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18   Introduction to the manual

Operation principle and hardware description

 describes the drive module.

Planning the cabinet installation

 guides in planning drive cabinets and installing the drive 

module into a user-defined cabinet. The chapter gives cabinet layout examples and free 
space requirements around the module for cooling. 

Planning the electrical installation

 instructs in the motor and cable selection, protections 

and cable routing.

Installation 

describes how to install the drive module into a cabinet, connect the cables to 

the drive, and wire the drive.

Installation checklist

 contains lists for checking the mechanical and electrical installation of 

the drive.

Start-up

 refers to the start-up instructions of the cabinet-installed drive.

Fault tracing

 describes the LED indications and refers to the fault tracing instructions of the 

drive.

Maintenance

 contains preventive maintenance instructions.

Technical data

 contains the technical specifications of the drive module, eg, the ratings, 

sizes and technical requirements, provisions for fulfilling the requirements for CE and other 
markings. 

Dimension drawings

 contains dimension drawings of the drive module installed into a 

Rittal TS 8 cabinet.

Example circuit diagrams

 shows an example circuit diagram for a cabinet-installed drive 

module.

du/dt filters

 describes how to select d

u

/d

t

 filters for the drive.

Categorization by frame size and option code

The instructions, technical data and dimension drawings which concern only certain drive 
frame sizes are marked with the symbol of the frame size (G1 or G2). The frame size is 
marked on the type designation label.

The instructions and technical data which concern only certain optional selections are 
marked with option codes, eg, +J410. The options included in the drive can be identified 
from the option codes visible on the type designation label. The option selections are listed 
in section 

Type designation key

 on page

 29

. 

Quick installation, commissioning and operating 
flowchart

Task

See

Plan the installation.
Check the ambient conditions, ratings, required cooling air 
flow, input power connection, compatibility of the motor, 
motor connection, and other technical data.
Select the cables.

Planning the cabinet installation 

(page

 31

)

Planning the electrical installation 

(page

 43

)

Technical data 

(page

 117

)

Option manual (if optional equipment is 
included)

Summary of Contents for ACQ810-04

Page 1: ...ABB industry specific drives Hardware manual ACQ810 04 drive modules 200 to 500 kW 300 to 700 hp ...

Page 2: ...300 to 700 hp hardware manual 3AUA0000120538 Safe torque off function for ACSM1 ACS850 and ACQ810 drives application guide 3AFE68929814 Drive firmware manuals and guides ACQ810 standard pump control program firmware manual 3AUA0000055144 ACS850 and ACQ810 application programming application guide 3AUA0000078664 ACQ810 04 drive modules start up guide 3AUA0000055159 Option manuals and guides ACS CP ...

Page 3: ...ware manual ACQ810 04 drive modules 200 to 500 kW 300 to 700 hp 3AUA0000120538 Rev A EN EFFECTIVE 2012 06 27 2012 ABB Oy All Rights Reserved 1 Safety instructions 6 Installation Table of contents 8 Start up ...

Page 4: ......

Page 5: ...iew 23 Layout 24 Control unit variants 26 Power connections and control interfaces 27 External control unit connection cables 28 Type designation label 29 Type designation key 29 4 Planning the cabinet installation What this chapter contains 31 Basic requirements for the cabinet 31 Planning the layout of the cabinet 32 Layout examples door closed 32 Layout examples door open 33 Arranging the groun...

Page 6: ...able shield 51 Additional US requirements 52 Conduit 52 Armored cable shielded power cable 52 Selecting the control cables 52 Shielding 52 Signals in separate cables 52 Signals allowed to be run in the same cable 53 Relay cable type 53 Control panel cable length and type 53 Routing the cables 53 Separate control cable ducts 54 Continuous motor cable shield or enlosure for equipment in the motor ca...

Page 7: ...0 Mounting procedure 81 Assembly drawing of installing the drive module to the cabinet frame G1 84 Assembly drawing of installing the drive module to the cabinet frame G2 85 Removing the protective covering from the module air outlet 86 Connecting the control cables 86 Flowchart of the control cable installation process external control unit 86 Flowchart of the control cable installation process i...

Page 8: ...e interior of the heatsink 111 Fans 112 Replacing the circuit board compartment cooling fan 112 Replacing the main cooling fans 113 Replacing the drive module 114 Capacitors 116 Reforming the capacitors 116 Memory unit 116 11 Technical data What this chapter contains 117 Ratings 117 Derating 118 Ambient temperature derating 118 Altitude derating 118 Fuses IEC 119 Ultrarapid aR fuses 119 Dimensions...

Page 9: ...optional cabling panels H381 131 Frame G1 Cabling panels H381 installed into a Rittal TS 8 cabinet 133 Frame G2 Drive module dimensions 134 Frame G2 Drive module dimensions with optional cabling panels H381 135 Frame G2 Cabling panels H381 installed into a Rittal TS 8 cabinet 137 Bottom plate 138 13 Example circuit diagrams What this chapter contains 139 Example circuit diagram 140 14 du dt filter...

Page 10: ...10 ...

Page 11: ...sult in serious injury or death and or damage to the equipment and advise on how to avoid the danger The following warning symbols are used in this manual Electricity warning warns of hazards from electricity which can cause physical injury and or damage to the equipment General warning warns about conditions other than those caused by electricity which can result in physical injury and or damage ...

Page 12: ...ame is close to 0 V units with additional DC busbars Do not work on the control cables when power is applied to the drive or to the external control circuits Externally supplied control circuits may cause dangerous voltages inside the drive even when the main power on the drive is switched off Do not make any insulation or voltage withstand tests on the drive or drive modules When reconnecting the...

Page 13: ... sized as required by safety regulations In a multiple drive installation connect each drive separately to protective earth PE Where EMC emissions must be minimized make a 360 high frequency grounding of cable entries at the cabinet lead through in order to suppress electromagnetic disturbances In addition connect the cable shields to protective earth PE in order to meet safety regulations Note Po...

Page 14: ...the drive module carefully Make sure that the module does not fall down when moving it on the floor and during installation and maintenance work Open the support legs by pressing each leg a little down 1 2 and turning it aside When ever possible secure the module also with chains Do not tilt the drive module A It is heavy over 160 kg 350 lb and its center of gravity is high The module will overtur...

Page 15: ...ed on the ramp next to the fastening screw The maximum plinth height is 50 mm when the telescopic ramp is shortest and 150 mm when the ramp is longest Tighten the two fastening bolts of the ramp carefully Beware of hot surfaces Some parts such as heatsinks of power semiconductors remain hot for a while after disconnection of the electrical supply Make sure that dust from borings and grindings does...

Page 16: ...uipment Before adjusting the drive and putting it into service make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive The drive can be adjusted to operate the motor at speeds above and below the speed provided by connecting the motor directly to the power line Do not activate any automatic fault reset functions of the drive con...

Page 17: ...user of the drive concerning the mechanical installation of the drive cabinet connection of power and control cables to the cabinet installed drive and maintenance of the drive Read the manual before working on the drive You are expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols The manual is written for readers worldwide Both SI and impe...

Page 18: ...r CE and other markings Dimension drawings contains dimension drawings of the drive module installed into a Rittal TS 8 cabinet Example circuit diagrams shows an example circuit diagram for a cabinet installed drive module du dt filters describes how to select du dt filters for the drive Categorization by frame size and option code The instructions technical data and dimension drawings which conce...

Page 19: ...ling panel terminals Connect the brake resistor and DC connection cables if any to the cabling panel terminals Install the drive module into the cabinet Fasten the cabling panel busbars to the drive module busbars If external drive control unit connect the power supply and fiber optic cables from the drive module to the control unit and install the control unit into the cabinet Units without optio...

Page 20: ...g the control cables page 86 Control cable connection procedure of units with internal control unit option P905 page 99 Check the installation Installation checklist page 101 Commission the drive Start up page 105 Operating of the drive start stop speed control etc Appropriate Firmware manual Task See ...

Page 21: ...DP adapter module Frame size Size of the drive module The drive modules described in this manual are of frame size G1 and G2 FSCA 01 Optional Modbus adapter HTL High threshold logic IGBT Insulated gate bipolar transistor a voltage controlled semiconductor type widely used in converters due to their easy controllability and high switching frequency I O Input Output JCU The control unit of the drive...

Page 22: ...22 Introduction to the manual ...

Page 23: ...a drive module for controlling asynchronous AC induction motors for water and wastewater industry pump applications The main circuit of the drive module is shown below 1 AC choke 2 Rectifier Converts alternating current and voltage to direct current and voltage 3 DC link DC circuit between rectifier and inverter 4 Inverter Converts direct current and voltage to alternating current and voltage U1 V...

Page 24: ...l control unit 5 PE terminal 6 Control cable duct 7 Main cooling fans 8 Pedestal 9 Retractable support legs 10 Base fastening screws 11 Handle for pulling the drive module out of the cabinet 12 Pedestal guide plate 13 Telescopic extraction and insertion ramp 14 Top guide plate 15 Common mode filter 16 Grounding busbar for optional output cabling panel H381 7 2 1 8 3 4 5 6 9 10 11 12 13 8 15 14 16 ...

Page 25: ...n A Drive module 1 Input power cabling panel fastened to the drive module 2 Output power cabling panel fastened to the drive module 3 Front cover With option P905 the control panel is placed on this cover 4 Input power cabling panel H381 5 Side guides 6 Output power cabling panel H381 7 Rubber grommet 3 1 2 3 A 4 4 6 5 7 ...

Page 26: ...holder 0J400 a When covers are removed Control unit with control panel standard Control unit without front cover 0C168 and 0J400 a Slots 1 for optional I O extensions Slot 2 for optional fieldbus adapter Relay outputs 24VD Digital inputs Digital input outputs Analog inputs Analog outputs Drive to drive link Control panel PC connection Memory unit JMU connection External 24 V power input Safe torqu...

Page 27: ...alog I O extension FIO 21 Analog and digital I O extension FIO 31 Digital I O extension with four relays Slot 2 Fieldbus adapter FDNA 01 DeviceNet FENA 11 Ethernet IP FLON 01 LonWorks FSCA 01 Modbus FPBA 01 PROFIBUS Note When no I O extension is used the fieldbus adapter can be connected to Slot 1 X7 M 3 2 du dt or sine filter optional see page 141 2 1 See page 116 External power input XPOW Relay ...

Page 28: ...ecting the drive module and control panel to the control unit are shown below See sections Connecting the external control unit to the drive module page 88 and Connecting a PC page 99 for the actual connections 3 m 9 8 ft JINT APOW 3 m 9 8 ft 2560 mm 8 4 ft Category 5e cable JRIB 8 0 3 1 5 JCU ACQ810 04 JGDR ...

Page 29: ...ore information refer to ACQ810 04 Ordering Information 3AXD00000588241 available on request Code Description Basic code eg ACQ810 04 377A 4 Product series ACQ810 ACQ810 product series Type 04 Air cooled drive module IP00 UL Open type control panel control unit front cover EMC C3 filter in built choke boards with coating pedestal Safe torque off Common mode filter Quick Start up Guide and CD with ...

Page 30: ...1 FDNA 01 DeviceNet fieldbus adapter module K452 FLON 01 LonWorks fieldbus adapter module K454 FPBA 01 PROFIBUS DP fieldbus adapter module K458 FSCA 01 Modbus adapter module K473 FENA 11 Ethernet IP and Modbus TCP fieldbus adapter module I O extension and feedback interface modules L500 FIO 11 analog I O extension module L519 FIO 21 analog and digital I O extension module L511 FIO 31 digital I O e...

Page 31: ...of the drive system Note The installation must always be designed and made according to applicable local laws and regulations ABB does not assume any liability whatsoever for any installation which breaches the local laws and or other regulations Basic requirements for the cabinet Use a cabinet which has a frame sturdy enough to carry the weight of the drive components control circuitry and other ...

Page 32: ... lead through from top and motor cable lead through from bottom IP54 IP22 Roof air flow viewed from top IP54 1a 4 3 1b 2a 2b 5 6 1a 4 3 1b 2a 2b 5 6 1a Air inlet for the drive module 1b Air inlet for the other equipment 2a Air outlet for the drive module 2b Air outlet for the other equipment 2c Air outlet for the drive module and the other equipment an extra exhaust fan 3 Drive control panel Contr...

Page 33: ...r baffles that separate the cool and hot areas leak proof lead throughs 3 Cabinet grounding busbar PE 4 Input power cable including the protective ground conductor PE of the drive 5 Disconnector and fuses 6 Contactor 7 Drive module 8 Motor cable including the protective ground conductor of the drive 9 JCU control unit 10 External control cables 11 Grounding screws 12 Fan IP54 3 IP22 IP54 Air flow ...

Page 34: ...also be used The oxide layer from aluminium busbar joints must be removed and suitable anti oxidant joint compound applied Tightening torques Apply the following torques to grade 8 8 screws with or without joint compound that tighten electric contacts Planning the fastening of the cabinet Note the following when planning the fastening of the cabinet Fasten the cabinet to the floor from the front a...

Page 35: ... hole in galvanic metal contact in the covering cabinet structure is 100 mm 3 94 in Pay special attention to the cooling air inlet and outlet gratings The best galvanic connection between the steel panels is achieved by welding them together as no holes are necessary If welding is not possible the seams between the panels are recommended to be left unpainted and equipped with special conductive EM...

Page 36: ...unding of the motor cable shields at their entries is recommended The grounding can be implemented by a knitted wire mesh screening as shown below 360 high frequency grounding of the control cable shields is recommended at their entries The shields can be grounded by means of conductive shielding cushions pressed against the cable shield from both directions Cable ties Knitted wire mesh Bare cable...

Page 37: ...the grounding of the cable shields at the cabinet lead through Example cable lead through 1 To power cable terminals 2 Cable shield 3 PE ground terminal of the cabinet cabling panel or drive module 4 Stripped part of the cable 5 EMC sleeve 6 Lead through plate 7 Base plate 8 Strain relief 9 Conductive shielding cushions for control cables 1 2 3 4 5 6 7 8 9 ...

Page 38: ...h component For the required free space around the drive module see page 40 Also ventilate the heat dissipated by cables and other additional equipment Equip the air inlets and outlets with gratings that guide the air flow protect against contact prevent water splashes from entering the cabinet The drawing below shows two typical cabinet cooling solutions The air inlet is at the bottom of the cabi...

Page 39: ...e air inlet and outlet air inlet and outlet at different sides of the cabinet cool air inlet in the lower part of the front door and an extra exhaust fan on the roof of the cabinet Prevent hot air circulation inside the cabinet with for example leak proof air baffles at the positions shown below No gaskets are usually required Air flow out Air flow in max 40 C 104 F Drive module Drive module Horiz...

Page 40: ...he lower part of the cabinet door Free space around the drive module 20 mm 0 79 in free space around the drive module is required from the cabinet back panel and front door No free space for cooling is required on the left and right hand sides of the module The module is designed to be installed in a cabinet with the following measurements width 400 mm 15 75 in depth 600 mm 23 62 in and height 200...

Page 41: ...nel can be mounted onto the cabinet door using the control panel mounting kit J410 For the installation instructions refer to ACS CP U Control Panel IP54 Mounting Platform Kit J410 Installation Guide 3AUA0000049072 English Planning the use of the cubicle heaters Use a cubicle heater if there is a risk of condensation in the cabinet Although the primary function of the heater is to keep the air dry...

Page 42: ...42 Planning the cabinet installation ...

Page 43: ...lecting the supply disconnecting device Install a hand operated input disconnecting device between the AC power source and the drive The disconnecting device must be of a type that can be locked to the open position for installation and maintenance work The disconnecting device must be located in the cabinet in which the drive module is installed European Union To meet the European Union Directive...

Page 44: ...rive bearings protect the motor bearings See section Checking the compatibility of the motor and drive below for the required filters and N end bearings to be used with the drive Select and install the cables according to the instructions given in the hardware manual Checking the compatibility of the motor and drive Use an AC induction motor with the drive Several induction motors can be connected...

Page 45: ...ed N end bearings 100 kW PN 350 kW or IEC 315 frame size IEC 400 PN 350 kW or frame size IEC 400 134 hp PN 469 hp or NEMA 500 frame size NEMA 580 PN 469 hp or frame size NEMA 580 A B B Random wound M2_ M3_ and M4_ UN 500 V Standard N N CMF 500 V UN 600 V Standard du dt N du dt N CMF or Reinforced N N CMF 600 V UN 690 V cable length 150 m Reinforced du dt N du dt N CMF 600 V UN 690 V cable length 1...

Page 46: ...du dt N du dt N CMF or du dt CMF or Reinforced ÛLL 1800 V N or CMF N CMF 600 V UN 690 V Reinforced ÛLL 1800 V du dt N du dt N CMF Reinforced ÛLL 2000 V 0 3 microsecond rise time N CMF N CMF Abbreviation Definition UN Nominal voltage of the supply network ÛLL Peak line to line voltage at motor terminals which the motor insulation must withstand PN Motor nominal power du dt du dt filter at the outpu...

Page 47: ...equirement for Motor insulation system ABB du dt and common mode filters insulated N end motor bearings 100 kW PN 200 kW PN 200 kW 140 hp PN 268 hp PN 268 hp UN 500 V Standard N N CMF 500 V UN 600 V Standard du dt N du dt N CMF or Reinforced N N CMF 600 V UN 690 V Reinforced du dt N du dt N CMF Nominal AC line voltage Requirement for Motor insulation system ABB du dt and common mode filters insula...

Page 48: ...ions with 30 meter and longer cables The rise time can be calculated as follows t 0 8 ÛLL du dt Read ÛLL and du dt from the diagrams below Multiply the values of the graph by the supply voltage UN In case of drives with resistor braking the ÛLL and du dt values are approximately 20 higher Sine filters Sine filters protect the motor insulation system Therefore du dt filter can be replaced with a si...

Page 49: ...le see page 51 Note When continuous metal conduit is employed shielded cable is not required The conduit must have bonding at both ends as with cable shield A four conductor system is allowed for input cabling but shielded symmetrical cable is recommended To operate as a protective conductor the shield conductivity requirements according to IEC 60439 1 are shown below when the protective conductor...

Page 50: ...r copper wires 75 C 167 F wire insulation at 40 C 104 F ambient temperature Not more than three current carrying conductors in raceway or cable or earth directly buried For other conditions dimension the cables according to local safety regulations appropriate input voltage and the load current of the drive ACQ810 04 IEC 1 US 2 Cu cable type Al cable type Cu cable type Al cable type mm2 mm2 AWG kc...

Page 51: ...s shown below It consists of a concentric layer of copper wires with an open helix of copper tape or copper wire The better and tighter the shield the lower the emission level and bearing currents Recommended Symmetrical shielded cable three phase conductors and a concentric or otherwise symmetrically constructed PE conductor and a shield PE conductor and shield Shield Shield Note A separate PE co...

Page 52: ...ve in the same conduit Armored cable shielded power cable Six conductor 3 phases and 3 ground type MC continuous corrugated aluminum armor cable with symmetrical grounds is available from the following suppliers trade names in parentheses Anixter Wire Cable Philsheath BICC General Corp Philsheath Rockbestos Co Gardex Oaknite CLX Shielded power cables are available from Belden LAPPKABEL ÖLFLEX and ...

Page 53: ... routes Motor cables of several drives can be run in parallel installed next to each other It is recommended that the motor cable input power cable and control cables be installed on separate trays Avoid long parallel runs of motor cables with other cables in order to decrease electromagnetic interference caused by the rapid changes in the drive output voltage Where control cables must cross power...

Page 54: ...quipment in a metal enclosure with 360 degree grounding for the shields of both the incoming and outgoing cable or connect the shields of the cables otherwise together US Install the equipment in a metal enclosure in a way that the conduit or motor cable shielding runs consistently without breaks from the drive to the motor 24 V Lead 24 V and 230 V 120 V control cables in separate ducts inside the...

Page 55: ...tuations restrict drive damage and prevent damage to adjoining equipment in case of a short circuit inside the drive No separate fuses for the input cable protection are needed Note 2 Circuit breakers must not be used without fuses Protecting the motor and motor cable in short circuits The drive protects the motor cable and motor in a short circuit situation when the motor cable is dimensioned acc...

Page 56: ... an internal ground fault protective function to protect the unit against ground faults in the motor and motor cable This is not a personal safety or a fire protection feature The ground fault protective function can be disabled with a parameter refer to the Firmware manual Measures for protection in case of direct or indirect contact such as separation from the environment by double or reinforced...

Page 57: ...ING The Safe torque off function does not disconnect the voltage of the main and auxiliary circuits from the drive Therefore maintenance work on the electrical parts of the drive or the motor can only be carried out after isolating the drive system from the main supply Note It is not recommended to stop the drive by using the Safe torque off function If a running drive is stopped by using the Safe...

Page 58: ... the motor cables between the drive and the motor They are not meant to be used with AC drives and can cause permanent damage to the drive or themselves If there are power factor compensation capacitors in parallel with the three phase input of the drive 1 Do not connect a high power capacitor to the power line while the drive is connected The connection will cause voltage transients that may trip...

Page 59: ...mand to the drive 2 Wait until the drive decelerates the motor to zero speed 3 Open the contactor Alternative 3 When you have selected to use the scalar motor control mode in the drive open the contactor as follows 1 Give a stop command to the drive 2 Open the contactor WARNING When you have the default motor control mode DTC in use never open the output contactor while the drive rotates the motor...

Page 60: ... supply power to the drive output terminals U2 V2 and W2 Line voltage applied to the output can result in permanent damage to the unit Example bypass connection An example bypass connection is shown below Switch Description Q1 Drive main switch Q4 Bypass circuit breaker K1 Drive main contactor K4 Bypass contactor K5 Drive output contactor S11 Drive main contactor on off control S40 Motor power sup...

Page 61: ...t the drive and the motor with the drive control panel drive in the local control mode or the external start signal drive in the remote control mode Protecting the contacts of relay outputs Inductive loads relays contactors motors cause voltage transients when switched off The relay contacts on the JCU control unit are protected with varistors 250 V against overvoltage peaks In spite of this it is...

Page 62: ...nents to the digital inputs of the drive can be implemented in three alternate ways 1 There is double or reinforced insulation between the thermistor and live parts of the motor 2 Circuits connected to all digital and analog inputs of the drive are protected against contact and insulated with basic insulation the same voltage level as the drive main circuit from other low voltage circuits 3 An ext...

Page 63: ... Fastening bracket Grounding busbar Pedestal guide plate Telescopic extraction and insertion ramp Fastening screws in a plastic bag External control unit Drive module options Option code Qty pcs Description H381 1 Power cabling panels P905 1 Internal control unit Rittal parts Rittal part code Qty pcs Description TS 8406 510 1 Enclosure without mounting plate Includes frame door side and back panel...

Page 64: ... of size 4 240 mm2 per phase If resistor cables are to be connected the lower side plate of the output cabling panel must be removed and the resistor cables lead from side to the terminals of the output cabling panel Note 3 Installations without the optional cabling panels H381 Install the PE terminal as shown below Customer defined parts Cabinet bottom plate 1 The delivery does not include a cabi...

Page 65: ...Installation 65 Note 4 Mounting the drive module to an assembly panel Mount the assembly support as shown below M4 12 Torx ...

Page 66: ...e 6 Alternative installation means In addition to the installation examples presented in this chapter there are a few alternative installation means such as The power cables can be connected directly to the drive module input and output terminals with cable lugs or by busbars The drive module can also be installed self standing to the floor in an electrical equipment room when the power cable term...

Page 67: ...et for mounting the drive module busbars to the optional cabling panels H381 10 mm magnetic end socket or a Torx screw driver for mounting the drive module top fastening bracket to the cabinet back and for mounting the optional cabling panels H381 to the cabinet side panels 13 mm socket for mounting the drive module to the cabinet bottom plate or floor 22 mm magnetic end socket for mounting the ca...

Page 68: ...esidual voltage warning sticker top guide plate pedestal guide plate telescopic ramp package fastening screws in a plastic bag external control unit with control cable clamp plate and factory installed optional modules control panel with door mounting kit option J410 delivery documents printed Hardware manual and multilingual Quick start up guide and manuals CD Other printed manuals with options R...

Page 69: ...mp 4 PE terminal 5 Cardboard box 6 Pedestal guide plate 7 Top guide plate 8 Support 5 6 7 8 9 SUB 3A 3A 1 8 2 3 4 5 6 7 9 7 1 2 3 4 5 6 8 Output power cabling panel option H381 package contents 1 Paper fill 2 Cardboard tray 3 Top cardboard cover 4 Support 5 Bands 6 Plastic bag 7 Output power cabling panel 8 Side guides for Rittal cabinet assembly ...

Page 70: ...ted 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 Input cable Check the insulation of the input cable according to local regulations before connecting it to the drive 2 1 3 4 5 6 7 8 9 10 Input power cabling panel option H381 package contents 1 Screw package 2 Paper f...

Page 71: ...will reduce the insulation resistance If moisture is suspected dry the motor and repeat the measurement Checking the compatibility with IT ungrounded systems The drive is not suitable for use in an IT ungrounded system as standard Disconnect the grounding wire of the AIBP board before connecting the drive to the supply network as instructed below WARNING If a drive is installed on an IT system an ...

Page 72: ...2 Step Task For instructions see 1 Install the Rittal parts cabinet bottom plate drive bottom guide plate and top guide and loose drive options cabling panels option H381 in the drive module cubicle Installing the mechanical accessories into the cabinet page 72 2 Install the auxiliary components such as mounting plates air baffles switches busbars etc The component manufacturer s instructions Layo...

Page 73: ...ngly 4 Install the output cabling panel 5 Install the side guides to the output cabling panel 2 screws for each side guide 6 Mount the grounding busbar to the input cabling panel option H381 Back view is shown below Note The design of the grounding busbar may differ from what is shown in the figure M4 10 Torx ...

Page 74: ...74 Installation 7 Mount the side guides to the input cabling panel 2 screws for each side guide and mount the input cabling panel to the punched section ...

Page 75: ...Installation 75 Assembly drawing frame G1 ...

Page 76: ...76 Installation Assembly drawing frame G2 ...

Page 77: ...tructions page 11 Ignoring the instructions can cause physical injury or death or damage to the equipment Connection diagram INPUT OUTPUT U1 V1 W1 U2 V2 W2 ACQ810 04 H381 U1 V1 W1 3 Motor UDC UDC U2 V2 W2 U1 V1 W1 UDC UDC PE PE PE L1 L2 L3 L1 L2 L3 1 2a 3 4 5 6 7 8 2b 9 4 PE ...

Page 78: ...le of this chapter the disconnecting device is not in the same cubicle with the drive module 2 If a shielded cable is used not required but recommended and the conductivity of the shield is 50 of the conductivity of the phase conductor use a separate PE cable 2a or a cable with a grounding conductor 2b 3 360 degree grounding is recommended at the cabinet entry if a shielded cable is used Ground th...

Page 79: ...serted into the cabinet C A View without cabinet side plate in place A 360 degree grounding at the lead through plate input power cables B Grounding busbar of the input power cabling panel C 360 degree grounding at the lead through plate for the output power cables D Grounding busbar of th power cabling panel E Allowed space for power cables A U1 V1 W1 B U2 V2 W2 C D 102 mm 4 in E E ...

Page 80: ... damage to the equipment Handle the drive module carefully Make sure that the module does not fall down when moving it on the floor and during installation and maintenance work Open the support legs by pressing each leg a little down and turning it aside 1 2 When ever possible secure the module also with chains from top Do not tilt the drive module A It is heavy over 160 kg 350 lb and its center o...

Page 81: ...ted to the input cabling panel to the drive module 3 Install the extraction and insertion ramp to the cabinet base with two screws 4 Remove the upper and lower left side front covers of the drive module M4 8 combi screws 2 N m 5 Push the drive module carefully into to the cabinet preferably with help from another person 1 M8 12 Hex M8 12 Hex 2 ...

Page 82: ...e assembly drawing on page 84 frame G1 or page 85 frame G2 Note The screws ground the module to the cabinet frame 8 Units with external control unit Put back the removed front covers of the drive module on the power cable sections Units with internal control unit option P905 Put back the removed front covers of the drive module on the power cable sections after connecting the control cables to the...

Page 83: ...Installation 83 3 6a 6b 5 4 8 4 8 6a 6b 7a 7b 7b ...

Page 84: ...84 Installation Assembly drawing of installing the drive module to the cabinet frame G1 ...

Page 85: ...Installation 85 Assembly drawing of installing the drive module to the cabinet frame G2 ...

Page 86: ...Fastening the control cable clamp plate page 88 3 Install the optional modules to the control unit if not mounted yet Connecting the control cables to the terminals of the control unit page 93 4 Connect the power supply and fiber optic cables between the control unit and the drive module Connecting the external control unit to the drive module page 88 5 Mount the control unit to the wall or DIN ra...

Page 87: ...r assembly The numbers refer to the illustrations below 1 Press the tab slightly with a screwdriver 2 Slide the lower cover plate slightly downwards and pull it out 3 Disconnect the panel cable if present 4 Remove the fastening screw at the top of the cover assembly 5 Carefully pull the lower part of the base outwards by the two tabs Refit the cover in reverse order to the above when the control c...

Page 88: ...mely sensitive to dirt Connect the fiber optic cables and power supply cable coming from the drive module through the U hole in the circuit board compartment cover to the external control unit as follows 1 Thread the cables inside the back frame of the control unit as shown below 2 Insert the fiber optic cables to the JRIB board terminals 3 Connect the power supply wires to the JRIB board terminal...

Page 89: ...Installation 89 3AUA0000038989 TXD transmitter RXD receiver JRIB V2 V1 V7 V6 1 2 APOW 2 JINT 3 JRIB 1 4 4 JGDR ...

Page 90: ...il Mounting the external control unit to wall 1 Fasten the fastening screws in the wall 2 Lift the unit onto the screws and tighten the screws Mounting the external control unit vertically on a DIN rail 1 Fasten the latch A to the back of the control unit with three screws 2 Click the control unit to the rail as shown below B 3aua0000038989 1 2 2 3aua0000038989 A A B B ...

Page 91: ...chanical installation Optional modules such as a fieldbus adapters an I O extensions and the pulse encoder interfaces are inserted in the optional module slot on the control unit See page 27 for the available slots 1 Remove the control unit cover 2 Remove the protective cover if present from the connector of the slot 3 Insert the module carefully into its position on the control unit 4 Fasten the ...

Page 92: ... the screw is essential for fulfilling the EMC requirements and for proper operation of the module Wiring the modules See the appropriate optional module manual for specific installation and wiring instructions See page 93 for routing the cables ...

Page 93: ...he clamp presses on the bare shield The shield especially in case of multiple shields can also be terminated with a lug and fastened with a screw at the clamp plate Leave the other end of the shield unconnected or ground it indirectly via a few nanofarads high frequency capacitor eg 3 3 nF 630 V The shield can also be grounded directly at both ends if they are in the 3 Remove outer jacket of cable...

Page 94: ...nect the conductors to the appropriate detachable terminals of the control unit See section Jumpers page 96 Use shrink tubing or insulating tape to contain any stray strands Note Keep any signal wire pairs twisted as close to the terminals as possible Twisting the wire with its return wire reduces disturbances caused by inductive coupling ...

Page 95: ...ltage selection jumper AI1 AI2 current voltage selection jumper AI2 XAO Analog output AO1 Current AO1 1 AO1 2 Analog output AO2 Speed rpm AO2 3 AO2 4 XD2D Drive to drive link termination jumper T Drive to drive link B 1 A 2 BGND 3 XSTO Safe torque off Both circuits must be closed for the drive to start OUT1 1 OUT2 2 IN1 3 IN2 4 Control panel connection Memory unit connection Notes denotes default ...

Page 96: ...nnected to XD24 2 The common can be either GND or Vcc as DI1 DI4 are of the NPN PNP type AI1 Determines whether analog input AI1 is used as a current or voltage input AI2 Determines whether analog input AI2 is used as a current or voltage input T Drive to drive link termination Must be set to the ON position when the drive is the last unit on the link 1 DIGND floats DIGND tied to DIOGND XD24 2 4 2...

Page 97: ... both ends of the cable shields directly to ground If a capacitor cannot be used at one end leave that end of the shield unconnected The connection of temperature sensors involves parameter adjustment See the Firmware manual of the drive Pt100 sensors are not to be connected to the thermistor input Instead an analog input and an analog current output located either on the JCU or on an I O extensio...

Page 98: ...f the drive to drive link On intermediate drives the jumper must be set to the OFF position Shielded twisted pair cable 100 ohm for example PROFIBUS compatible cable must be used for the wiring For best immunity high quality cable is recommended The cable should be kept as short as possible the maximum length of the link is 100 meters 328 ft Unnecessary loops and running the cable near power cable...

Page 99: ...grees at the cabinet lead through plate recommendation 6 Ground the control cables at the clamp plate as described in bullet 2 under Connecting the control cables to the terminals of the control unit on page 93 7 Connect the conductors to the appropriate detachable terminals of the control unit see page 96 Use shrink tubing or insulating tape to contain any stray strands Tighten the screws to secu...

Page 100: ...100 Installation ...

Page 101: ...cal injury or death or damage to the equipment Check that Cabinet construction The drive module is fastened properly to the cabinet See chapters Planning the cabinet installation and Installation Mechanical joints are tightened and not broken Parts are clean and painted surfaces not scratched The cabinet frame and parts which are in metal to metal contact with the frame for example seams component...

Page 102: ...ntrol panel cable is connected properly Cables are not lying against sharp edges or bare live parts Bending radius of fiber optic cables at least 3 5 cm 1 38 in The type markings insulation plates and cross connections of terminal blocks are correct Grounding and protection The grounding colors cross section and grounding points of modules and other equipment match the circuit diagrams No long rou...

Page 103: ...age of the drive Check the type designation label The input power cable has been connected to the appropriate terminals the phase order is right and the terminals have been tightened Pull the conductors to check Appropriate AC fuses and main disconnector have been installed The motor cable has been connected to the appropriate terminals the phase order is right and the terminals have been tightene...

Page 104: ...104 Installation checklist ...

Page 105: ...lation of the drive has been checked according to the checklist in chapter Installation checklist and that the motor and driven equipment are ready for start 2 Perform the start up tasks instructed by the cabinet installer of the drive module 3 Switch the power on and set up the drive control program according to the start up instructions given in the drive Firmware manual ...

Page 106: ...106 Start up ...

Page 107: ...rning and fault messages See the Firmware manual for the descriptions causes and remedies of the control program warning and fault messages Where LED When the LED is lit JINT board V204 green 5 V voltage of the board is OK V309 red Not in use V310 green IGBT control signal transmission to the gate driver control boards is enabled BFPS board V79 green 5 V voltage of the board is OK ...

Page 108: ...108 Fault tracing ...

Page 109: ...s table lists the routine maintenance intervals recommended by ABB Interval Maintenance Instruction Every year Checking main cooling fan and circuit board cooling fan tightness of terminals dustiness corrosion temperature and quality of supply voltage Maintenance if needed See sections Cabinet and Heatsink on page 111 Every year when stored Capacitor reforming See section Reforming the capacitors ...

Page 110: ...ibed under Safety in installation and maintenance on page 12 have been taken into consideration 2 When necessary clean the interior of the cabinet with a soft brush and a vacuum cleaner Every 9 years Every 6 years if ambient temperature in continuous operation is over 40 C 104 F Main cooling fan change See section Fans on page 112 Every 6 years Every 3 years if the ambient temperature is 40 C 104 ...

Page 111: ... with antistatic hose and nozzle Using a normal vacuum cleaner creates static discharges which can damage circuit boards 1 Ensure that the drive is disconnected from the power line and all other precautions described under Safety in installation and maintenance on page 12 have been taken into consideration 2 Undo the fastening screws of the handle plate of the drive module 3 Remove the handle plat...

Page 112: ...ans are available from ABB Do not use other than ABB specified spare parts Replacing the circuit board compartment cooling fan WARNING Follow the safety instructions page 11 Ignoring the instructions can cause physical injury or death or damage to the equipment 1 Remove the drive module out of the cabinet as described in section Replacing the drive module on page 114 2 Undo the fastening screw of ...

Page 113: ...ibed in section Replacing the drive module on page 114 2 Open the support legs of the pedestal 3 Undo the two screws that fasten the fan assembly plate 4 Tilt the fan assembly plate down 5 Disconnect the power supply wires of the fans 6 Remove the fan assembly from the drive module 7 Undo the fastening screws of the fan s and remove the fan s from the assembly plate 8 Install the new fan s in reve...

Page 114: ...ion and maintenance on page 12 have been taken into consideration 2 Remove the left hand side upper and lower front covers of the drive module by undoing the fastening screws M4 8 combi screws 2 N m 3 Disconnect the drive module busbars from the input cabling panel Combi screw M12 70 N m 52 lbf ft 4 Disconnect the drive module busbars from the output cabling panel Combi screw M12 70 N m 52 lbf ft ...

Page 115: ...Maintenance 115 8 Pull the drive module carefully out of the cabinet preferably with help from another person 9 Install the new module in reverse order to the above 6 3 4 8 5 5 2 2 ...

Page 116: ...pacitors must be reformed if the drive module has been stored for a year or more See page 29 for information on finding out the manufacturing date For the reforming instructions see Converter modules with electrolytic DC capacitors in the DC link capacitor reforming instructions 3BFE64059629 English Memory unit When a drive module is replaced the parameter settings can be retained by transferring ...

Page 117: ...and 480 V AC 50 Hz and 60 Hz supply are given below Drive type ACQ810 04 Frame size Input ratings Output ratings Nominal IEC M2 M3 UL NEMA I1N I2N Icont Imax I P kW I P hp A A A A A Un 400 V A Un 480 V 377A 4 G1 377 377 387 470 387 200 361 300 480A 4 G1 480 480 500 560 492 250 477 400 570A 4 G1 570 570 580 680 580 315 515 450 634A 4 G1 634 634 650 730 650 355 590 500 700A 4 G2 700 700 710 850 710 ...

Page 118: ... Nominal input current rms I2N Nominal output current 110 overload is allowed for 1 minute every 5 minutes Icont Continuous rms output currents with no overload capability Imax Maximum output current Available for 10 seconds at start otherwise as long as allowed by drive temperature Un Supply voltage P Typical motor power Note 1 The ratings apply at an ambient temperature of 40 C 104 F Note 2 To a...

Page 119: ...8554D DIN3 785A 4 790 1400 2700000 690 Bussmann 170M8555D DIN3 857A 4 860 1400 2700000 690 Bussmann 170M8555D DIN3 Note 1 See also Implementing thermal overload and short circuit protection on page 55 Note 2 In multicable installations install only one fuse per phase not one fuse per conductor Note 3 Larger fuses than the recommended ones must not be used Note 4 Fuses from other manufacturers can ...

Page 120: ... 355 570A 4 57 56 61 42 12 01 12 95 19 88 20 28 355 634A 4 57 56 61 42 12 01 12 95 19 88 20 28 355 700A 4 65 43 67 32 12 01 12 95 19 88 20 28 439 785A 4 65 43 67 32 12 01 12 95 19 88 20 28 439 857A 4 65 43 67 32 12 01 12 95 19 88 20 28 439 H1 Height of the basic unit H2 Height of the unit with optional cabling panels H381 Note The no pedestal option H354 reduces the height of the unit by 125 mm 4 ...

Page 121: ...ional cabling panels no H381 In units without optional cabling panels option H381 not selected it is possible to use the maximum cable size 4 3 240 mm2 or 4 3 500 AWG only with special cable lugs and additional insulation For more information contact your local ABB representative Terminal data for the control cables See page 95 Drive type ACQ810 04 Frame size Air flow Heat dissipation Noise m3 h f...

Page 122: ...trol Scalar control 300 m 984 ft 300 m 984 ft Note Motor cable longer than 100 m 328 ft is allowed but then the EMC Directive requirements of Category C3 may not be fulfilled Control unit JCU 21 connection data Power supply 24 V 10 DC 1 6 A Supplied from the power unit of the drive or from an external power supply through connector XPOW pitch 5 mm wire size 2 5 mm2 Relay outputs RO1 RO2 XRO1 XRO2 ...

Page 123: ... Rload 1 kohm Analog inputs AI1 and AI2 XAI 4 XAI 7 Current voltage input mode selection by jumpers See page 96 Connector pitch 3 5 mm wire size 1 5 mm2 Current input 20 20 mA Rin 100 ohm Voltage input 10 10 V Rin 200 kohm Differential inputs common mode 20 V Sampling interval per channel 0 25 ms Filtering 0 25 ms Resolution 11 bit sign bit Inaccuracy 1 of full scale range Analog outputs AO1 and A...

Page 124: ...on top of the module Ambient conditions Environmental limits for the drive are given below The drive is to be used in a heated indoor controlled environment Operation installed for stationary use Storage in the protective package Transportation in the protective package Installation site altitude 0 to 4000 m 0 to 13000 ft IT network 2000 m 6560 ft derating above 1000 m 3280 ft 1 100 m 328 ft See s...

Page 125: ...ould be recycled to preserve energy and natural resources The package materials are environmentally compatible and recyclable All metal parts can be recycled The plastic parts can either be recycled or burned under controlled circumstances according to local regulations Most recyclable parts are marked with recycling marks If recycling is not feasible all parts excluding electrolytic capacitors an...

Page 126: ...nitions EMC stands for Electromagnetic Compatibility It is the ability of electrical electronic equipment to operate without problems within an electromagnetic environment Likewise the equipment must not disturb or interfere with any other product or system within its locality First environment includes establishments connected to a low voltage network which supplies buildings used for domestic pu...

Page 127: ...bouring low voltage networks In some cases the inherent suppression in transformers and cables is sufficient If in doubt the supply transformer with static screening between the primary and secondary windings can be used 2 An EMC plan for preventing disturbances is drawn up for the installation A template is available from the local ABB representative 3 The motor and control cables are selected as...

Page 128: ...128 Technical data ...

Page 129: ...Dimension drawings 129 12 Dimension drawings What this chapter contains This chapter contains dimension drawings of the drive modules with optional parts for Rittal TS 8 cabinet assembly ...

Page 130: ...130 Dimension drawings Frame G1 Drive module dimensions ...

Page 131: ...Dimension drawings 131 Frame G1 Drive module dimensions with optional cabling panels H381 ...

Page 132: ...132 Dimension drawings ...

Page 133: ...Dimension drawings 133 Frame G1 Cabling panels H381 installed into a Rittal TS 8 cabinet ...

Page 134: ...134 Dimension drawings Frame G2 Drive module dimensions ...

Page 135: ...Dimension drawings 135 Frame G2 Drive module dimensions with optional cabling panels H381 ...

Page 136: ...136 Dimension drawings ...

Page 137: ...Dimension drawings 137 Frame G2 Cabling panels H381 installed into a Rittal TS 8 cabinet ...

Page 138: ...138 Dimension drawings Bottom plate ...

Page 139: ...Example circuit diagrams 139 13 Example circuit diagrams What this chapter contains This chapter shows an example circuit diagram for a cabinet installed drive module ...

Page 140: ...h are not included in a basic delivery plus code options other options to be acquired by the customer Motor temperature supervision ACS CP U Control Panel Switch fuse disconnector Main contactor Supply Alarm Drive module JCU Control Unit 3 Motor Cabinet Common mode filter du dt filter Line filter Input and output signals see page 95 360 degree grounding recommended ...

Page 141: ... motor and drive page 44 Selection table du dt filter types for the drive module types are given below Contact ABB for the filter type Description installation and technical data of the FOCH filters See FOCH du dt filters hardware manual 3AFE68577519 English Drive type ACQ810 04 du dt filter type 377A 4 FOCH0610 70 480A 4 FOCH0610 70 570A 4 FOCH0610 70 634A 4 FOCH0610 70 700A 4 FOCH0610 70 785A 4 ...

Page 142: ...142 du dt filters ...

Page 143: ...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 144: ...3AUA0000120538 Rev A EN 2012 06 27 Contact us www abb com drives www abb com drivespartners ...

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