Figure 9: Line supply unit inputdata)

Figure 9: Line supply unit input data

Entering line supply unit loadIf you have selected the inverters, DriveSize calculates the supply unit motoring andregeneration powers. Change the power and cycle time values. The view has also fieldsfor regenerative powers when the supply unit type is TSU or ISU.

Table 6: Abbreviations used to describe the supply unit load

Abbreviation Meaning

Pcont (kW) Continuous power for the supply unit.

Pmax (kW) Maximum power for the supply unit.

Changing line supply unit specificationsThe default supply unit is a 6-pulse DSU cabinet but other types and pulse numbers andIP classes are available. For the thyristor supply units, two additional parameters are

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available: the braking voltage and motor voltage. These parameters are mutuallyexclusive.

Selecting liquid cooled supply unitWhen you select the liquid cooled (LC) supply option in the Cooling specification, twonew specifications Glycol concentration and Liquid temperature appear. Thesespecifications determine also all the inverters connected to that supply unit. The coolingmethod of line supply unit is valid also for all the inverters connected to that line supplyunit.

Table 7: Options for Line Supply Unit Specifications

Specification Options

Name Any text or number string

Type DSU cabinet, DSU module, TSU cabinet, TSU module, ISU cabinet, ISUmodule, LC DSU cabinet

IP Class IP00, IP21, IP22, IP42, IP54

Cooling Air, Liquid.This option determines also the cooling method for all the invertersconnected to that line-up.

Pulse 6-pulse, 12-pulse, 18-pulse, 24-pulse (DSU, TSU). When the 12-pulseoption is selected, the transformer must be of a three-winding type.

Braking Voltage (%) 85, 90, 100 (TSU)A lower braking voltage means that prior to braking, the DC voltage isreduced.Note: A lower DC voltage means that there is less available motor voltageand therefore the maximum torque a motor produces is also lower. Thissetting has to be understood so that TSU makes a lower than nominal DCvoltage and the motor voltages are also lower. In this case, TSU can quicklychange from motoring to regenerating.

Motor Voltage (V) 380, 400, 415, 500, 525, 660, 690, 830 for 50 Hz and 380, 440, 460, 480,575, 600, 660, 690 for 60 Hz.

Glycol concentration 0%, 30%, 50%. For liquid cooled units only. The supply unit determines alsoglycol concentration for all the inverters connected to that line-up.

Liquidtemperature

25 °C … 45 °C. For liquid cooled units only. The supply unit determines alsoliquid temperature for all the inverters connected to that line-up.

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System configurationThe status icon in System configuration represents the status of the computing for theunit. Table 8 describes the meanings of the status icons.

Table 8: Status icons

Status Icon Meaning

SUPPLY UNIT Line supply unit is not selected.

Line supply unit is selected.

Line supply unit selection is not valid.

INVERTER UNIT Inverter unit is not selected.

Inverter unit is selected.

Inverter unit selection is not valid.

MOTOR Motor is not selected.

Motor is selected.

Motor selection is not valid.

Names of unitsSystem configuration displays the type designation or name of the unit depending onwhat you have selected in Options.

Inserting, copying or deleting componentsUse Insert and Edit on the menu bar when you wish to insert, copy or deletecomponents in the System configuration tree or when you wish to remove any of them.If you wish to copy-paste, you must, for example, highlight the drive you wish to copy andpaste it on top of a transformer. The pasted drive is displayed as the last item in the tree.

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Highlighting componentsWhen you click an item in the System configuration tree, it is highlighted as yourworking item and the input data and possible selected item appear.

Tip: You can highlight several components at one time. When you highlight severalcomponents at one time, it is easier to copy (copy-paste) or delete a group ofcomponents, or move (cut-paste) them from one line to another. To highlight componentsuse the Ctrl key, mouse and left mouse button. Press and hold down the Ctrl key whenselecting the components. Figure 10: Highlighting several units at a time shows how tohighlight components.

Figure 10: Highlighting several units at a time

Dragging and droppingYou can move an inverter or line supply unit to another location in the Systemconfiguration tree. Highlight the component you wish to move. Press the left mousebutton, move the component to a new location and release the mouse button. If you wishto drag the unit, you must move each component separately.

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Automatic trackThe program always keeps the dimensioning status valid. If you change some input data,which can have effect on the dimensioning of other units, then those dimensions willbecome not valid.

Table 9: DriveSize dimension updating

Changed data Dimensioning not valid for

Motor ambient conditions All motors, inverters and line supply units

Drive ambient conditions All inverters and line supply units

Network voltage All motors, inverters and line supply units

Network frequency All motors, inverters and line supply units

Supply unit load Only the line supply unit whose load you changed

Line supply unit type, motor voltage or brakingvoltage

All motors, inverters and line supply units in thatline-up

Line supply unit IP class Only line supply unit whose IP class you changed

Inverter load Only the inverter and line supply unit where theinverter is connected

Inverter IP class Only that inverter and line supply unit where theinverter is connected

Motor load Only that motor and inverter where the motor isconnected. Also that line supply unit in that line-up

Motor number, type, IC class or TempRiseClass Only that motor and inverter where the motor isconnected. Also that incoming unit in that line-up

Inserting motor and inverter Only the line-up’s line supply unit

Deleting or pasting motor and inverter Only the line-up’s line supply unit

Dimensioning motor The inverter where the motor is connected. Alsothat line supply unit in that line-up

Dimensioning inverter Only the line-up’s line supply unit

34 Dimensioning

Opening a saved projectWhen you open a previously saved project, a window shows all of the available projectsin the selected path. When you highlight a file, you can view the project information in theProject info field before opening the project. Figure 11: Opening project view shows theOpen file window.

Figure 11: Opening project view

Opening a project fileTo open a project file, highlight it or type its name in the File Name text box and click OK.You can also open a project file by double-clicking its name in the file list. By changingthe List of file Types option, you can open projects which are based on differentproducts.

Changing the Drive or the Directories pathTo change the Directories or Drive path, double-click the path in the list on the righthand side of the window. If you are using a keyboard, you can press the spacebar tohighlight the path.

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Special features

What this chapter containsThis chapter describes the special features of DriveSize, such as making moresophisticated load definitions. This section also describes how to use special motors andhow to create your motor database.

Motor loadEnter the motor load data in the main dimensioning window. If the project is morecomplicated, start from Overload definitions. See

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36 Special features

Figure 12: Overload definitions.

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Figure 12: Overload definitions

Custom duty cycleEnter the duty cycle in the Load points table. Define the duty load by intervals and loadsin percent on top of base power or with power or with torque values. To enter thesevalues, click a cell in the table and type the new value. To accept the value, press Enter.Use the arrow keys on your keyboard to move inside the table. To accept your customduty cycle, click OK. If you click Cancel, you will lose all your changes. As you areentering the load's cycle parts, the Load graph shows you the defined custom duty cycle.

Rms over the load cycle and Rms during the worst 10 minutes are calculated. Whenoverloads are severe (long lasting) and thermally important, DriveSize computes a highercontinuous load value which it uses as the base power later on. For motor selection thereis an option to skip RMS computing form Tools menu’s options. Notice that thermal loadcapability against overloads is not checked when RMS computing is off.

Table 10: Duty cycle view abbreviations

Abbreviation Meaning

Rms Rms value for the whole duty cycle

Rms10 Rms value for the duty cycle’s worst 10 minutes

Highest load The highest load for the user’ s duty cycle

100% Base power in kW

Cont.load Calculated continuous load in kW

Overload Calculated overload in percent

Line supply unit loadYou often have to optimize a line supply unit selection and define the power requirementsmanually. DriveSize has fields for regenerative power when the supply unit type is TSUand ISU. The Pmax motoring power value is the sum of positive Pmax motoring valuesincluding losses. The same logic is used for Pmax generating, Pcont motoring andPcont generating values as well.

38 Special features

Figure 13: Line supply unit load

DriveSize fills in the time fields with defaults but you must check and, if necessary, modifythe times and power values. DriveSize does not know the mutual timings of differentinverters.

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Customer-specific motorsSome motors are called customer-specific because they are not picked from any list butthe rated power and frequency are computed from load requirements. When youdimension a customer-specific motor like HXR, AMA or AMI, ABB Sophiè automaticallyselects the number of poles and the field weakening point (Fwp frequency). After theautomatic selection you can alter the value of field weakening frequency between thegiven limits. The minimum and maximum limits for field weakening are shown in theselected motor data. Additionally, there is also a value for the recommended maximum(Rec). Before you change the value of Fwp frequency, select the pole number. Whenthe value of the pole number is changed, the Fwp frequency returns to Automatic.Figure 14: Drop-down list of field weakening frequency shows the drop-down list for acustomer-specific motor.

ABB Sophiè automatically starts when the program cannot find any standard motor andthe Motor type is Auto selection or if you have selected HXR, AMA & AMI motors as themotor type.

Figure 14: Drop-down list of field weakening frequency

40 Special features

Existing motorsYou can define an existing motor in the Existing Motor dialog. It automatically openswhen you select the Existing motor type. Figure 15: Existing Motor dialog box showsthe dialog for an existing motor. The loadability curves of the ABB standard motors areused for existing motors. DriveSize assumes that the existing motor is already installedand driving the load. The loadability of an existing motor is not checked, but the graphsshow if it is undersized according to the rules for standard motors.

Figure 15: Existing Motor dialog box

User motorsYou can make dimensioning for motors from your own motor list. This section describeshow you can import your own motor database into DriveSize.

The format of the motor list is an Excel worksheet with specified column headers and onerow for the information of one motor. The motor list is expected to start on the firstworksheet in the book and the upper right corner is cell A1. Before you can use the motorlist, import it to a UserMotor database in DriveSize. The import is always a full import andall previously existing user motors are removed when you import a new list.

User motors are used independently from supply frequency but the motor voltage mustmatch the supply voltage. The rating value conversion from one voltage to another is notdone for user motors (You can make the conversion yourself in Excel.) Different voltagesmust have separate rows in the database.

Creating a user motors fileEnter the motor data and loadability curves in UserMotors.xls. By default, you can findthis file in your working directory inC:\\ProgramFiles\DriveWare\DriveSize\VsdSize20\system. You can change the file namebut not the extension.

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Importing from a fileTo import new data to the database, select File -> User motors -> Import from file. Thisaction overwrites the existing UserMotor database.

Figure 16: Import Database window

The import function validates the information in the Excel sheet before updating thedatabase. The validation rules are:· Correct column headers· Correct data types (text, numeric)· All numeric values must be > 0· Text values must fit into a maximum length· The frequency column must be between 8…400 (Hz) so that also values other than

50 Hz or 60 Hz are accepted.· The voltage must be known by DriveSize

In case of import errors, the program tells you which values are not accepted and theimport is cancelled.

The import date is stored in the General table and it is visible in the About box.

If there is at least one motor imported to the database, a new item is added to the Motortype list: User defined in the motor specification grid.

When you select User defined, DriveSize updates the Family list with all families fromthe Database. The other specification items are:· Family: “Not specified”, + rest of list from the database· Pole number: “Automatic”, 2, 4, 6, 8, 10, 12· Design: Not specified, Basic, High-Output· Connection: Not specified, Y, D· IC class: IC411, IC416· IM class: IM10001, …· Max speed rule: Standard· Temp rise: Not specified, B, F· Motor Tmax Margin: 20%, 30%, 43%

42 Special features

Entering loadability curvesIn the Excel list, you can give a reference to an existing loadability curve in the standarddatabases (for example, IEC, Existing etc.) that is used when dimensioning. If an emptyloadability curve name is found, the existing motor type is assumed.

You can also import the loadability curves for your motors. Use the same Excel file(UserMotors.xls) to import loadability curves. The loadability curve must start from thezero frequency and extend to 1 (relative). The number of loadability curves is unlimited.

Importing motor loadsYou can import several pre-collected loads at once. Fill in the motor loads toMotorLoadData.xlsx. By default, you can find this file in your working directory inC:\\ProgramFiles\DriveWare\DriveSize\ VsdSize20\system. You can change the file namebut not the extension.· Load type: Pump/fan load or Constant torque· Speed, base: number in rpm· Power, base: number in kW· Overload, base: value in percent, relative to base power· Overload, time: overload duration in seconds· Overload repeating: total cycle duration in seconds

First select the product series type. To import motor loads data, select File -> Importmotor loads. Select Excel file like MotorLoadData.xlsx. After some seconds motor loadsappear in the System configuration tree. You can continue with DriveSize as usual. Thepurpose of importing motor loads is to speed up dimensioning when motor load list isavailable and contains several motors.

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44 Results

Results

What this chapter containsThis chapter describes how to interpret DriveSize’s Results shown on screen.

Dimensioning resultsDriveSize always try to select some unit. The selection may not be optimal but it providesa result quickly. When you change the input data, you get another result. DriveSizecomputes the selections quickly but you make the final decision. Figure 17: Maindimensioning window shows an example of the motor results.

Figure 17: Main dimensioning window

You can read the dimensioning results in the main dimensioning window, but you can findmore detailed information in the dimensioning Result view where results appearnumerically or in the Graph view where results appear graphically. If you are not satisfiedwith the software dimensioning result, make your own selection. This is possible in theUser Selection view. All the individual sections dimensioned for the project can be seenin the List of Selected view.

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Result viewThe Result view shows the results in a numeric form for the item you have highlighted.The view is similar for motors, inverters and incoming units. The Specifications datashows the user requirements. The Catalogue data displays the unit and selectioncalculations in different points and shows how the unit meets the requirements. TheSelection data has columns for Required, Result and Margin values. The required datais calculated from the user load demands. The result data is based on selected unit(motor, drive etc). The margin indicates the percentage of capacity still available(difference between the input requirements and the resulting data of the component).

Figure 18: Result view for motors

Table 11: Selection data for motors

Point Meaning

Torque (Nm)min, base, max

Calculated torque at the user-defined speed: Minimum, base, maximum speed.

Power (kW)min, base, max

Calculated power at the user-defined speed: Minimum, base, maximum speed.

Overload (Nm)min, base, max

Calculated overload torque at the user-defined speed: Minimum, base,maximum speed for the user-defined time.

46 Results

Table 12: Selection data for inverters

Point Meaning

Icont (A),Imax (A) orImax start (A)

Calculated current load for an inverter in two situations:· Continuous load and maximum load for the user-defined time· Maximum load at start is shown in case the load type is One time at start

overload

Temperature Temperature margin in percent for the IGBT module. There is also anadditional temperature margin for other components like a choke when liquidcooled.

Table 13: Selection data for diode or thyristor supply units

Point Meaning

Power (kW)mot cont,mot max,gen cont,gen max

Calculated power load for an incoming unit for motoring and generating bridgesin two situations:· Continuous load· Maximum load for the user-defined time

DC-current (A)cont motoring,max motoring,cont generatingmax generating

Calculated DC bus current with minimum voltage and power for motoring andgenerating bridges in two situations:· Continuous load· Maximum load for the user-defined time

Temperaturemot temp,gen temp

Temperature margin in percent for motoring and generating bridges. There isalso an additional temperature margin for other components like a choke whenliquid cooled.

Table 14: Selection data for IGBT supply units

Point Meaning

Power (kW)mot cont,mot max

Calculated power load for an incoming unit in two situations:· Continuous load· Maximum load for the user-defined time

AC-current (A)cont motoring,max motoring

Calculated current with minimum voltage and power:· Continuous load· Maximum load for the user-defined time

Temperaturemot temp

Temperature margin in percent for a supply unit. There is also an additionaltemperature margin for other components like an LCL filter when liquid cooled.

Table 15: Liquid flow sums of line-up (ACS800 LC multidrives)

Point Meaning

Total flow (l/min) Calculated total mass flow for this line-up. The liquid flow of line supply unit isshown in the catalogue data table of the LSU result sheet.

Heat loss (kW) Calculated loss power for that line-up.

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You can see in the selection data the required load margin for the selected unit. Whenthe margins are positive, the unit meets the requirements.

Note: A large margin causes over-dimensioning. If the margin is negative, the unit cannotmeet the requirements. When the motor type is ACS800, where a thermal model is used,the margin of continuous current can be negative when the ambient temperature is below40 °C.

Efficiency reportClick the Efficiency Report button in Motor data view to see the efficiencies and lossesin a printable form (See Figure 18: Result view for motors). This view is available only forsingle drives.

48 Results

Graph viewThe Graph view helps you to check how well the unit fits the requirements. The graphsdisplay load and motor torques, load and motor powers and load and inverter currents.Figure 19: Graphs for motor shows the graph for load and motor torques as a function ofspeed.

Figure 19: Graphs for motor

In the view, a legend explains the curves. Each curve has its own color.

Table 16: Curves in the Load / Motor torque graph

Curve Meaning

max. loadability Motor maximum capability as a function of speed

max. load User-defined maximum load (overload)

cont. loadability Motor continuous loadability – thermal limit

cont. load User-defined continuous load

Table 17: Curves in the inverter graph

Curve Meaning

max. loadability Inverter maximum capability

max. load User- defined maximum

cont. loadability Inverter continuous loadability

cont. load User-defined continuous load

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User selection viewIn the User selection view, you can view and even select a smaller or larger unit insteadof your current selection (made by the software or by your own previous selection). Theselected unit has number 0 and its row is highlighted. Smaller units have a negativemark. Larger units have a positive mark. The table includes some catalogue values andcalculated margins to help with the new selection process. In some cases when theoverloads are decisive there are no smaller units in the list.

Figure 20: User selection view for motor shows the alternative selections. The view isavailable for ABB standard motors, inverters and supply units.

Figure 20: User selection view for motorTable 18: Items in User selection view, motor table

Item Meaning

# Identity number

PU Production unit

Type designation The motor’s type designation

Power (kW) Rated power

Efficiency class Motor efficiency class

Poles Pole number

Speed (rpm) Nominal speed

In (A) Nominal current

Tn (Nm) Nominal torque

Tmax/Tn Maximum torque / Nominal torque

Tcont margin Calculated continuous load margin. The smallest margin over the complete speedrange.

Tmax margin Calculated maximum load margin. The smallest margin over the complete speedrange.

50 Results

Im (A) Calculated continuous load current

Immax (A) Calculated maximum load current

Table 19: Items in the User selection view, inverter table

Item Meaning

# Identity number

Type designation Inverter’s type designation

Apparent power (kVA) Inverter’s apparent power

Power (kW) Inverter’s nominal motor power

Icont (A) Nominal continuous loadability current

Margin Calculated margin for your continuous load

Imax (A) Nominal maximum loadability current

Margin Calculated margin for maximum load

Selection method Selection criterion

Temp. margin Calculated temperature margin

Table 20: Items in the User selection view, line supply unit table

Item Meaning

# Identity number

Type designation Line supply unit’s type designation

Apparent power (kVA) Line supply unit’s apparent power

Power fwd margin Calculated power margin for motoring load. Minimum of continuous andmaximum load.

Current fwd margin Calculated current margin for motoring load with required power and minimumvoltage. Minimum of continuous and maximum load.

Power rev margin Calculated power margin for generating load. Minimum of continuous andmaximum load.

Current rev margin Calculated current margin for generating load with required power andminimum voltage. Minimum of continuous and maximum load.

To select a different unit, click the row in which you wish the unit to be listed. To verifyyour selection, click OK. Your selection is highlighted. If you click Cancel, the selection isdiscarded.

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List of selectedList of selected displays the selected units. The list contains: Type designation, Unitname and Dimension status. Dimension status shows whether you or the softwaremade the dimensioning. Figure 21: List of selected

shows an example of this view.

Figure 21: List of selected

52 Network Check

Network Check

What this chapter containsThis chapter describes how to compute the effects of drives on a network. Harmonicscalculation is based on discrete Fourier transformation and tabulation.

Network Check viewWith Network Check you can calculate:· the network harmonics and power factor for an individual drive· the network harmonics and power factor for a line supply unit· combined harmonics for several units.

Both the voltage and the current harmonics are calculated. DC voltage calculationsprovide DC link voltage. Figure 22: Network Check view shows an example.

Tip: Compute the combined harmonics, not harmonics for individual drives because theparallel drives will smoothen and, in some cases, compensate each other. Combine ISUand DSU drives.

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Figure 22: Network Check view

IEEE and IEC standardsDriveSize calculates total harmonics distortion according to IEEE Standard 519-1992 andIEC61800-3 standard. IEEE standard values indicate how big effect the drive load has onthe network at the point of common coupling. The rated current of the transformer is usedas load current.

Note: In the IEEE standard, harmonics are calculated up to the 50th and in the IECstandard, up to the 40th.

Table 21: Network and Transformer Data items

Items Meaning

Primary voltage Network voltage on the primary side

Secondary voltage Network voltage on the secondary side

Frequency Network frequency

Network Sk Network short-circuit power MVA. Currently the maximum value is 900 MVA

Transformer Sn Transformer nominal power

Transformer Pk Transformer load loss power in kW

Transformer Zk Transformer short-circuit impedance in percent

Supply cable type Cable / Busbar

Cable quantity Parallel connected cable quantity

54 Network Check

Cable length Length of the cable

Table 22: Supply Unit items

Items Meaning

Lac (µH) AC choke inductance

Ldc (µH) DC link inductance

Cdc (mF) DC link capacitance

Pdc (kW) DC power; the default value is base power plus the losses in the motor andinverter.

Table 23: Result items

Items Meaning

cos Φ1 Fundamental power factor, main wave power factor

Tot power factor Calculated total power factor with the harmonics included

Udc (V) Calculated DC voltage

Table 24: Harmonic items

Items Meaning

Voltage THD (%) Voltage total harmonic distortion

Current THD (%) Current total harmonic distortion

N Harmonic order number

f (Hz) Harmonic frequency

Current (A) Harmonic current

In/I1 Harmonic proportional current to base current

Voltage (V) Harmonic voltage

Un/U1 Harmonic proportional voltage to base voltage

Calculating harmonicsTo calculate the harmonics, highlight the transformer and click Network check in thetoolbar. The Network Check view opens. If necessary, adjust the Pdc and other settings.Click Calculate. If you have not given the network data in the main dimensioning window,fill in the network voltage and frequency with deviations.

Note: The network data you fill in Network Check does not have effect on the networkdata in the main dimensioning window.

To view the harmonics output as a table or a graph, select the Table or Graph radiobutton in Show Mode. When you select the graph view, you can choose between thevoltage and current harmonics.

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56 Printing and saving results with Excel format

Printing and saving results withExcel format

What this chapter containsThis chapter gives information on the printing functions. The printed results are meant tobe used as appendixes for offer or request for offer or just for documentation purposes.

Instead of printing we encourage you to save the results on Excel format and if you wish,convert them into PDF format. This is one way to avoid consumption of printers andpaper.

Printing the dimensioning resultsYou can use the printing functions for two purposes:· exporting the project information to Excel, which can be used as shopping lists for

motors and drives. To do this, select Preview.· printing on paper. To do this, select Print.In the Print dialog, define what information you wish to move to Excel.

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DriveSize uses Microsoft Office® Excel 97 English version or later for printing. Figure 23:Print dialog shows the Print dialog.

Figure 23: Print dialog

Many DriveSize views have a Report button. Click Report to print the view data in Excel.

Efficiency ReportClick the Efficiency Report button in Motor data view to see the efficiencies and lossesin a printable form. Note that print All Data Sheets does not contain the Efficiency Reportsheet. This sheet is available for single drives.

Network check reportClick the Report button in the Network Check view to see the printable result sheet ofthe harmonics.

58 Printing and saving results with Excel format

Further information

Product and service inquiriesAddress any inquiries about the product to your local ABB representative, quoting thetype designation and serial number of the unit in question. A listing of ABB sales, supportand service contacts can be found by navigating to www.abb.com/drives and selectingSales, Support and Service network.

Product trainingFor information on ABB product training, navigate to www.abb.com/drives and selectTraining courses.

Providing feedback on ABB Drives manualsYour comments on our manuals are welcome. Go to www.abb.com/drives and selectDocument Library – Manuals feedback form (LV AC drives).

Document library on the InternetYou can find manuals and other product documents in PDF format on the Internet. Go towww.abb.com/drives and select Document Library. You can browse the library or enterselection criteria, for example a document code, in the search field.

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Contact us

www.abb.com/drives