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ABB Grid Edge Solutions

PS1000 690VacProduct manual

Document ID: 1MZB101795Issued: March 2020

Revision: AProduct version: 1.0

© Copyright 2020 ABB. All rights reserved

NOTICE

This document contains information about one or more ABB products and may include adescription of or a reference to one or more standards that may be generally relevant to theABB products. The presence of any such description of a standard or reference to a standard isnot a representation that all of the ABB products referenced in this document support all ofthe features of the described or referenced standard. In order to determine the specificfeatures supported by a particular ABB product, the reader should consult the productspecifications for the particular ABB product.

ABB may have one or more patents or pending patent applications protecting the intellectualproperty in the ABB products described in this document.

The information in this document is subject to change without notice and should not beconstrued as a commitment by ABB. ABB assumes no responsibility for any errors that mayappear in this document.

Products described or referenced in this document are designed to be connected and tocommunicate information and data through network interfaces, which should be connected toa secure network. It is the sole responsibility of the system/product owner to provide andcontinuously ensure a secure connection between the product and the system network and/orany other networks that may be connected.

The system/product owners must establish and maintain appropriate measures, including,but not limited to, the installation of firewalls, application of authentication measures,encryption of data, installation of antivirus programs, and so on, to protect these products,the network, its system, and interfaces against security breaches, unauthorized access,interference, intrusion, leakage, and/or theft of data or information.

ABB performs functionality testing on the products and updates that we release. Howeversystem/product owners are ultimately responsible for ensuring that any product updates orother major system updates (to include but not limited to code changes, configuration filechanges, third-party software updates or patches, hardware change out, and so on) arecompatible with the security measures implemented. The system/product owners must verifythat the system and associated products function as expected in the environment in whichthey are deployed.

In no event shall ABB be liable for direct, indirect, special, incidental or consequential damagesof any nature or kind arising from the use of this document, nor shall ABB be liable forincidental or consequential damages arising from use of any software or hardware describedin this document.

This document and parts thereof must not be reproduced or copied without writtenpermission from ABB, and the contents thereof must not be imparted to a third party nor usedfor any unauthorized purpose.

Copyright

ABB reserves all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is forbidden. Nopart of this document may be reproduced, stored in a retrieval system or transmitted in anyform or by any means without the prior written permission of ABB.

Trademarks

e-mesh™ and PowerStore™ are registered trademarks of the ABB Group. All other brand orproduct names mentioned in this document may be trademarks or registered trademarks oftheir respective holders.

Preface

This manual covers the hardware features of the ABB PS 1000 converter. The ABB PS 1000 is abidirectional converter for outdoor use that transfers the electrical power between the powergenerator such as the battery system and the electrical power system, such as the distributiongrid. In the battery energy storage application, the power transfer is bidirectional.

This manual describes the mechanical installation of the converter and give instructions onhow to select the electrical components and connections for the converter.

Support Services

ABB will provide assistance in the operation and repair of its products. Requests for sales orapplication services should be made to your nearest sales or service office. ABB can alsoprovide installation, repair and maintenance contract services.

When ordering parts, use nomenclature or part numbers and part descriptions fromequipment manuals. Parts without a description must be ordered from the nearest sales orservice office. Recommended spare parts lists, including prices are available through thenearest sales or service office.

ABB has modern training facilities available for training your personnel. On-site training is alsoavailable. Contact your nearest ABB sales office for specific information and scheduling.

Additional copies of this instruction, or other instructions, can be obtained from the nearestABB sales office at a reasonable charge.

Safety instructions

This section contains important information regarding safe and proper use of equipment.System integrators & OEMs must provide a final set of service instructions / manual to theirend customer as part of the final product. Trained and qualified personnel are required forinstallation and operation of this equipment. Failure to follow safety instructions can result indamage to equipment, injury, or death.

This manual contains the following safety notices:

Safety precaution Description

DANGER indicates a hazardoussituation which, if not avoided, willresult in death or serious injury.

DANGER indique une situationdangereuse qui, si elle n’est pasévitée, causera des blessuresgraves ou la mort.

WARNING indicates hazardousconditions that could damageequipment or cause personalinjury or death.

AVERTISSEMENT indique desconditions dangereuses quipourraient endommagerl'équipement ou causer desblessures ou la mort depersonnes.

CAUTION indicates a hazardoussituation which, if not avoided,could result in equipment damage,minor or moderate injury.

ATTENTION indique une situationdangereuse qui, si elle n’est pasévitée, pourrait causer desdommages à l'équipement et desblessures mineures ou modéréesau personnes.

ESD Electrostatic dischargewarning, indicating thatequipment can be damaged ifproper ESD protections (example,wrist straps) are not used.

ESD Risques de déchargesélectrostatiques, ceci indique quel'équipement peut êtreendommagé si les protectionsESD appropriées (par exemplebracelets antistatiques) ne sontpas utilisées.

The information icon alerts thereader of important facts andconditions.

Electrical safety

Table 1: Electrical safety

WARNING Basic electricalprecautions must be followed byall personnel when working onelectrical systems. Equipmentdamage, injury, or death can occuras a result of failure to followthese instructions or installationby unqualified personnel.

AVERTISSEMENT Les précautionsélectriques de base doivent êtrerespectées par toute personnetravaillant sur les systèmesélectriques. Des dommagesmatériels, blessures ou la mortpeuvent être provoqués suite aunon respect de ces instructions oul'installation par du personnel nonqualifié.

Review the following steps before performing any installation or maintenance work:

1. Work must be performed by qualified personnel only.2. Clearly identify work locations.3. Ensure that all sources of power are disconnected.4. Inverters contain capacitors which require several minutes to discharge after

removing power. Verify that system and component voltages are at or near 0 V bymeasuring with a voltmeter.

5. All electrical installations must comply with the electrical standards applicable on-site.

Stored energy

Table 2: Stored energy

DANGER Inverters containcapacitors which retain voltageeven after the system is de-energized. By design, thesecapacitors self-discharge to lessthan 25 V within 5 minutes.System and component voltageshould always be verified prior toworking on equipment to ensurethe discharge has completedsuccessfully.

DANGER Les onduleurscontiennent des condensateursqui restent chargés après lacoupure de toutes les sourcesd’alimentation. Ces condensateurssont conçus pour se décharger àmoins de 25V en moins de 5minutes. Il faudra toujoursmesurer les tensions du systèmeet de ces composants pours’assurer qu’elles ne soient plusdangereuses.

After powering down, and before working on the inverter:

1. Disconnect or turn off all sources of power, such as:

1.1. Main AC1.2. Main DC1.3. Auxiliary power (optional for properly trained personnel)

2. Ensure that power cannot be re-applied while working on the equipment by followingproper lockout/tagout procedures for all power sources (example, the AC griddisconnect switch, battery bank disconnect switch, and so on).

• Ensure that both AC and DC power source voltages are at or near zero volts (lineto line, line to ground for AC and DC, illustration shown below) at the PS1000AC/DC terminals on the grid/battery side of the switches.

3. Wait at least 5 minutes after disconnecting power to the inverter to allow storedenergy to discharge (example, charged capacitors within the inverter).

4. After 5 minutes, use a suitable multimeter to

4.1. Measure between the DC+ and DC- conductors at the top and of the DC switchand ensure that the DC voltage is < 25 VDC. Measure from DC+ and DC- toground and verify that voltage is below 25 VDC.

4.2. Measure all AC terminals on the inverter for both AC and DC voltage (line-lineand line-ground) and ensure that voltages are < 25 V.

5. Install safety grounding as appropriate.

GES20000038 V1 EN-US

Figure 1: Measuring line to line and line to ground voltages

V_1 shows line to line.V_2 shows line to ground

Grounding and Hipot

WARNING This inverter may ormay not include a GFDI device. Ifnot, this system must be usedwith an external GFDI device asrequired by local jurisdictions.

AVERTISSEMENT Cet onduleurn'est peut-être pas équipé d'undispositif de détection de défaut àla terre interne. S’il n’est pasprésent, cet onduleur doit êtreéquipé d’un dispositif dedétection de défaut à la terreexterne en conformité avec lesréglementations locales.

CAUTION Only qualified personnelshould perform this work. If youdo not follow these instructions,electrical noise may be increased,resulting in operational errors, orcommunication interference.

ATTENTION Seul le personnelqualifié est habilité à effectuer cetravail. Si vous ne suivez pas cesinstructions, les perturbationsélectromagnétiques serontamplifiées entraînant des défautsde fonctionnement et desinterférences au niveau descommunications.

Grounding

• Always install a protective ground from the inverter chassis to the assembly with aconductor of enough cross section (see Control and Auxiliary Connections). Input andoutput circuits are isolated from the enclosure.

• System grounding is the responsibility of the integrator or installer.• When servicing the system, protective grounds may be used and they must be

removed upon completion of work, prior to energizing the equipment.

Hipot

• A hipot test is performed by ABB at the factory and is NOT PERMITTED to beperformed in the field by the user.

Cleanliness / Debris

CAUTION The inverter has airvents. Debris should not beallowed to fall into the venting,including metallic chips fromdrilling, weld splatter, and so on.As it may result in damage to theinverter. Covering the vents isgood practice if there is a chanceof falling debris. The covers MUSTbe removed prior to operation toprovide adequate ventilation.

ATTENTION L’onduleur est pourvude bouches d'aération. Il fautéviter d’y faire tomber des débris,entre autres les copeauxmétalliques de forage, lesprojections de soudure, etc. car ilsprovoqueront des dommages àl’onduleur. Recouvrir les bouchesest une bonne pratique s'il y a unrisque de chute de débris. Lescouvercles doivent être enlevésavant l’utilisation pour assurer unebonne ventilation.

Table of contents

Section 1 Introduction.................................................................................................... 31.1 Intended audience........................................................................................................................31.2 Required skills............................................................................................................................... 31.3 Required tools............................................................................................................................... 31.4 Product documentation..............................................................................................................41.4.1 References................................................................................................................................... 41.4.2 Abbreviations and acronyms................................................................................................... 41.5 Document symbols and conventions....................................................................................... 51.5.1 Symbols........................................................................................................................................ 51.5.2 Document conventions............................................................................................................. 6

Section 2 Specifications................................................................................................. 72.1 Specification label.......................................................................................................................112.2 Test reports..................................................................................................................................11

Section 3 Technical considerations.............................................................................153.1 Standalone vs parallel................................................................................................................ 153.2 System grounding...................................................................................................................... 153.3 Isolation transformers...............................................................................................................153.4 Source impedance...................................................................................................................... 153.5 External disconnect requirement............................................................................................ 163.6 Precharge..................................................................................................................................... 163.7 DC Precharge............................................................................................................................... 163.8 AC Precharge (Optional)............................................................................................................173.9 Precharge and startup sequence............................................................................................ 183.10 Precharge parameters............................................................................................................... 19

Section 4 Integration.....................................................................................................214.1 Site installation requirements..................................................................................................214.1.1 Cabinet dimensions and anchor foots................................................................................. 214.1.2 Ventilation spacing...................................................................................................................214.1.3 Conduit entry points................................................................................................................224.1.4 Environmental considerations...............................................................................................234.2 Installation and handling.......................................................................................................... 234.2.1 Lifting the converter with a forklift......................................................................................244.2.2 Installation procedure............................................................................................................. 254.3 Single line diagrams................................................................................................................... 274.4 Electrical connection overview................................................................................................ 284.4.1 AC connections......................................................................................................................... 294.4.2 DC connection...........................................................................................................................294.4.3 Ground connection.................................................................................................................. 304.5 Control and Aux. connections..................................................................................................30

Table of contents

PS1000 690Vac 1Product manual


4.5.1 Auxiliary power consumption................................................................................................ 364.5.2 Hardware fast stop (F-Stop)..................................................................................................384.5.3 Communications...................................................................................................................... 39

Section 5 Operations.................................................................................................... 455.1 System protections................................................................................................................... 455.1.1 Hardware protection mechanisms.......................................................................................455.1.2 Software protection mechanisms........................................................................................465.2 Startup......................................................................................................................................... 46

Section 6 Maintenance..................................................................................................496.1 Replaceable components and accessories........................................................................... 496.2 Recommended maintenance schedule..................................................................................50

Appendix A Reference tables........................................................................................... 51

Table of contents

2 PS1000 690VacProduct manual


Section 1 IntroductionGUID-B361EB3C-82C1-4C86-9859-82DF014272EA v1

This document serves to

• Aid engineering teams in proper selection, integration, and usage of PS1000 690Vacinverters for end user and OEM applications.

• Provide engineering information to support successful integration of ABB PS1000 690Vacinverters.

Read all applicable sections during the engineering process and before youapply power to your inverter.

1.1 Intended audienceGUID-F8D2DAEE-6FE2-42E7-9F1F-EE7977661706 v1

This manual is intended for persons who plan the installation of, install, use and service theconverter.

Read the manual before starting the work on converter.

1.2 Required skillsGUID-D1124637-45A2-41B7-AC9F-AE7CEEA2AD54 v1

Expected to know the fundamentals of electricity, wiring, electrical components, and electricalschematic symbols.

When servicing the converter or working under voltage (power or auxiliary), local regulationscan apply including qualifications by local authorities.

1.3 Required toolsGUID-C2B325A3-5E73-420D-9C7F-9EF60EEEB893 v1

The tools required to move the converter, fasten it to the foundation, and tighten theconnections:

• Forklift / Crane• Screwdrivers, Torque wrench• Set of wrenches and sockets

For parameter configuration the EPyQ tool is required.

1MZB101795 A Section 1Introduction



1.4 Product documentation

1.4.1 ReferencesGUID-52D20A3E-1453-4BC0-A090-87DBBDD60418 v1

A selection of additional, supporting documentation is available for the e-mesh™ PS1000690Vac. A listing and brief description of these documents has been included in Table 1.4.11

Following files are obtained form the ABB representative.

Table 1: Supporting documents

[1] PS1000 Data Sheet (4CAE000825)

[2] PC tool (EPyQ) for inverter control via laptop and associated files Inverter-specificfiles; example, .epz, .epp, and so on. (proprietary formats)

[3] CAN parameter summary (available as .sym, .dbc, and .pdf)

[4] Modbus data map (available as .xlsx and .xml format)

1.4.2 Abbreviations and acronymsGUID-E6095BA5-5CE0-4E63-91FB-5656B65B504A v1

Abbreviation Description

AC Alternating Current

AHJ Authority having jurisdiction

AWG American Wire Gauge

BMS Battery Management System

CAN Controller Area Network

CEC California Energy Commission

DC Direct Current

DR Distributed Resource

EPS Electric Power System

ESD Electrostatic Discharge

EGW Ethylene Glycol and Water

GFDI Ground Fault Detector Interrupter

GUI Graphical User Interface

IEEE Institute of Electrical and Electronics Engineers

LI Long-Instantaneous

LOTO Lockout Tagout

LS Long-Short

NC Normally Closed

NFPA National Fire Protection Association

NO Normally Open

NRTL Nationally Recognized Testing Laboratory

OCPD Overcurrent Protection Device

OEM Original Equipment Manufacturer

PLL Phase Lock Loop

PV Photovoltaic

Table continues on next page

Section 1 1MZB101795 AIntroduction



Abbreviation Description

PGW Propylene Glycol and Water

PWM Pulse Width Modulation

RH Relative Humidity

SIL Safety Integrity Level

SPD Surge Protection Device

SPDT Single Pole Double Throw (Switch)

SRD System Requirements Document

TCC Time-Current Characteristic

TDDi Total Current Demand Distortion

TVS Transient Voltage Suppressor

UL Underwriters Laboratories

UPS Uninterruptible Power Supply

VFD Variable-Frequency Drive

1.5 Document symbols and conventions

1.5.1 SymbolsGUID-711B82CE-1218-4633-886F-3E109AFBE8FD v2

The electrical warning icon indicates the presence of a hazard which couldresult in electrical shock.

The warning icon indicates the presence of a hazard which could result in plantshutdown or personal injury.

The caution hot surface icon indicates important information or warning aboutthe temperature of product surfaces.

The caution icon indicates important information or warning related to theconcept discussed in the text. It might indicate the presence of a hazard whichcould result in corruption of software or damage to equipment or property.

The information icon alerts the reader of important facts and conditions.

The tip icon indicates advice on, for example, how to design your project orhow to use a certain function.

1MZB101795 A Section 1Introduction



Although warning hazards are related to personal injury, it is necessary to understand thatunder certain operational conditions, operation of damaged equipment may result indegraded process performance leading to personal injury or death. It is important that theuser fully complies with all warning and cautionary notices.

1.5.2 Document conventionsGUID-19491955-63E5-47D7-A8F4-70208B068A52 v2

Microsoft Windows conventions are normally used for the standard presentation of materialwhen entering text, key sequences, prompts, messages, menu items, screen elements and soon.

• Abbreviations and acronyms in this manual are spelled out in the Section Abbreviationsand Acronyms. This section also contains definitions of important terms.

• All references and the file paths are in italics.

Illustrations are used as an example and might show other products than theone the manual describes. The example that is illustrated is still valid.

Section 1 1MZB101795 AIntroduction



Section 2 SpecificationsGUID-9CF6429D-066E-480C-9BF6-C873E086F908 v1

Table 2: PS1000 specifications

Model PS1000 690Vac

LINEUP QTY 1 … 4

AC AC port configuration 3-wire (3P3W)

AC voltages 600-630-660- 690 VRMS ±10%. Others on request

AC export capacity @25°C

1146 ARMS 4584 ARMS

AC export capacity @45°C

1032 ARMS 4128 ARMS

AC import capacity @25°C

1000 ARMS 4000 ARMS

AC import capacity @45°C

882 ARMS 3528 ARMS

AC import / exportpower

see charts

Converter Type 3-Level VSC (5) / CSI (6)

Nominal frequency 50 – 60 Hz

Harmonic distortion <2% TDDi per IEEE 519

Power factor/reactivepower

0 leading … 0 lagging (full 4-quadrant operation)

Maximum aux. powerconsumption

1500 W 6000 W

Efficiency: Max | CEC |Euro

98.6% (est.) >98% (est.) >98% (est.)

DC DC voltage range atnominal AC voltage (7)

1000 - 1500 VDC

DC voltage range at110% nominal ACvoltage (8)

1095 – 1500 VDC

Maximum DC current 1404 ADC 5616 ADC

Battery technology all battery types, fuel cells, other DC sources, and so on

Number of DC inputs 1 … 4

Enviromental Ambient temperature(operation)

-20°C to 50°C

Ambient temperature(storage)

-20°C to 60°C

Protection degree NEMA 3R/IP54

Relative humidity 5% - 100% condensing

Max elevation 2000 m [6500 ft.]

Airborne noise <75 dBA @ 5 m

Temperature de-rating Automatic; see charts below


1MZB101795 A Section 2Specifications



Model PS1000 690Vac

Cabinet Maximum dimensions(H x W x D)

mm: [2275 x 1004 x1200]in.: [89.6 x 39.5 x 47.2]

mm: [2275 x 4931 x1200]in.: [89.6 x 194 x 47.2]

Weight ( est.) 1043 kg [2300 lb.] 4 x 1043 kg [4 x 2300lb.]

Mounting Pad mounted

Cooling Hybrid liquid /air

Cooling fluid 30% - 50% EWG (9) or PWG (10)

Certification (pending) Safety UL 1741 | C22.2 No.107.1-16 & CE mark

Utility interconnect UL 1741:2010 R2.18 (SA) | IEEE 1547.1-2005 | CA Rule 21 No.16-06-052Hawaii Rule 14 No. 2014-0192EU Grid codes: DE, FR, SE, PT & IT. Others on request.

Protections AC protection fuses

DC protection fuses (optional)

Humidity Internal cabinet heating

Safety features overvoltage, overcurrent, overtemperature

Ground fault detection optional

Control Control interface CAN, Modbus RS 485, or Modbus TCP

Basic control modes

Grid Following (OnGrid) control modes

External PQ (power) / DQ (Current) / Cos Phi (pf) references

Grid Connected / Offgrid transition

Seamless transition in both directions available for PQ control

Grid Forming (Off grid)control modes

External PQ references

Black Start Capable Yes, includes DC pre-charge. Requires external auxiliary control power

Extended control modes

Grid Following controlmodes

External f & V references for ABB’s GSM (4) primary control functionalities:

• Fast Voltage & Frequency support based on droops & dead band• Virtual Inertia

Grid Forming –Following transitions

Seamless transition from VGM to GSM in grid connected and island

Grid Forming controlmodes

External f & V references for ABB’s VGM (3) primary control functionalities:

• Droop control with dead band• Synthetic Inertia & Synthetic impedance• Current limiting during faults and inrush

Fully integrated with ABB’s e-meshTM secondary control

Auxiliary supply Control power options 208 – 240 VAC | DC: 24 VDC

Auxiliary power 480 VAC 3P3W

Section 2 1MZB101795 ASpecifications



1. ZVRT: Zero Voltage Ride Through2. LVRT: Low Voltage Ride Through3. VGM: Virtual Generator Mode4. GSM: Grid Support Mode5. VSC: Voltage Source Converter6. CSI: Current Source Inverter7. DC voltage at nominal AC line voltage for 690Vac8. Minimum DC voltage at nominal AC line voltage for 1.1 x 690Vac9. EGW: Ethylene Glycol and Water10. PGW: Propylene Glycol and Water


Figure 1: PS1000 AC power charts versus temperature for different LV AC voltages

Full-function, independent blocks

Each PS1000 contains fully independent AC & DC disconnects, fuses, utility-grade surgesuppression, environmental controls, recharge, enabling an easy installation.

Keep the transformer simple

When connection several PS1000 in parallel internal busbar connection allows simple ACparallel connection and simplifies the coupling transformer connection. Note that each 1 MWblock is designed to support connections to independent battery banks.




The MV transformer can be provided by ABB with pre-engineered units to suit yourapplication’s power and voltage needs.


Figure 2: PS1000 single line diagram


Figure 3: PS1000 layout drawing




2.1 Specification labelGUID-131DC3DC-E5AB-401C-9117-339671EA8807 v1


Figure 4: Sample PS1000 nameplate

2.2 Test reportsGUID-D251D801-94B7-47B5-88F7-097EEC568B64 v1

ABB provides a certificate of conformance with every inverter that guarantees the unit ispassed all acceptance tests before leaving the factory. Below figure is an example Certificateof Conformance.




Figure 5: Example certificate of conformance with factory acceptance tests


Figure 6: Sample test data




Section 3 Technical considerations

3.1 Standalone vs parallelGUID-DE8A7E9E-DA8F-4BB0-86AE-29F70DEA9DD4 v1

Up to four PS1000s can be easily paralleled by using the PS1000 throat connections. Checkdatasheets to verify the maximum number of inverters that may be connected via throatconnections.

3.2 System groundingGUID-9E471573-13C9-408F-AD7A-4EB6E9FE1118 v1

PS1000 may be used in a fully floating system in one of the configurations shown below. SeeTechnical Guidance on Isolation Transformers Annex for additional information.


Figure 7: System configurations

3.3 Isolation transformersGUID-2E8990E6-1CA2-49A7-9836-8275FB7B0374 v1

For isolation transformer guidance, see Technical Guidance on Isolation Transformers Annex.

3.4 Source impedanceGUID-DE9AF8C3-C15E-4D8D-963C-17C54F27A863 v1

For basic control modes, the grid impedance (transformer + utility impedance) should be lessthan 8%. Operation at greater than 8% is possible using enhanced control modes. If yoursystem has more than 8% source impedance, contact ABB for further discussion.

1MZB101795 A Section 3Technical considerations



3.5 External disconnect requirementGUID-FC492031-E999-43F5-903B-0FCE55EC8F99 v1

Review local requirements for necessity of external AC and DC disconnects. The inverter itselfdoes not require them.

3.6 PrechargeGUID-8E08E81F-33E1-4D38-93BD-E0DAFF869EB7 v1

The inverter supports two precharge methods:

• DC Precharge - equipped as a standard option• AC Precharge - must be specified as special option when ordering

In both precharge modes, the inverter will automatically execute precharge as part of itsnormal startup sequence. Please note that the precharge parameters must be configured forAC or DC precharge within the inverter (through the communications interface), such that theinverter can anticipate which precharge method is used.

3.7 DC PrechargeGUID-AB91FD0C-2970-4784-9EED-836060625DEA v1

DC precharge is the typical method used for systems which utilize a DC energy source such asa battery. In this case, the inverter’s internal DC capacitors are charged from the DC source aspart of the startup sequence.


Figure 8: DC Precharge sequence

Section 3 1MZB101795 ATechnical considerations




Figure 9: DC Precharge circuit

3.8 AC Precharge (Optional)GUID-A7E40C8E-D0D8-4EEF-9643-8F84FC9A8C36 v1

AC precharge is the typical method used for systems which do not have a DC energy source,such as in a STATCOM application. In this case, the inverter must charge its internal DCcapacitors from the AC source, and then actively regulate its DC voltage (active front endmode). The startup sequence is otherwise identical to a DC precharge.


Figure 10: AC Precharge sequence





Figure 11: AC Precharge circuit

3.9 Precharge and startup sequenceGUID-56E0FD05-B04A-4E87-88DE-7E0F9ED2570E v1

• Precharge contactor (typically designated as K1) closes.• Inverter observes the DC voltage ramp rate to ensure precharge is successfully operating.

If ramp rate is insufficient, inverter will abort precharge sequence and indicate a faultedstate.

• Once the inverter DC voltage has stabilized, the main DC contactor (K2) will close and theprecharge contactor will open, completing the precharge sequence.

• AC startup

• If grid voltage is present and the inverter enters a grid following mode, theinverter will spool up the LCL filter in sync with the grid (matched phase angle andmagnitude). Once in sync, the main AC contactor (MX1) closes and the inverterconnects to the grid with little to no transient inrush. The inverter is now online in a‘grid following’ mode.

• If grid voltage is NOT present and the inverter enters grid forming mode, once theprecharge sequence is completed, the inverter will first close its AC contactor (MX1),and then ramp up its output voltage to its commanded setpoint. The inverter is nowonline in a grid forming mode.

Section 3 1MZB101795 ATechnical considerations



3.10 Precharge parametersGUID-CD1342A3-3EAF-4A99-9656-0E3783A740C7 v1

The precharge sequence is configured for DC precharge by default. AC precharge is needed incases where the inverter is to be used as a DC source, when interfacing with a flow-battery, orother similar cases. User can configure this by changing the following parameters on EPyQ:

• PrechargeConfig:PrechargeRelay• PrechargeConfig:PrechargeType




Section 4 Integration

4.1 Site installation requirements

4.1.1 Cabinet dimensions and anchor footsGUID-0906CACC-74C2-4354-B971-A73E7589C282 v1


Figure 12: Cabinet space clearances and anchor foot dimensions [mm]

4.1.2 Ventilation spacingGUID-FF5CE0AA-5E77-4D46-AB6A-5230F98A67A4 v1

There are two intake vents and an exhaust fan on the back of the inverter to circulate airthrough the inverter. In the final installation, the vents may not be covered or obstructed andmust have at least 2 meters clearance in the rear of the inverter to allow for air flow, as shownbelow.

1MZB101795 A Section 4Integration




Figure 13: Cabinet ventilation spacing (units in mm [in])

4.1.3 Conduit entry pointsGUID-076AADBF-4F77-4A95-9305-F8B8ACF63BD2 v1


Figure 14: Bottom view of cabinet (units in mm [in])

Conduit entry points must be cut through the conduit entry floor panel on the base of theinverter for all power connections made from the ground.

Section 4 1MZB101795 AIntegration



4.1.4 Environmental considerationsGUID-364A36C7-3C21-4505-9015-46214E42AC16 v1

The PS1000 has a NEMA Type 3R rated enclosure, providing protection against rain, sleet, andsnow in outdoor environments. The enclosure is powder-coated to protect against corrosionin salt-fog environments.

4.2 Installation and handlingGUID-81E16643-AD83-4602-8E54-B241AC3C7634 v1

This unit is intended to be installed on a flat surface. Consider conduit entry points andventilation spacing requirements when placing inverter.

Follow the spacing as shown in below figure when connecting two or more inverters via ACthroat.


Figure 15: Multi-unit pad mounting locations




CAUTION Do not allow inverter to tip over; always set inverter on a levelsurface. Use lifting eyes and straps when appropriate.ATTENTION Ne pas permettre à l’onduleur de basculer; il faut toujours le placersur une surface plane. Au besoin, utilisez des crochets et des sangles de levage.

4.2.1 Lifting the converter with a forkliftGUID-C891B246-4C45-4A5A-8D9A-8382DF26761C v1

• The inverter may be installed with a forklift by using the forklift channels on the front ofthe inverter.

• When inserting the forks:

• Remove both the front and rear access covers on the pedestal.• Open the front door and inspect the forklift channels.• Insert forks as far as possible from the front• DO NOT ALLOW THE FORKLIFT TO CONTACT THE FRONT DOOR OR THE CONTROL

SWITCHES.

• Take care not to damage the control connectors or assemblies when lifting and handlingthe inverter assemblies.

• Once the cabinet is placed in its final location, inspect each of the listing eyes to ensurethat they are not damaged and still retain weather integrity.





Figure 16: Forklift channels

The unit must be permanently fixed to the ground via the 4 pad mounting holes at the base ofthe cabinet.

4.2.2 Installation procedureGUID-FFE8479B-DF3A-4AB9-844F-72BB9DBD1459 v1

• Remove the pedestal access panels from the front and rear of the pedestal.• Remove the front ventilation hood (if applicable).• Remove the conduit entry floor panel.• Position inverter with a forklift.• Fasten the inverter to the ground using ¾” anchor bolts in each of the four pad mounting

holes.• Measure conduit entry points on floor panel and cut holes in panel slightly larger than

conduits.• Install floor panel, and seal entry points, leaving no gaps between the floor panel and

conduits.• Replace the pedestal access panels and ventilation hood.• Check the entire surface of the inverter for defects in the paint. Fill any defects in the

paint.• Make sure that both front and rear doors are fully closed.• Any damage to the paint must be repaired once installation in complete, to prevent

corrosion.




Sealing the conduit

• Once the conduit entry floor panel is reinstalled the conduit must be sealed around itsouter surface to prevent moisture, dust, air and debris from entering the cabinet.

• Once the power lines are installed and are in their final position any excess space in theconduit should be sealed with an expansion foam or sealant to prevent moisture, dust, airand debris from entering through the conduit.

• Ensure that the chemistry of the foam/sealant used to seal the interior of theconduit is compatible with insulation used in the power cables and that themaximum expected temperature of the cables does not exceed that of thedegradation temperature of the foam/sealant.

• Improper sealing could compromise the enclosure.




4.3 Single line diagramsGUID-39DC062A-E0B3-438B-8BF8-858E8CF4BB0F v1


Figure 17: PS1000 Single line diagram




• DC (+) and (-) input terminals

• Standard

• DC-side precharge circuit• DC main circuit motorized disconnect• DC surge protective devices

• Optional

• DC fuses• DC choke

• AC network connection (L1, L2, L3 terminals)

• Standard

• AC main circuit motorized load break switch• AC surge protective devices

• Optional

• AC fuses as standard

4.4 Electrical connection overviewGUID-67B48811-3AC9-4332-8354-5442A515DA62 v1

Connections to the inverter must comply with the National Electric Code (US) or applicablestandards.


Figure 18: Main AC, DC, and ground connections




This unit may not be provided with a GFDI device. This inverter must be usedwith an external GFDI device if required by the Article 690 [Solar Photovoltaic(PV) Systems] of the National Electrical Code for the installation location.AVERTISSEMENT: Cet appareil n'a pas été équipé d'un dispositif de détectionde défaut à la terre. Cet onduleur doit être utilisé avec un dispositif de défaut àla terre externe tel que requis par l'article 690 du Code national de l'électricitéselon l’endroit d'installation.

4.4.1 AC connectionsGUID-8121313B-EFB1-4878-A50D-9756547B56A5 v1


Figure 19: AC disconnect switch terminals (units in mm)

For instructions on preparing the installation location for a conduit connected PS1000, see thesection Installation and Handling.

• Connection Points

• AC terminations are located at the lower terminals of the AC disconnect switch, onthe left side of the inverter.

• Maximum 4 lugs / cables per phase R, S and T.

• Voltage Rating

• ABB recommends using a copper cable that is rated for at least 1.8/3.0 kV AC for1500Vdc battery systems.

• Cross Section

• Cables connected to the AC switch should not exceed 80°C in operation. Mostampacity charts provide cable size as a function of temperature rise above 30°Cambient. This must be adjusted to the inverter’s maximum temperature at which itcan supply full current, typically ~40°C.

See Table 9 of the Appendix A for NEC 2014 section 310.15 for proper cable size selection. ACconductor temperature ratings must comply with the Specifications table.

4.4.2 DC connectionGUID-279083FF-2352-4918-BD1B-6CD5686E8442 v1


Figure 20: DC busbar termination detail (units in mm)




• ABB recommends using a cooper cable that is rated for 1.5 kV DC.• Maximum 6 lugs / cables per pole + and -.

4.4.3 Ground connectionGUID-7B4E82B6-1856-4653-89C8-94B1A559B702 v1

The equipment grounding conductor must be connected to the grounded bus bar on theinside the dead front of the cabinet. Hole size and spacing is shown below.


Figure 21: Grounding terminal highlighted in green (units in mm)

The equipment grounding conductor must be sized per the governing standard for yourapplication, typically rated at ⅓ of the current rating of the main conductors.

PE grounding conductor to be sized according with IEC standard IEC 61439-1 and/or localregulation.

4.5 Control and Aux. connectionsGUID-82BE75F2-46FF-47C6-9F62-4C99AB15E003 v1

When working on control orcommunication circuits, a wriststrap, heel strap, or other ESDprecaution should be used. Failureto do so may result in damage tothe inverter or its control circuits.

Lorsque vous travaillez sur descircuits de commande ou decommunication, un braceletantistatique, une sangle de talonou d'autres précautions ESDdoivent être utilisés. Le non-respect des instructions peutentraîner des dommages àl’onduleur ou aux circuits decommande.

When directly supplying 24 VDCpower to the inverter the suppliedvoltage must not exceed 27 VDC.

The ABB designed wire routing for both the communications and the auxiliary power lines areshown in below two photos. If communicating with the PS1000 via Modbus TCP over anethernet cable, see section Ethernet Cable Routing.





Figure 22: Auxiliary and communications wire routing to the user interface





Figure 23: Auxiliary and communications wire routing to the user interface

All control and auxiliary wiring connections are located on the lower DIN rail mounted insidethe front door of the inverter. Wires are routed through the wire duct and zip tied to avoidcontact with the busbars or other electrical equipment, as shown highlighted in green above.Do not zip tie any wires to the outermost frame face, highlighted in red above. Wire should beappropriate gauge to handle 15 A of continuous current, as defined by NEC or other applicablestandards. See Appendix A for tables regarding conductor ampacity ratings.

Not all connections are required in some applications. Read the descriptions to determinewhich functions are relevant to your system.

Installer is responsible for connecting auxiliary power through the input circuit breakermounted on the DIN rail. The auxiliary power input provides power for:

• Controls• Cooling fan• Coolant pump• Heaters for condensation mitigation




If the PS1000 is to be operated as a black start capable unit then the auxiliary powerdistribution will change.

Table 3: Interface connection summary

Interface Section Block # Function

208 VAC INPUT XD18 1 Line 1

2 Line 2

3 Line 3

4 Ground

208 VAC Output XD20 1 Line 1

2 Line 2

3 Line 3

4 Ground

24 VDC Output XD21 1 24 VDC HIGH

2 24 VDC GND

CAN Bus interface XD22 1 CAN HIGH

2 CAN GND

3 CAN LOW

Modbus XD23 1 Modbus D1

2 Modbus Return

3 Modbus D0

Dry ContactControl Inputs

XD24 1 Common

2 Program Enable

3 Program Restart

4 F-STOP

5 No connection





Figure 24: User interface: communications and controls DIN rail

Use a small screwdriver or similar tool to open terminal block clamps when installing wires asshown in Figure 25.





Figure 25: Opening terminal block clamp

Wires should be terminated by ferrules before inserting into terminal blocks. If ferrules cannotbe used, any other termination method specified by manufacturer’s instructions is acceptable.Use strain relief methods for conductors terminating on the DIN rail.

Terminal blocks can accommodate conductors described in Table 4.

Table 4: DIN-rail connection specifications

Connection type Limit

Conductor cross section solid min. 0.14 mm2

Conductor cross section solid max. 1.5 mm2

Conductor cross section AWG min. 26

Conductor cross section AWG max. 14

Conductor cross section flexible min. 0.14 mm2

Conductor cross section flexible max. 1.5 mm2

Min. AWG conductor cross section, flexible 26

Max AWG conductor cross section, flexible 14

Conductor cross section flexible, with ferrule withoutplastic sleeve min.

0.14 mm2

Conductor cross section flexible, with ferrule withoutplastic sleeve max.

1.5 mm2





Connection type Limit

Conductor cross section flexible, with ferrule withplastic sleeve min.

0.14 mm2

Conductor cross section flexible, with ferrule withplastic sleeve max.

1 mm2

Stripping length 8 mm … 10 mm

Internal cylindrical gage A1 / B1

4.5.1 Auxiliary power consumptionGUID-E9AD39E4-840F-43B4-9BCC-7D9A8C114FBD v1

The total installed power is:

• 3 phase fixed speed pump - 208-240VAC, 1072W• 3 phase variable speed fans - 208-240VAC, 1100W• AC & DC DISCONNECT - 208-240VAC, 2x 728W• single phase / 24 Vdc control devices - 208-240VAC, 480W

Figure 26 shows the auxiliary power consumption for different operation status:





Figure 26: Auxiliary power demand




Table 5: Aux power consumption

State 208 / 240 VRMS average aux. power consumption

Standby (controls powered, inverter not operating) 155 W

Grid tied at zero power (fans only operating at lowspeed, intermittently, and so excluded)

800 W

Full power (cooling fans at full speed) 1500 W

Recommended aux power breaker size for a single PS1000: 15 ARMS

4.5.2 Hardware fast stop (F-Stop)GUID-A8BA9CA0-438B-49A3-8E50-EFB0BA182E06 v1

The inverter includes a hardware loop that may be optionally used to initiate a hardware onlyshutdown independent of the communications interface. If utilized, this should be donethrough a normally closed dry contact on terminal blocks XD24:1 and XD24:4, as shown inFigure 27. The shutdown will be triggered by opening the dry contact.


Figure 27: Hardware F-stop configuration example




4.5.3 CommunicationsGUID-DDBB4E3D-7FB5-4969-B452-13C4F40F5E32 v1

Field service is only supported via CAN by ABB Power’s Field Service tool (EPyQ)

Table 6: CAN / Modbus communications summary

CAN MODBUS RTU MODBUS TCP

Low LevelImplementation

CAN 2.0b Modbus RTU over RS-485(half duplex)

Modbus TCP overEthernet

High LevelImplementation

SAE J1939 See spreadsheet

ABB EPyQ GUI Support Yes No

Full Interface Yes No

120 Ω Terminationprovided

Yes Yes N/A

Isolated Yes Yes

Default ID 247 1

Interface Summary dbc or sym file xlsx or smdx (xml) file

Default Configuration 500 kBd operational, 250kBd programming

9600 Bd, N81 Port 502

Communication Rate 125, 250, 500,1000 kBd

2400, 4800, 9600, 19200,38400, 57600, 115200 Bd

10/100M

Trunk Length < 40 m, frequencydependent

< 1200 m, frequencydependent

<100 m

Stub Length < 40 m, frequencydependent

< 1 m, frequencydependent

N/A, point-point wiringonly

Best practices for routing of communications cables

• Maintain separation from power cables; example, run control cabling in a dedicatedconduit

• If control cables must pass power cables, avoid parallel runs• Minimize wire lengths and keep all conductors twisted to ensure signal integrity

CAN - General recommendations

The overall communication bus should be a single, main communication trunk line with shortstubs off to individual devices (see Figure ). Main trunk line should use balanced, twisted,shielded pair wiring with a minimum of 24 AWG. Connect similarly labeled data terminals usingtwisted pair conductors and tie common terminal to the cable shield. Shielding must be tied tochassis or earth ground at or near the system controller connection point.





Figure 28: Communications main trunk line

To minimize signal reflection at the end of the main trunk line, insert a 120 Ω, ≥ ¼ Watt resistorat each end of the trunk line (example, between CAN-high and CAN-low or between D ( + ) andD ( - ) as needed).

• Failure to install termination resistors may result in communication issues (example,control message faults) or overloading transceiver circuits.

• If termination at the inverter does not suit your application, contact ABB for instructionson removing the termination resistor.

• Net resistance between the data lines on de-energized communication circuits should be~ 60 Ω.

• Higher readings indicate a trunk line with no termination resistors.• Lower readings indicate an excessive number of terminations which may draw

excessive currents.

MODBUS RTU

General recommendations

The signal polarity of RS-485 devices (example, D+/D-, A/B, and so on) can be unclear whenintegrating multiple components due to a divergence of industry practices. Reversal of D+/D-connections will not cause electrical damage to the interface circuitry and should beconsidered as a troubleshooting effort during initial integration.

Connecting to the LANTRONIX device (Setting Up/Obtaining IP Address)

Communication to the PS1000 is available through Modbus TCP over an Ethernet cable. Tofacilitate this the system integrator needs to obtain (and if desired, change) the PS1000’s IPaddress.

The PS1000 is configured to use DHCP to obtain an IP address.

Ethernet cable routing

The Ethernet cable should be routed alongside the door panel wire bundle, down through therubber wire gland, and out of the cabinet wherever the system integrator has created aprovision for the communication and auxiliary lines. This is illustrated in the pictures below.

• The system integrator will need to cut a small hole in the rubber wire gland to pass theEthernet line from the clean compartment into the area below. This can be accomplished




by poking through twice with a razor blade, each insertion offset by 90 degrees, creatingan X shaped incision (much like the straw hole in the lid of a soft drink cup).

When zip tying the Ethernet (and any other lines) to the inside of the cabinet behind the deadfront, do not connect to the red highlighted portion of the frame shown below. This will hinderthe dead front from being re-installed.


Figure 29: Ethernet cable routing





Figure 30: Ethernet cable routing (continued)

Do not zip tie the cable to the red highlighted section of the frame, as thisinterferes with dead front installation.





Figure 31: CAN based maintenance port

• This is NOT an Ethernet port.• Use maintenance port with ABB supplied connection to laptop.• The cap must be replaced after use for environmental protection.




Section 5 Operations

5.1 System protections

5.1.1 Hardware protection mechanismsGUID-48747185-D5C4-46C6-A7AA-0CD7914BB1C9 v1

AC Over-current protection

AC over-current protection (AC fuses) are optionally included in the inverter. The inverterincludes an AC motorized switch which automatically disconnects the AC connection when theinverter is not operating.

Fault current contributions measured during system certification testing are summarized inthe table below for AC faults.

Table 7: AC Fault current contribution - PS1000 bolted Line-Line fault

Max AC Fault Current Contribution

Max Peak Current 2,415 A (peak)

Time to Peak Current 380 µs

Peak Current over 1 grid cycle 705 A

Peak Current over 3 grid cycles 150 A


Figure 32: AC Short-circuit waveform for PS1000

DC Over-current protection

DC over-current protection (DC fuses) are optionally included in the inverter. The inverterincludes a DC motorized switch which automatically disconnects the AC connection when theinverter is not operating.

Fault current contributions from the inverter measured during system certification testing are:

1MZB101795 A Section 5Operations



• Max Peak Current: 11,775 A• Time to Peak Current: 184 µs

Surge protection

Transient voltage surge protection is installed at the AC and DC terminals of the invertersystem. A failure of the SPD will cause the main fuses to open, thereby stopping all import orexport of energy. In the event of a failure, replace fuses with same type and ratings as detailedelsewhere in this manual.


Figure 33: Transient voltage suppressors (red), and fuses (blue)

5.1.2 Software protection mechanismsGUID-279C0BE4-5B52-4E19-B79B-B246B1F829C1 v1

• Line Monitoring (Voltage/Frequency) and Reconnect Delay• Timed Overloads• DC & AC Voltage and Current Limits• Control voltage protections• Thermal model trips

… and more

5.2 StartupGUID-2F6EA37D-4BD4-41EC-BD22-889BC8D626F8 v1

1. Verify that the DC source is ready. Note that even if DC voltage is present at the inverterterminals, the inverter will not indicate this voltage until precharge is complete and theinverter is enabled.

2. Verify that the inverter reports the correct voltage and frequency of the AC connection.Unlike the DC voltage, the AC voltage and frequency is monitored and reported by thecontroller even when the inverter is disabled.

3. Review any parameters that may be needed for the specific application.

Section 5 1MZB101795 AOperations



4. Ensure the inverter is reporting AC Power Available as TRUE.5. Ensure the inverter state is reporting as Ready. If any faults are flagged, verify their root

cause is evaluated and that the inverter is safe to enable before issuing a fault clearcommand.

6. Enable the inverter.

1MZB101795 A Section 5Operations



Section 6 MaintenanceGUID-0C44E757-0C8E-4EF7-8812-70B4E860E7A8 v1

Follow all applicable safety instructions when performing maintenance operations on theinverter. Maintenance operations should only be performed by qualified and trained personnel.

6.1 Replaceable components and accessoriesGUID-6CC503D3-9A85-4B7F-9C60-040F61DDE952 v1

Table 8: Replaceable components for PS1000

Component ABB Part # Qty / Cabinet

Main Assembly

Power Stage 45-100098 1

DC Main Fuses 31-100230 6

AC Main Fuses 31-100424 6

DC OVRs 31-100409 2

AC OVRs 31-100408 4

DC Disconnect Switch 31-100350 1

AC Disconnect Switch 31-100349 1

Environmental

Cooling Skid 75-100413 1

Clean Compartment Filter 21-100206 1

Cabinet Fan 31-100411 1

Coolant Fan 31-100396 1

Power Module Cooling Fans 31-100243 3

Table 9: Replaceable protective components for PS1000

Component Ratings ABB Part # Manufacturer Qty /Cabinet

MFR Part #

Main Assembly

AC Line SenseFuse1

2 A, 600 VRMS 31-100116 Mersen 3 ATMR2

DC Pre-ChargeFuse

30 A, 1500 VDC 31-100384 Littelfuse 2 SPXV030.L

Replace only with the same rating of listed fuses. Procedures must be followed to make theinverter safe prior to checking or replacing components.

1MZB101795 A Section 6Maintenance



Table 10: Accessories compatible with PS1000 series inverters

Component Type ABB Part # Manufacturer MFR Part #

Recommended Ground Fault Detection (Installed by integrator)

Bender iso685-D Application dependent,see Power SystemGrounding

31-100028 Bender iso685-D

Communication Bus

USB-CAN Adapter Optional 31-100072 PEAK-System IPEH-002022

120 Ω, ¼ W Resistors Optional N/A N/A N/A

DB9 Cable Optional N/A N/A N/A

Mating connector forDB9 to Inverter ControlInterface

Optional N/A N/A N/A

Cooling System

Ethylene or propyleneglycol with corrosioninhibitors (Volumevaries by installation)

Required, alternativesmay be used

10-100010 Peak Auto 085-13-0525

6.2 Recommended maintenance scheduleGUID-A28A0C37-B756-43C2-B4EC-70A326256525 v1

Table 11: PS1000 component replacement schedule

ABB Part # Component

Replace annually:

21-100206 Clean Compartment Filter

Replace every 4000 start / stop cycles or as needed:

31-100349 AC Disconnect Switch

31-100350 DC Disconnect Switch

Replace in case of lightning strike or as needed:

31-100424 AC Fuses (x6)

31-100426 250V Microswitch (x3)

30-100230 DC Fuses (x6)

31-100346 AC Measurement Fuses (x3)

31-100408 Type 1 SPDs (AC side)

31-100409 Type 1 SPDs (DC side)

Replace every 5 years or as needed:

31-100243 Power Module Cooling Fans

31-100396 Main Cooling Fan (for glycol loop)

31-100411 Cooling Fan for Clean Compartment

75-100413 Cooling Assembly (pump, tank, glycol heater,strainer), with return of old assembly

Section 6 1MZB101795 AMaintenance



Appendix A Reference tablesGUID-A5635C3B-E444-4A38-887B-B274565C1C78 v1

Ampacity based on NEC Table 310.15(B) (16) (Formerly Table 310.16) – Allowable ampacities ofinsulated conductors rated up to and including 2000 Volts, 60° through 90°C (140° Through194°F), not More than three current-carrying conductors in raceway, cable, or Earth (directlyburied), based on ambient temperature of 30°C (86°F).

Temperature Rating of Conductor

Ampacity75°C (167°F)




Types RHW, THHW, THW,THWN, XHHW, USE, ZW

Types TBS, SA, SIS, FEP, FEPB,MI, RHH, RHW-2, THHN,THHW, THW-2, THWN-2, USE-2, XHH, XHHW, XHHW-2, ZW-2

Types RH, RHW, THHW, THW,THWN, XHHW, USE

Types TBS, SA, SIS, THHN,THHW, THW-2, THWN-2, RHH,RHW-2, USE-2, XHH, XHHW,XHHW-2, ZW-2

Table 12: Conductor ampacity based on the 2014 National Electrical Code®

AWG/kcmil (mm2) Copper Aluminum or Copper-Clad Aluminum

8 (8.4) 50 55 40 45

6 (13.3) 65 75 50 55

4 (21.2) 85 95 65 75

3 (26.7) 100 115 75 85

2 (33.6) 115 130 90 100

1 (42.4) 130 145 100 115

1/0 (53.5) 150 170 120 135

2/0 (67.4) 175 195 135 150

3/0 (85.0) 200 225 155 175

4/0 (107.2) 230 260 180 205

250 (127) 255 290 205 230

300 (152) 285 320 230 260

350 (177) 310 350 250 280

400 (203) 335 380 270 305

500 (253) 380 430 310 350

600 (304) 420 475 340 385

700 (354) 460 520 375 425

750 (380) 475 535 385 435

800 (406) 490 555 395 445

900 520 585 425 480

1000 (508) 545 615 445 500

For ambient temperatures other than 30°C (86°F), use the ampacity correction factors in thefollowing table:

1MZB101795 A Appendix AReference tables



Table 13: Ambient temperature correction factors (from 30 °C) from NEC 310.15(B)(2)(a)

Ambient temperature(°C)

Temperature rating of conductor Ambient temperature(°F)60°C 75°C 90°C

10 or less 1.29 1.20 1.15 50 or less

11–15 1.22 1.15 1.12 51–59

16–20 1.15 1.11 1.08 60–68

21–25 1.08 1.05 1.04 69–77

26–30 1.00 1.00 1.00 78–86

31–35 0.91 0.94 0.96 87–95

36–40 0.82 0.88 0.91 96–104

41–45 0.71 0.82 0.87 105–113

46–50 0.58 0.75 0.82 114–122

51–55 0.41 0.67 0.76 123–131

56–60 — 0.58 0.71 132–140

Table 14: Tightening torque for pressure wire connectors

Size of wire that is to be used forconnection of the unit

Tightening torque, Nm (pound-inch)Hexagonal head – external drive socket wrench

AWG/kcmil (mm2) Split-bolt Connectors Other Connectors

18 – 10 (0.82 – 5.3) 9.0 (80) 8.5 (75)

8 (8.4) 9.0 (80) 8.5 (75)

6 – 4 (13.3 – 21.2) 18.6 (165) 12.4 (110)

3 (26.7) 31.1 (275) 16.9 (150)

2 (33.6) 31.1 (275) 16.9 (150)

1 (42.4) 31.1 (275) 16.9 (150)

1/0 – 2/0 (53.5 – 67.4) 43.5 (385) 20.3 (180)

3/0 – 4/0 (85.0 – 107.2) 56.5 (500) 28.2 (250)

250 – 350 (127 – 177) 73.4 (650) 36.7 (325)

400 (203) 93.2 (825) 36.7 (325)

500 (253) 93.2 (825) 42.4 (375)

600 – 750 (304 – 380) 113.0 (1000) 42.4 (375)

800 – 1000 (406 – 508) 124.3 (1100) 56.5 (500)

1250 – 2000 (635 – 1016) 124.3 (1100) 67.8 (600)

Table 15: Conductor ampacity based on UL 508A: Industrial Control Panels

Conductor Size AmpacityAWG or kcmil (mm2)

18 (0.82) 7

16 (1.3) 10

14 (2.1) 20

12 (3.3) 25

10 (5.3) 40

8 (8.4) 60


Appendix A 1MZB101795 AReference tables



Conductor Size AmpacityAWG or kcmil (mm2)

6 (13.3) 80

4 (21.2) 105

3 (26.7) 120

2 (33.6) 140

1 (42.4) 165

1/0 (53.5) 195

2/0 (67.4) 225

3/0 (85.0) 260

4/0 (107.2) 300

250 (127) 340

300 (152) 375

350 (177) 420

400 (203) 455

500 (253) 515

600 (304) 575

700 (354) 630

750 (380) 655

800 (406) 680

1000 (508) 780

Table 16: Accessories compatible with PS1000 Fluid System

Component Type EPC Part # Manufacturer MFR Part #

Hose Barb Adapter,straight, -12 ANAluminum

Optional /Replacement

21-100106 XRP 230012BB

Hose Barb Adapter,90°, -12 AN Aluminum


21-100114 XRP 239012BB

Flare cap, -12 AN,Aluminum


21-100181 XRP 992912

Flare plug, -12 AN,Aluminum

Optional/Replacement

21-100182 XRP 980612

Hose, -12 AN size Optional /Replacement

21-100194 Aeroquip FC322-12

Ethylene or propyleneglycol with corrosioninhibitors (Volumevaries by installation)


10-100010 Peak Auto 085-13-0525

Molykote® 55 O-RingGrease


N/A Dow Corning 131997

1MZB101795 A Appendix AReference tables



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