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ABB ACQ800 Series, Hardware Manual

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68

ACQ800-37 Hardware Manual

Electrical installation

Before installation

Checking the insulation of the assembly

Drive

Do not make any voltage tolerance or insulation resistance tests (e.g. hi-pot or 
megger) on any part of the drive as testing can damage the drive. Every drive has 
been tested for insulation between the main circuit and the chassis at the factory. 
Also, there are voltage-limiting circuits inside the drive which cut down the testing 
voltage automatically.

Supply cable

Check the insulation of the supply (input) cable according to local regulations before 
connecting to the drive.

Motor and motor cable

Check the insulation of the motor and motor cable as follows:

1. Check that the motor cable is connected to the motor, and disconnected from the 

drive output terminals U2, V2 and W2.

2. Measure the insulation resistances of the motor cable and the motor between 

each phase and the Protective Earth conductor using a measuring voltage of 
500 V DC. The insulation resistance of an ABB motor must exceed 100 Mohm 
(reference value at 25 °C or 77 °F). For the insulation resistance of other motors, 
please consult the manufacturer’s instructions. 

Note:

 Moisture inside the motor 

casing will reduce the insulation resistance. If moisture is suspected, dry the 
motor and repeat the measurement.

ohm

M

3~

U1

V1

W1 PE

Summary of Contents for ACQ800 Series

Page 1: ...Hardware Manual ACQ800 37 Drives 55 to 450 kW 75 to 550 hp ACQ800 ...

Page 2: ...l ABB representative Drive hardware manuals and guides ACQ800 37 Drives 55 to 450 kW 75 to 550 hp Hardware Manual 3AXD50000038534 Drive inverter firmware manuals and guides ACQ800 Pump Control Program Firmware Manual 3AXD50000035604 Adaptive Programming Application Guide 3AFE64527274 Option manuals and guides Cabinet Options for ACS800 07 U7 17 37 Description 3AUA0000053130 Manuals and quick guide...

Page 3: ...ACQ800 37 Drives 55 to 450 kW 75 to 550 hp Hardware Manual 3AXD50000038534 REV A EN EFFECTIVE 2016 06 01 2016 ABB Oy All Rights Reserved ...

Page 4: ......

Page 5: ... manual warnings and notes Warnings caution you about conditions which can result in serious injury or death and or damage to the equipment and advise on how to avoid the danger Notes draw attention to a particular condition or fact or give information on a subject The warning symbols are used as follows Dangerous voltage warning warns of high voltages which can cause physical injury and or damage...

Page 6: ...r is applied to the drive or to the external control circuits Externally supplied control circuits may cause dangerous voltages to exist inside the drive even when the main power of the drive is switched off Do not make any insulation or voltage withstand tests on the drive or drive modules When reconnecting the motor cable always check that the phase order is correct When joining shipping splits ...

Page 7: ... instructions The brake control terminals UDC UDC R and R terminals carry a dangerous DC voltage over 500 V Depending on the external wiring dangerous voltages 115 V 220 V or 230 V may be present on the relay outputs of the drive system ...

Page 8: ...d carelessly Do not use the ramp which is supplied with the drive with heights over 50 mm 1 97 in the standard plinth height of ABB cabinets The ramp is designed for a plinth height of 50 mm 1 97 in Do not tilt Support the top and bottom of the module while removing Lift the module by the upper part only using the lifting hole s at the top Extend the support legs outside the cabinet Mind your fing...

Page 9: ...e damage or lead to malfunction Make sure that dust from drilling does not enter the drive when installing Fastening the cabinet by riveting or welding is not recommended However if welding is necessary ensure the return wire is properly connected in order not to damage the electronic equipment in the cabinet Also ensure that welding fumes are not inhaled Ensure sufficient cooling of the unit Cool...

Page 10: ...egulations As the normal leakage current of the drive is higher than 3 5 mA AC or 10 mA DC a fixed protective earth connection is required by EN 61800 5 1 4 3 5 5 2 The cross section of the protective grounding conductor must be at least 10 mm2 Cu or 16 mm2 Al WARNING Handle the fiber optic cables with care When unplugging optic cables always grab the connector not the cable itself Do not touch th...

Page 11: ...the disconnecting device means instead use the control panel keys and or commands via the I O board of the drive The maximum allowed number of charging cycles of the DC capacitors i e power ups by applying power is five in ten minutes Do not use the Prevention of unexpected start up function option Q950 for stopping the drive when the inverter unit s is running Give a Stop command instead The Safe...

Page 12: ...12 ACQ800 37 Hardware Manual Safety instructions ...

Page 13: ...on according to the frame size 19 Contents 20 Installation and commissioning flowchart 21 Inquiries 22 Terms and abbreviations 22 The ACQ800 37 What this chapter contains 25 The ACQ800 37 25 Cabinet line up 25 Frame R6 26 Frame R7i 27 Frame R8i 28 Swing out frame 29 Cabling direction 31 Operation principle 33 Line side converter 33 AC voltage and current waveforms 33 Motor side converter 35 Frame ...

Page 14: ...ing the cabinet to the floor 47 Clamping 47 Holes inside the cabinet 48 Miscellaneous 49 Cable conduit in the floor below the cabinet 49 Cooling air intake through bottom of cabinet 50 Example 50 Electric welding 51 Planning the electrical installation What this chapter contains 53 Motor selection and compatibility 53 Protecting the motor insulation and bearings 54 Requirements table 54 Thermal ov...

Page 15: ...hat this chapter contains 67 Option coding 67 Before installation 68 Checking the insulation of the assembly 68 Drive 68 Supply cable 68 Motor and motor cable 68 Input power connection Frame R6 69 Connection diagram 69 Connection procedure 69 Input power connection Frame R7i 70 Connection diagram 70 Connection procedure 70 Input power connection Frame R8i 71 Connection diagram 71 Connection proced...

Page 16: ... outputs 82 DDCS fiber optic link 82 24 V DC power input 82 Installation checklist and start up What this chapter contains 85 Installation checklist 85 Start up procedure 86 Basic checks with no voltage connected 86 Connecting voltage to input terminals and auxiliary circuit 86 Starting the supply unit 86 Checks with the supply unit running 86 Supply unit line side converter program set up 87 Inve...

Page 17: ...eplacement Frame R8i with IP21 42 101 Cabinet fan replacement Frame R8i with IP54 102 Heatsinks 103 Capacitors 103 Reforming 103 Capacitor replacement 103 Power module replacement Frame R8i 104 Extracting the module from the cubicle 105 Inserting the module into the cubicle 108 Fault tracing Faults and warnings displayed by the CDP 312R Control Panel 109 Warning Fault message from unit not being m...

Page 18: ...ean Machinery directive 122 Declaration of Conformity 123 Compliance with EN 61800 3 2004 125 Definitions 125 Category C2 125 Category C3 125 Category C4 126 C tick marking 126 Dimensions What this chapter contains 127 Cabinet line ups 127 R6 127 R7i 127 R8i 127 Frame R6 128 Frame R7i 130 Frame R8i 134 Further information Product and service inquiries 139 Product training 139 Providing feedback on...

Page 19: ...d electrical schematic symbols The manual is written for readers worldwide Both SI and imperial units are shown Special US instructions for installations within the United States that must be installed per the National Electrical Code and local codes are marked with US Common chapters for multiple products Some chapters in this manual apply to several products including the ACQ800 37 Other product...

Page 20: ...and cable routing Electrical installation describes the cabling and wiring of the drive Motor control and I O board RMIO shows external control connections to the motor control and I O board and its specifications Installation checklist and start up helps in checking the mechanical and electrical installation of the drive Maintenance contains preventive maintenance instructions Fault tracing conta...

Page 21: ...ent and correct Mechanical installation The ACQ800 37 For instructions on how to disconnect the EMC RFI filtering contact your local ABB representative If the converter has been non operational for more than one year the converter DC link capacitors need to be reformed Contact your local ABB representative for more information Only intact units may be started up Check the installation site Mechani...

Page 22: ...l drive types with different power ratings may have the same basic construction and this term is used in reference to all those drive types With the ACQ800 37 the frame size of the drive indicates the quantity and frame size of the inverter modules e g R8i To determine the frame size of a drive type see the rating tables in chapter Technical data IGBT Insulated Gate Bipolar Transistor a voltage co...

Page 23: ...ommunication System a protocol used in the optical fiber link that controls the output semiconductors of an inverter module RDCU Drive control unit The RDCU is a separate unit consisting of an RMIO board built in a plastic housing RFI Radio Frequency Interference RMIO Motor control and I O board Contains the principal inputs and outputs of the drive The RMIO is contained within the RDCU drive cont...

Page 24: ...24 ACQ800 37 Hardware Manual About this manual ...

Page 25: ...net line up The drive consists of one or more cubicles that contain the supply and motor terminals 1 IGBT supply module forming the line side converter 1 inverter module forming the motor side converter and optional equipment Frame R6 drives employ an integrated supply inverter module The actual arrangement of the cubicles varies from type to type and with the selected options See also chapter Dim...

Page 26: ...e entry exit models 3 Cable entries for power and control cables top cable entry exit models 4 Switch fuse 5 Auxiliary voltage transformer 6 Integrated line side motor side converter module 7 Input terminals bottom cable entry exit models 8 Input terminals top cable entry exit models 9 Output terminals bottom cable entry exit models 10 Output terminals top cable entry exit models 11 Control unit R...

Page 27: ... page 29 not shown The drive control units for both converter modules are installed on the swing out frame 2 Cable entries for power and control cables bottom cable entry exit models 3 Cable entries for power and control cables top cable entry exit models 4 Switch fuse 5 Auxiliary voltage transformer 6 Line side converter module 7 LCL filter 8 Motor side converter module 9 Input terminals 10 Outpu...

Page 28: ...t controller RDCU 3 Inverter unit controller RDCU 4 Switch disconnector 5 Input contactor 6 LCL filter 7 IGBT supply module 8 Intermediate DC link 9 Inverter module 10 Cooling fan for LCL filter 11 Cooling fan for IGBT supply module 12 Cooling fan for inverter module 13 Auxiliary voltage transformer accessible by opening the swing out frame 14 Auxiliary voltage circuitry relays etc 9 6 13 3 4 8 7 ...

Page 29: ...ews arrowed in the picture below and moving the swing out frame aside Depending on the frame size of the drive the actual equipment of the drive may differ from what is depicted Mounting rails for additional equipment Remove screws arrowed to open swing out frame Drive control unit RDCU with I O terminal blocks Space for optional terminal block X2 Terminal block X1 I O cable entries into swing out...

Page 30: ...ing is a generic device layout diagram for the swing out frame drive frame size R8i The diagram is also attached to the inside of the cubicle door with installed devices marked Refer to the circuit diagrams delivered with the drive for device designations ...

Page 31: ... entry IP21 42 3 Input Motor output Top entry IP54 4 Signal cable input output Bottom entry 5 Signal cable input output Top entry IP21 42 6 Signal cable input output Top entry IP54 1 6 Frame size R6 4 2 5 3 1 4 IP54 IP21 42 Description 1 Input Motor output Bottom entry 2 Input Motor output Top entry 3 Signal cable input output Bottom entry 4 Signal cable input output Top entry Frame size R7i 1 3 2...

Page 32: ...nd inverter unit cubicle 1 Standard input bottom entry 2 Standard input top entry 3 Standard output bottom exit 4 Standard output top exit 5 Signal cable input output Bottom entry 6 Signal cable input output Top entry IP54 7 Signal cable input output Top entry IP21 42 3 2 4 7 Frame size R8i 5 B ...

Page 33: ... of the drive By default the line side converter controls the DC link voltage to the peak value of the line to line voltage The DC voltage reference can also be set higher by a parameter The control of the IGBT power semiconductors is based on the Direct Torque Control DTC method also used in the motor control of the drive Two line currents and the DC link voltage are measured and used for the con...

Page 34: ...elow An example spectrum and THD value of the current at the input of the drive are shown below Each harmonic is presented in percent of nominal current n denotes the ordinal number of the harmonic I U uU iU t ms 0 1 2 3 4 5 6 7 8 9 10 THD 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 I n ...

Page 35: ...converter is controlled by an RDCU drive control unit located in the integrated line side converter side module Frame R7 and up The motor side converter is controlled by an RDCU drive control unit located in the swing out frame of the cabinet The RDCU is connected to the inverter module s by a fiber optic link distributed through an optical branching unit In the inverter modules the optic link con...

Page 36: ...tics through CDP 312R Control Panel and related accessories Note By default the Control Panel of the drive is set to control the inverter unit Motor Control and I O Board RMIO Drive Control Unit RDCU Optional module 1 I O extension RAIO RDIO or fieldbus adapter e g RMBA RDNA RPBA Optional module 2 I O extension RAIO RDIO Optional module 3 DDCS communication module RDCO 03 Fiber optic link RDCO CH0...

Page 37: ... emergency stop function G Emergency stop button Start switch 0 Cooling fans are disabled Other auxiliary voltages are on 0 S Starts the cooling fans closes the main contactor and starts the supply unit 1 0 Switches off the drive and opens the main contactor Other auxiliary voltages are on E M ER EN C Y O S T P 0 1 RESET Reset button Resets an emergency stop after which the supply unit can be star...

Page 38: ...ed between the units as follows To control the supply unit WARNING The drive does not stop by pressing the control panel Stop key in local control mode To control the inverter unit Step Action Press Display example 1 To enter the Drive Selection Mode Note In local control mode the motor side converter trips if parameter 30 02 PANEL LOSS is set to FAULT Refer to the appropriate inverter control pro...

Page 39: ...verter Dataset 123 CH1 95 08 LCU PAR1 SEL 95 09 LCU PAR2 SEL 24 04 Dataset 122 CH0 MSW fixed 106 value 110 value PARAM 23 01 AI1 AI2 AI3 FIELD BUS 11 01 DC REF SELECT 23 01 Dataset 121 CH0 MCW fixed Q REF fixed DC REF fixed Dataset 121 CH1 MCW 95 06 LCU Q PW REF 95 07 LCU DC REF Dataset 122 CH1 MSW 9 12 LCU ACT SIGNAL 1 9 13 LCU ACT SIGNAL 2 98 02 COMM MODULE INU COM LIM MCW Main Control Word MSW ...

Page 40: ...Panel regenerative braking EMC RFI filtering for 2nd Environment except frame R6 common mode filtering except frame R6 Standard Control Program top entry exit of cables coated circuit boards set of English manuals Size Refer to Technical data IEC ratings Voltage range nominal rating in bold 5 380 400 415 440 460 480 500 V AC options I O options Refer to ACQ800 Ordering Information code 64556568 En...

Page 41: ...r final position The maximum allowed deviation from the surface level is 5 mm in every 3 m 0 25 in per 12 5 ft The installation site should be levelled if necessary as the cabinet is not equipped with adjustable feet The wall behind the unit should be of non flammable material Provide the drive with the amount of fresh cooling air given in Technical data Note Very wide cabinet line ups 4200 mm 165...

Page 42: ...he lifting ropes or slings into the holes of the lifting lugs The lifting lugs can be removed not mandatory once the cabinet is in its final position If the lifting lugs are removed the bolts must be refastened to retain the degree of protection of the cabinet IP54 units Allowed minimum height of lifting ropes or slings for IP54 units is 2 m 6 6 ft ...

Page 43: ...e attempting to move the unit Remove the wooden bottom frame which is part of the shipment Lay the unit on the rollers and move it carefully until close to its final location Remove the rollers by lifting the unit with a crane fork lift pallet truck or jack as described above If the cabinet needs to be laid on its back it must be supported from below beside the cubicle seams as shown Notes Transpo...

Page 44: ...llation Final placement of the unit The cabinet can be moved into its final position with an iron bar and a wooden piece at the bottom edge of the cabinet Care is to be taken to properly place the wooden piece so as not to damage the cabinet frame ...

Page 45: ...n check the information on the type designation label of the drive to verify that the unit is of the correct type The label includes an IEC and NEMA rating C UL US and CSA markings a type code and a serial number which allow individual recognition of each unit The first digit of the serial number refers to the manufacturing plant The next four digits refer to the unit s manufacturing year and week...

Page 46: ...above the basic roof level of the cabinet see inset on left is required Note Leave some space at the left hand and right hand sides of the line up A to allow the doors to open sufficiently Note Any height adjustment must be done before fastening the units or shipping splits together Height adjustment can be done by using metal shims between the bottom frame and floor 2 Remove the lifting bars if p...

Page 47: ... a bolt The recommended maximum distance between the clamps is 800 mm 31 5 in If there is not enough working space behind the cabinet for mounting replace the lifting lugs at the top with L brackets not included and fasten the top of the cabinet to the wall Clamp dimensions in mm Cabinet frame Distances between slots Cubicle Width mm Distance in mm and inches 300 150 5 9 in 400 250 9 85 in 600 450...

Page 48: ...brackets not included and fasten the top of the cabinet to the wall Fastening holes inside the cabinet arrowed 0 5 IP 54 IP 20 42 25 mm 0 985 in Added width Side panels of the cabinet 15 mm 0 6 in Back panel of the cabinet 10 mm 0 4 in Gap between cubicles mm Distances between fastening holes Bolt size M10 to M12 3 8 in to 1 2 in Cubicle Width Distance between holes 300 150 mm 5 9 in 400 250 9 85 ...

Page 49: ...ections which the floor must carry Viewed from above Side view This area can be used for a cable conduit With heavy cabinets support the structural C sections from below Prevent the cooling air flow from the cable conduit to the cabinet with bottom plates To ensure the degree of protection for the cabinet use the original bottom plates delivered with the unit With user defined cable entries take c...

Page 50: ...e w equals the total width of adjacent cubicles with air inlets This area may or may not be consistent through the width of the whole line up Example Notes The plinth of the cabinet must be supported all around The air duct must be able to supply a sufficient volume of cooling air The minimum air flow values are given in the Technical data section of the Hardware Manual The cubicles of diode suppl...

Page 51: ...Weld only the flat bar under the cabinet never the cabinet frame itself Clamp the welding electrode onto the flat bar about to be welded or onto the floor within 0 5 m 20 in of the welding point WARNING If the welding return wire is connected improperly the welding circuit may damage electronic circuits in the cabinet The thickness of the zinc coating of the cabinet frame is 100 to 200 micrometers...

Page 52: ...52 ACQ800 37 Hardware Manual Mechanical installation ...

Page 53: ... lie within the allowed ranges of the drive control program motor nominal voltage is 1 2 to 2 UN of the drive motor nominal current is 1 6 to 2 I2hd of the drive in DTC control and 0 to 2 I2hd in scalar control The control mode is selected by a drive parameter 3 Check that the motor voltage rating meets the application requirements See notes 6 and 7 below the Requirements table If the drive is equ...

Page 54: ...rter technology The voltage of the pulses can be almost double at the motor terminals depending on the attenuation and reflection properties of the motor cable and the terminals This in turn can cause additional stress on the motor and motor cable insulation Modern variable speed drives with their fast rising voltage pulses and high switching frequencies can cause current pulses that flow through ...

Page 55: ...C 315 PN 350 kW or frame size IEC 400 PN 134 hp and frame size NEMA 500 134 hp PN 469 hp or frame size NEMA 500 PN 469 hp or frame size NEMA 580 A B B Random wound M2_ and M3_ UN 500 V Standard N N CMF 500 V UN 600 V Standard du dt du dt N du dt N CMF or Reinforced N N CMF 600 V UN 690 V Reinforced du dt du dt N du dt N CMF Form wound HX_ and AM_ 380 V UN 690 V Standard n a N CMF PN 500 kW N CMF P...

Page 56: ... voltage of the drive increases the effect being similar to increasing the supply voltage by up to 20 percent The voltage increase should be taken into consideration when determining the motor insulation requirement Example Motor insulation requirement for a 400 V application must be selected as if the drive were supplied with 480 V Note 7 Drives with an IGBT supply unit If voltage is raised by th...

Page 57: ...below Multiply the values of the graph by the supply voltage UN In case of drives with an IGBT supply unit or resistor braking the ÛLL and du dt values are approximately 20 higher Note 9 Sine filters Sine filters protect the motor insulation system Therefore a du dt filter can be replaced with a sine filter The peak phase to phase voltage with a sine filter is approximately 1 5 UN ÛLL UN Without d...

Page 58: ...t the drive input If the drive is supplied through busbars fuses must be installed at the drive input In networks with a short circuit withstand of less than 50 kA standard gG fuses are sufficient If the network has a short circuit withstand of 50 to 65 kA aR fuses are required Size the fuses according to local safety regulations appropriate input voltage and the rated current of the drive Check t...

Page 59: ...re supply cables in IT ungrounded networks A dangerous voltage can become present on the non conductive outer sheath of the cable This can cause injury or death Symmetrical shielded cable must be used for motor cabling see section Alternative power cable types on page 60 Note When continuous conduit is employed shielded cable is not required To operate as a protective conductor the shield conducti...

Page 60: ...r overall shield PE conductor and shield Shield Shield A separate PE conductor is required if the conductivity of the cable shield is less than 50 of the conductivity of a phase conductor Shield PE PE PE Not allowed for motor cabling with phase conductor cross section larger than 10 mm2 motor power 30 kW Asymmetric cable Not allowed Symmetrical cable with individual shields for each phase conducto...

Page 61: ... below 600 V AC For drives rated over 100 amperes the power cables must be rated for 75 C 167 F Conduit Where conduits must be coupled together bridge the joint with a ground conductor bonded to the conduit on each side of the joint Bond the conduits also to the drive enclosure Use separate conduits for input power motor brake resistors and control wiring When conduit is employed type MC continuou...

Page 62: ... that would trip the drive 3 Check that the power factor compensation unit is suitable for use in systems with AC drives i e harmonic generating loads In such systems the compensation unit should typically be equipped with a blocking reactor or harmonic filter Equipment connected to the motor cable Installation of safety switches contactors connection boxes etc To minimize the emission level when ...

Page 63: ...cause voltage transients when switched off The relay contacts of the RMIO board are protected with varistors 250 V against overvoltage peaks In spite of this it is highly recommended to equip inductive loads with noise attenuating circuits varistors RC filters AC or diodes DC in order to minimize the EMC emission at switch off If not suppressed the disturbances may connect capacitively or inductiv...

Page 64: ...elay controlled signals providing their voltage does not exceed 48 V can be run in the same cables as digital input signals It is recommended that the relay controlled signals be run as twisted pairs Never mix 24 V DC and 115 230 V AC signals in the same cable Relay cable The cable type with braided metallic screen e g ÖLFLEX by Lapp Kabel has been tested and approved by ABB Control panel cable In...

Page 65: ...s the main circuit of the drive For connection see the Firmware Manual Installation sites above 2000 m 6562 ft WARNING Wear appropriate protection when installing operating or servicing the RMIO board wiring and optional modules attached to the board The Protective Extra Low Voltage PELV requirements stated in EN 61800 5 1 are not fulfilled at altitudes above 2000 m 6562 ft Routing the cables Rout...

Page 66: ... Motor cable Input power cable Control cables min 200 mm 8 in min 300 mm 12 in Motor cable Power cable Drive 230 120 V 24 V 24 V 230 120 V Lead 24 V and 230 120 V control cables in separate ducts into the inside of the cabinet Not allowed unless the 24 V cable is insulated for 230 V 120 V or insulated with an insulation sleeving for 230 V 120 V ...

Page 67: ...eath WARNING During the installation procedure inverter modules may have to be temporarily extracted from the cabinet The modules have a high center of gravity In order to minimize the danger of toppling over keep the support legs if provided of the modules extended whenever maneuvering the modules outside the cabinet Option coding Some instructions contained within this chapter are intended for d...

Page 68: ...ulations before connecting to the drive Motor and motor cable Check the insulation of the motor and motor cable as follows 1 Check that the motor cable is connected to the motor and disconnected from the drive output terminals U2 V2 and W2 2 Measure the insulation resistances of the motor cable and the motor between each phase and the Protective Earth conductor using a measuring voltage of 500 V D...

Page 69: ...tries 3 Lead the cables into the inside of the cubicle It is recommended to apply 360 grounding of the cable shields at the entry as shown below 4 Connect the cables as follows Twist the cable shields into bundles and connect to cabinet PE ground busbar Connect any separate ground conductors or cables to cabinet PE ground busbar Connect the phase conductors to the input power terminals L1 L2 L3 Fo...

Page 70: ...ries 3 Lead the cables into the inside of the cubicle It is recommended to apply 360 grounding of the cable shields at the entry as shown below 4 Connect the cables as follows Twist the cable shields into bundles and connect to cabinet PE ground busbar Connect any separate ground conductors or cables to cabinet PE ground busbar Connect the phase conductors to the input power terminals L1 L2 L3 For...

Page 71: ...emove any shrouds that protect the input busbars and cable entries 3 Lead the cables into the inside of the cubicle It is recommended to apply 360 grounding of the cable shields at the entry as shown below 4 Connect the cables as follows Twist the cable shields into bundles and connect to cabinet PE ground busbar Connect any separate ground conductors or cables to cabinet PE ground busbar Connect ...

Page 72: ...ead the cables into the inside of the cubicle It is recommended to apply 360 grounding of the cable shields at the entry as shown below 4 Connect the cables as follows Twist the cable shields into bundles and connect to cabinet PE ground busbar Connect any separate ground conductors or cables to cabinet PE ground busbar Connect the phase conductors to the output power terminals U2 V2 W2 For the ti...

Page 73: ...ounding of the cable shields at the entry as shown below 4 Connect the cables as follows Twist the cable shields into bundles and connect to cabinet PE ground busbar Connect any separate ground conductors or cables to cabinet PE ground busbar Connect the phase conductors to the output power terminals U2 V2 W2 For the tightening torques see chapter Technical data 5 Provide support for the cables wh...

Page 74: ...y 360 grounding of the cable shields at the entry as shown below 4 Connect the cables as follows Twist the cable shields into bundles and connect to cabinet PE ground busbar Connect any separate ground conductors or cables to cabinet PE ground busbar Connect the phase conductors to the output power terminals U2 V2 W2 For the tightening torques see chapter Technical data 5 Provide support for the c...

Page 75: ...oor s Remove the locking screws at the edge of the swing out frame and open the frame Remove any shrouds that limit access to the cable lead throughs and cable trunking Run the cables into the inside of the cabinet through the grommets provided Top entry units only If several cables need to be run through one grommet use Loctite 5221 cat no 25551 under the grommet to seal the cable entry Run the c...

Page 76: ...xxx See the RDCO User s Manual 3AFE 64492209 English for the connections Observe color coding when installing fiber optic cables Blue connectors go to blue terminals and grey connectors to grey terminals When installing multiple modules on the same channel connect them in a ring Shield Module 2 3 4 1 Keep unshielded portion as short as possible To nearest PE terminal 2 3 4 1 Note 1 If the encoder ...

Page 77: ...A1 B1 C1 C3 A3 B3 600 V a3 n1 230 a4 n1 115 a1 b1 c1 a2 b2 c2 575 V A1 B1 C1 C3 A3 B3 575 V a3 n1 230 a4 n1 115 a1 b1 c1 a2 b2 c2 525 V A1 B1 C1 C4 A4 B4 525 V a3 n1 230 a4 n1 115 a1 b1 c1 a2 b2 c2 500 V A1 B1 C1 C4 A4 B4 500 V a3 n1 230 a4 n1 115 a1 b1 c1 a2 b2 c2 480 V A1 B1 C1 C5 A5 B5 480 V a3 n1 230 a4 n1 115 a1 b1 c1 a2 b2 c2 460 V A1 B1 C1 C5 A5 B5 460 V a3 n1 230 a4 n1 115 a1 b1 c1 a2 b2 c...

Page 78: ...78 ACQ800 37 Hardware Manual Electrical installation ...

Page 79: ...abinet installed ACQ800 drives The terminals of the RMIO board are optionally wired to terminal block X2 The connections shown below apply also to terminal block X2 the markings are identical to the ones on the RMIO board Terminals of X2 accept cables from 0 5 to 4 0 mm2 22 to 12 AWG The tightening torque for screw terminals is 0 4 to 0 8 Nm 0 3 to 0 6 lb ft For disconnecting wires from spring ter...

Page 80: ... Rin 100 ohm 6 AI2 7 AI3 By default not in use 0 4 20 mA Rin 100 ohm 8 AI3 9 AO1 Frequency 0 4 20 mA 0 motor nom speed RL 700 ohm 10 AO1 11 AO2 Actual 1 PI controller actual value 0 4 20 mA 12 AO2 X22 1 DI1 By default not in use 2 DI2 Interlock motor 1 off on 3 DI3 Interlock motor 2 off on 4 DI4 By default not in use 5 DI5 By default not in use 6 DI6 Stop Start 7 24 V 24 VDC max 100 mA 8 24 V 9 DG...

Page 81: ...load 10 mA Applicable potentiometer 1 kohm to 10 kohm Auxiliary power output Voltage 24 V DC 10 short circuit proof Maximum current 250 mA shared between this output and optional modules installed on the RMIO Analog outputs Two programmable current outputs 0 4 to 20 mA RL 700 ohm Resolution 0 1 10 bit Inaccuracy 1 Full Scale Range at 25 C 77 F Temperature coefficient 200 ppm C 111 ppm F max Digita...

Page 82: ...ibuted Drives Communication System 24 V DC power input Voltage 24 V DC 10 Typical current consumption without optional modules 250 mA Maximum current consumption 1200 mA with optional modules inserted The terminals on the RMIO board as well as on the optional modules attachable to the board fulfil the Protective Extra Low Voltage PELV requirements stated in EN 61800 5 1 provided that the external ...

Page 83: ...I3 4 DI4 9 DGND1 5 DI5 6 DI6 7 24VD 8 24VD 11 DIIL 10 DGND2 X23 1 24 V 2 GND X25 1 RO1 2 RO1 3 RO1 X26 1 RO2 2 RO2 3 RO2 X27 1 RO3 2 RO3 3 RO3 Common mode voltage between channels 15 V J1 Test voltage 500 V AC or Jumper J1 settings All digital inputs share a common ground This is the default setting Grounds of input groups DI1 DI4 and DI5 DI6 DIIL are separate isolation voltage 50 V Ground Test vo...

Page 84: ...84 ACQ800 37 Hardware Manual Motor control and I O board RMIO ...

Page 85: ...s The unit is fixed properly to floor See Mechanical installation The cooling air will flow freely ELECTRICAL INSTALLATION See Planning the electrical installation Electrical installation The motor and the driven equipment are ready for start The drive is grounded properly The supply input power voltage matches the nominal input voltage of the drive The supply input power connection to the input t...

Page 86: ...See the delivery specific circuit diagrams Check the settings of the relays and breakers switches of the auxiliary circuits Optional devices See delivery specific circuit diagrams Disconnect any unfinished or unchecked 230 115 V AC cables that lead from the terminal blocks to the outside of the equipment Connecting voltage to input terminals and auxiliary circuit WARNING When voltage is connected ...

Page 87: ...start the Line side Identification routine needs to be repeated Note It is recommended to set parameter 16 15 START MODE to LEVEL if the motor is started and stopped frequently This prolongs the life of the charging contactor if the drive is equipped with the emergency stop option when it is required to start the motor without delay after the start command or if the drive is connected to a common ...

Page 88: ... selected by parameter 98 01 COMMAND SEL and 98 02 COMM MODULE WARNING After a fault reset the converter will start if the start signal is on 0 EDGE Starts converter by EDGE of control command Control command is selected by parameter 98 01 COMMAND SEL and 98 02 COMM MODULE 1 31 AUTOMATIC RESET Automatic fault reset Automatic resets are possible only for certain fault types and when the automatic r...

Page 89: ...e for the automatic fault reset function See parameter 31 01 R 30 s 1 0 180 0 s Allowed resetting time 100 18000 31 03 DELAY TIME Defines the time that the drive will wait after a fault before attempting an automatic reset See parameter 31 01 R 0 s 0 0 3 0 s Resetting delay 0 300 31 04 OVERCURRENT Activates deactivates the automatic reset for the line converter overcurrent fault B NO NO Inactive 0...

Page 90: ...st commonly used inverter control program ACQ800 Pump Control Program Terms and abbreviations Term Definition Actual signal Signal measured or calculated by the drive Can be monitored by the user No user setting possible FbEq Fieldbus equivalent The scaling between the value shown on the control panel and the integer used in serial communication Parameter A user adjustable operation instruction of...

Page 91: ...L is set to kVAr A value of 1000 of par 95 06 equals to 1000 kVAr of par 24 02 Q POWER REF2 Value of par 24 01 Q POWER REF is then 100 1000 kVAr divided by converter nominal power in kVAr Scaling example 3 Par 24 03 Q POWER REF2 SEL is set to PHI A value of 10000 of par 95 06 equals to a value of 100 deg of parameter 24 02 Q POWER REF2 which is limited to 30 deg The value of par 24 01 Q POWER REF ...

Page 92: ...92 ACQ800 37 Hardware Manual Installation checklist and start up ...

Page 93: ...ate environment the drive requires very little maintenance This table lists the routine maintenance intervals recommended by ABB Interval Maintenance action Instruction Every year of storage Capacitor reforming See Converter module capacitor reforming instructions Code 3BFE 64059629 English and Capacitors Every 6 to 12 months depending on dustiness of environment Heatsink temperature check and cle...

Page 94: ...Open the cabinet doors 3 Check the air filters and replace if necessary see chapter Technical data for the correct filter types The inlet door filters can be accessed by removing the fastener s at the top of the grille then lifting the grille and pulling it away from the door The outlet roof filter in IP54 units has a similar mechanism 4 Check the cleanliness of the cabinet Clean the interior of t...

Page 95: ...when you handle the heavy module 4 Check the tightness of the cable connections at the quick connector Use the tightening torque table in chapter Technical data 5 Clean all contact surfaces of the quick connector and apply a layer of suitable joint compound e g Isoflex Topas NB 52 from Klüber Lubrication onto them 6 Re insert the supply inverter module 7 Repeat steps 3 to 6 for all remaining suppl...

Page 96: ...Read and repeat the steps in section Safety instructions on page 93 2 Loosen the fastening screws of the fan housing 3 Push the fan housing backwards 4 Lift the fan housing up out of the way 5 Disconnect the fan supply wires detachable connector 6 Remove the fan 7 Install the new fan in reverse order 5 2 2 6 3 4 ...

Page 97: ...verter module cooling fan replacement Frame R7i 1 Disconnect the wire plug 2 Remove the two screws holding the fan unit 3 Pull the fan unit slightly towards the front of the cubicle then downwards to free it 4 Install the new fan in reverse order 3 2 1 ...

Page 98: ...e Manual Maintenance LCL filter module cooling fan replacement Frame R7i 1 Disconnect the wire plug 1 2 Remove the two screws holding the fan unit 2 3 Pull the fan unit out 3 4 Install the new fan in reverse order 2 2 3 1 ...

Page 99: ...n ABB specified spare parts The supply and inverter control programs keep track of the running times of the cooling fans of the supply and inverter modules respectively See the Firmware Manuals delivered with the drive for the actual signals which indicate the running time Module fan replacement procedure 1 Read and repeat the steps in section Safety instructions on page 93 2 Disconnect the fan wi...

Page 100: ...ust concentration Replacements are available from ABB Do not use other than ABB specified spare parts LCL filter fan replacement procedure 1 Read and repeat the steps in section Safety instructions on page 93 2 Disconnect the fan wiring plug 1 3 Remove the screws of the fan fastening rail clip 2 4 Pull the fan out 3 5 Install a new fan in reverse order 2 1 ALCL 1x ALCL 2x 3 1 2 2 3 ...

Page 101: ...r plate together with the fan 7 Remove the four screws that fasten the fan to the holder 8 Install new fan in reverse order Cabinet fan replacement Frame R8i with IP21 42 1 Remove the eight screws attaching the fan holder to the cabinet roof 2 Lift the fan holder until the fan cable can be disconnected 3 Disconnect the fan cable 4 Remove the fan from the fan holder 5 Fasten a new fan to the fan ho...

Page 102: ...nnect the fan supply wire connector from the cabinet roof on top and inside the cabinet 6 Undo the fastening screws of the fan cassette at each corner 7 Lift the fan cassette off 8 Undo the cable ties on the top of the fan cassette 9 Disconnect the fan 10 Remove the fan capacitor by undoing the fastening screw of the clamp 11 Undo the fastening screws of the fan 12 Pull the fan out 13 Install the ...

Page 103: ...Prevent the dust from entering adjoining equipment 3 Refit the cooling fan Capacitors The inverter modules employ several electrolytic capacitors Their actual lifespan depends on the operating time of the drive loading and ambient temperature Capacitor life can be prolonged by lowering the ambient temperature It is not possible to predict capacitor failure Capacitor failure is usually followed by ...

Page 104: ...asily if handled carelessly Do not use the ramp which is supplied with the drive with heights over 50 mm 1 97 in the standard plinth height of ABB cabinets The ramp is designed for a plinth height of 50 mm 1 97 in Do not tilt Support the top and bottom of the module while removing Lift the module by the upper part only using the lifting hole s at the top Extend the support legs outside the cabinet...

Page 105: ...place lift the bracket 7b into the up position Loosen the locking screws on the sides of the bracket a bit too if necessary 8 Insert the module pull out ramp under the two screws at the base of the module and tighten WARNING Do not use the ramp which is supplied with the drive with heights over 50 mm 1 97 in the standard plinth height of ABB cabinets The ramp is designed for a plinth height of 50 ...

Page 106: ...106 ACQ800 37 Hardware Manual Maintenance 3 4 5 6 8 7b 7a ...

Page 107: ...ACQ800 37 Hardware Manual 107 Maintenance 9 10 11 View from back ...

Page 108: ...id pinching them between the module and the cubicle Also keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back 3 Fasten the module fixing screws at the top and reconnect the DC busbars 4 Connect the cables X50 fiber optic cables 5 Loosen the fastening screws at the base of the module and remove the pull out ramp Flip the module fastening br...

Page 109: ...n the line side converter when the panel is controlling the motor side converter To display the warning or fault identification text switch the control panel to view the line side converter as described in section Control panel on page 38 Conflicting ID numbers If the ID numbers of the line side and the motor side converters are set equal the control panel stops functioning To clear the situation ...

Page 110: ...form with the control panel removed Red Fault state Green The main 24 V power supply for the control panel and the RMIO board is OK AINT board visible through the transparent cover on the front of the supply and inverter modules V204 green 5 V voltage of the board is OK V309 red Prevention of unexpected start up is ON V310 green IGBT control signal transmission to the gate driver control boards is...

Page 111: ... flow Noise level I1N A Icont max A Imax A Pcont max kW I2N A PN kW I2hd A Phd kW kW m3 h dBA Three phase supply voltage 380 V 400 V 415 V 440 V 460 V 480 V or 500 V ACQ800 37 0070 5 112 120 168 75 114 75 88 55 2 4 500 73 ACQ800 37 0100 5 129 139 234 90 132 90 114 75 2 8 500 73 ACQ800 37 0120 5 145 156 264 110 148 1 90 125 75 3 4 500 73 ACQ800 37 0170 5 180 200 291 132 192 132 150 90 6 1300 74 ACQ...

Page 112: ...Size PC tool If the installation site is higher than 2000 m 6600 ft above sea level please contact your local ABB distributor or office for further information Nominal ratings I1N Nominal input current Icont max Continuous RMS output current No overloadability at 40 C 104 F Imax Maximum output current Allowable for 10 seconds at start otherwise as long as allowed by drive temperature Typical ratin...

Page 113: ...50 302 250 226 150 8 1860 75 ACQ800 37 0320 5 329 530 300 361 300 273 200 10 1860 75 ACQ800 37 0400 5 410 660 350 437 350 340 250 12 1860 75 ACQ800 37 0460 5 473 762 450 504 400 393 300 14 1860 75 ACQ800 37 0510 5 536 863 500 571 450 445 350 16 1860 75 ACQ800 37 0610 5 630 1016 550 672 550 524 400 20 1860 75 Nominal ratings I1N Nominal input current Imax Maximum output current Allowable for 10 sec...

Page 114: ...8i 1 ACS800 104 0320 5 E205 1 ALCL 12 5 1 ACS800 104 0260 5 ACQ800 37 0320 5 R8i 1 ACS800 104 0400 5 E205 1 ALCL 13 5 1 ACS800 104 0320 5 ACQ800 37 0400 5 R8i 1 ACS800 104 0460 5 E205 1 ALCL 14 5 1 ACS800 104 0400 5 ACQ800 37 0460 5 R8i 1 ACS800 104 0610 5 E205 1 ALCL 15 5 1 ACS800 104 0460 5 ACQ800 37 0510 5 R8i 1 ACS800 104 0610 5 E205 1 ALCL 15 5 1 ACS800 104 0610 5 ACQ800 37 0610 5 R8i 1 ACS80...

Page 115: ...rotection CSA C22 2 No 14 05 The drive is suitable for use on a circuit capable of delivering not more than 65 kA rms symmetrical amperes at 600 V maximum when protected by the fuses given in the fuse tables Frequency 48 63 Hz Imbalance Max 3 of nominal phase to phase input voltage Voltage dips Max 25 Power factor Harmonic distortion Harmonics are below the limits defined in IEEE519 for all Isc IL...

Page 116: ...ize M10 Tightening torque 40 Nm 29 5 lb ft 11 mm 0 43 in 24 mm 0 94 in 13 mm 0 51 in Top cable entry exit Front view Bolt size M10 Tightening torque 40 Nm 29 5 lb ft 24 mm 0 94 in Ø11 mm 0 43 in 13 mm 0 51 in Side view Bolt size M12 or 1 2 in Tightening torque 70 Nm 52 lb ft 44 5 mm 1 75 in 18 mm 0 71 in 40 mm 1 57 in 13x18 mm 0 51x0 71 in 13x18 mm 2 pcs ...

Page 117: ... frequency Frequency resolution 0 01 Hz Current See section IEC ratings Power limit 2 Phd After approximately 2 minutes at 2 Phd the limit is set at Pcont max Field weakening point 8 to 300 Hz Switching frequency 2 to 3 kHz average Motor cable lead throughs 3 Ø60 mm at each inverter module units without common motor terminal cubicle Units with common motor terminal cubicle See chapter Dimensions F...

Page 118: ...torque 40 Nm 29 5 lb ft 13 mm 0 51 in Ø11 mm 0 43 in 24 mm 0 94 in 24 mm 0 94 in Ø11 mm 0 43 in 13 mm 0 51 in Top cable entry exit Front view Bolt size M10 Tightening torque 40 Nm 29 5 lb ft Front view Bolt size M12 or 1 2 in Tightening torque 70 Nm 52 lb ft Ø11 mm 0 43 in 62 3 mm 2 45 in 85 mm 3 35 in 62 5 mm 2 46 in 40 mm 1 57 in Ø14 mm 0 55 in 40 mm 1 57 in 17 8 mm 0 70 in ...

Page 119: ...7 at rated current and nominal supply voltage Cooling Method Internal fans flow direction from bottom to top Filter material Inlet door Outlet roof IP22 IP42 units Luftfilter airTex G150 IP54 units Luftfilter airComp 300 50 Luftfilter airTex G150 Free space around the unit See chapter Mechanical installation Cooling air flow See IEC ratings Degrees of protection IP21 IP22 IP42 IP54 Bottom or top e...

Page 120: ...g Chemical gases Class 1C2 Solid particles Class 1S3 Boards without coating Chemical gases Class 2C2 Solid particles Class 2S2 Boards with coating Chemical gases Class 2C2 Solid particles Class 2S2 Atmospheric pressure 70 to 106 kPa 0 7 to 1 05 atmospheres 70 to 106 kPa 0 7 to 1 05 atmospheres 60 to 106 kPa 0 6 to 1 05 atmospheres Vibration IEC 60068 2 Max 1 mm 0 04 in 5 to 13 2 Hz max 7 m s2 23 f...

Page 121: ...orque M5 3 5 Nm 2 6 lb ft M6 9 Nm 6 6 lb ft M8 20 Nm 14 8 lb ft M10 40 Nm 29 5 lb ft M12 70 Nm 52 lb ft M16 180 Nm 133 lb ft Applicable standards The drive complies with the following standards The compliance with the European Low Voltage Directive is verified according to standards EN 61800 5 1 and EN 60204 1 EN 61800 5 1 2007 Adjustable speed electrical drives Part 5 1 Safety requirements Electr...

Page 122: ... The EMC Directive defines the requirements for immunity and emissions of electrical equipment used within the European Union The EMC product standard EN 61800 3 2004 covers requirements stated for drives See section Compliance with EN 61800 3 2004 on page 125 Compliance with the European Machinery directive The drive is an electronic product which is covered by the European Low Voltage Directive ...

Page 123: ...ACQ800 37 Hardware Manual 123 Technical data Declaration of Conformity ...

Page 124: ...124 ACQ800 37 Hardware Manual Technical data ...

Page 125: ...and control cables are selected as specified in the Hardware Manual 3 The drive is installed according to the instructions given in the Hardware Manual 4 Maximum motor cable length is 100 m 328 ft WARNING The drive may cause radio interference if used in a residential or domestic environment The user is required to take measures to prevent interference in addition to the requirements for CE compli...

Page 126: ...ual 4 The drive is installed according to the instructions given in the Hardware Manual WARNING A drive of category C4 is not intended to be used on a low voltage public network which supplies domestic premises Radio frequency interference is expected if the drive is used on such a network C tick marking C tick marking is required in Australia and New Zealand A C tick mark is attached to each driv...

Page 127: ...cabinet line up is 650 mm 25 6 in excluding door equipment such as switches and air inlet gratings This is increased by 130 mm 5 1 in with top entry exit models as well as units with cooling air intake through the bottom of the cabinet The measurements given apply to 6 pulse input non UL CSA units For dimensions of 12 pulse input or UL CSA units contact your local ABB representative The tables are...

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Page 139: ...uct training For information on ABB product training navigate to www abb com drives and select Training courses Providing feedback on ABB Drives manuals Your comments on our manuals are welcome Go to www abb com drives and select Document Library Manuals feedback form LV AC drives Document library on the Internet You can find manuals and other product documents in PDF format on the Internet Go to ...

Page 140: ...ABB Inc Discrete Automation Motion Drives and Controls 16250 West Glendale Drive New Berlin WI 53151 USA Telephone 800 752 0696 www abb com drives 3AXD50000038534 REV A EN EFFECTIVE 2016 06 01 ...

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