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ABB ACQ810, Hardware Manual

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1)

  Delivered in PDF format on a manuals CD with the drive module.

2)

  Delivered as a printed copy with the drive module.

3)

  Delivered as a printed copy with the option.

All manuals are available in PDF format on the Internet. See section 

Document library on 

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Drive hardware manual and guide

Code (English)

ACQ810-04 hardware manual (200 to 400 kW)

3AUA0000055155

1)

ACQ810-04 quick start-up guide

3AUA0000055159

2)

Drive firmware manual

ACQ810 standard pump control program firmware manual

3AUA0000055144

1)

Option manuals and quides

ACS-CP-U control panel IP54 mounting platform kit (+J410) 
installation guide

3AUA0000049072

3)

Manuals and quick guides for I/O extension modules, fieldbus 
adapters, etc.

1)

Summary of Contents for ACQ810

Page 1: ...ABB industrial drives Hardware manual ACQ810 drive modules 200 to 400 kW 250 to 600 hp...

Page 2: ...e Internet on the inside of the back cover Drive hardware manual and guide Code English ACQ810 04 hardware manual 200 to 400 kW 3AUA0000055155 1 ACQ810 04 quick start up guide 3AUA0000055159 2 Drive f...

Page 3: ...EN EFFECTIVE 2009 09 15 2009 ABB Oy All Rights Reserved Safety instructions Mechanical installation Table of contents Electrical installation Start up Hardware manual ACQ810 04 drive modules 200 to 4...

Page 4: ......

Page 5: ...ration principle and hardware description What this chapter contains 21 Product overview 21 Layout 23 Alternative output busbar configurations 25 Control unit variants 25 Component placement 26 Power...

Page 6: ...contains 43 Safety 44 Checking the installation site 44 Required tools 44 Moving and unpacking the unit 45 Checking the delivery 45 Attaching the warning stickers 46 Fastening the cable lug terminals...

Page 7: ...verload 63 Protecting the drive against ground faults 63 Residual current device compatibility 63 Implementing the Emergency stop function 63 Implementing the Safe torque off function 64 Implementing...

Page 8: ...es 87 8 Installation checklist What this chapter contains 89 Mechanical installation 89 Cabinet construction 89 Instrumentation busbars and cabling 90 Groundings and protection 91 Labels switches fuse...

Page 9: ...13 Motor connection data 113 Control unit JCU 21 connection data 114 Efficiency 116 Degree of protection 116 Ambient conditions 116 Materials 117 Applicable standards 117 CE marking 118 Compliance wit...

Page 10: ...chapter contains 131 du dt filters 131 When is du dt filter needed 131 Selection table 131 Description installation and technical data of the FOCH filters 131 Sine filters 132 Further information Pro...

Page 11: ...ult 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 elec...

Page 12: ...me 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 ca...

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...

Page 14: ...destal before lifting Do not tilt the drive The centre of gravity of the unit is high The unit will overturn from a tilt of about 6 degrees An overturning unit can cause physical injury Beware of hot...

Page 15: ...ipment 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 ca...

Page 16: ...16 Safety instructions...

Page 17: ...rive cabinet make instructions for the end user of the drive concerning the mechanical installation of the drive cabinet power and control cabling and maintenance Read the manual before working on the...

Page 18: ...visions for fulfilling the requirements for CE and other markings Dimension drawings contains dimension drawings of the drive modules and auxiliary components Example circuit diagrams shows an example...

Page 19: ...the cabinet Mechanical installation page 43 Route the cables Routing the cables page 60 Check the insulation of the supply cable the motor and the motor cable Checking the insulation of the assembly p...

Page 20: ...Optional Modbus adapter FPBA 0x Optional PROFIBUS DP adapter Frame size Size of the drive module The drive modules described in this manual are of frame size G IGBT Insulated Gate Bipolar Transistor...

Page 21: ...er describes the operating principle and construction of the drive module in short Product overview The ACQ850 04 is a drive module for controlling asynchronous AC induction motors for water and waste...

Page 22: ...t Description Rectifier Converts the three phase AC voltage to DC voltage Capacitor bank Energy storage which stabilizes the intermediate circuit DC voltage Inverter Converts the DC voltage to AC volt...

Page 23: ...PE terminal Alternative output cable terminals when no vertical busbars are used Fastening bracket Fastening points Fastening points Additional holes for fastening the cable terminals Control unit JC...

Page 24: ...coverings of the slots removed 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 dr...

Page 25: ...he right hand long side of the module and DC busbars on the left hand side The output busbars can also be fastened on the short back side of the module For more information contact your local ABB repr...

Page 26: ...yout stickers of the drive module are shown below The stickers show all possible components Not all of them are present in each delivery or described here Components that need to be changed regularly...

Page 27: ...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 0x DeviceNet FENA 0x Ethernet IP FLON 01 LonWorks FSCA 01 Modbus FPBA...

Page 28: ...n board AIBP which includes snubbers for the thyristors and varistors power supply board APOW gate driver control board AGDR diagnostics and panel interface board JDPI Type designation label The type...

Page 29: ...dard pump control program Safe torque off function coated boards pedestal with output on the long side output busbar set for motor base and wall mounting brackets Quick start up guide multilingual and...

Page 30: ...30 Operation principle and hardware description...

Page 31: ...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 la...

Page 32: ...xamples for IP22 and IP54 cabinets are shown below 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 Ai...

Page 33: ...me of the cabinet 2 Air baffles that separate the cool and hot areas leak proof lead throughs 3 Input power cable including the protective conductors to cabinet grounding PE 4 Disconnector and fuses 5...

Page 34: ...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...

Page 35: ...ion 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 wi...

Page 36: ...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 f...

Page 37: ...so that the cooling air flow and ambient temperature requirements of the drive module are met see pages 112 and 116 The internal cooling fan of the drive module rotates at a constant speed thus blowi...

Page 38: ...oling solutions The air inlet is at the bottom of the cabinet while the outlet is at the top either on the upper part of the door or on the roof The internal cooling fans of the drive modules and reac...

Page 39: ...r and an extra exhaust fan on the roof of the cabinet Prevention the air recirculation inside the cabinet Prevent hot air circulation inside the cabinet with eg leak proof air baffles at the positions...

Page 40: ...ree space at the top of the module is shown below when the air inlet gratings are located only in the lower part of the cabinet door Note Air inlet gratings only at the lower part of the cabinet door...

Page 41: ...ars is required for cooling 2 When cables connected to the vertical output busbar terminals 50 mm 1 97 in free space around the busbar terminals is required for cooling 3 The required free space in fr...

Page 42: ...n 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 3AUA00...

Page 43: ...Mechanical installation 43 5 Mechanical installation What this chapter contains This chapter describes how to install the drive module into a cabinet...

Page 44: ...unit will overturn from a tilt of about 6 degrees An overturning unit can cause physical injury Checking the installation site The material below the drive must be non flammable and strong enough to...

Page 45: ...e present Check that there are no signs of damage Before attempting installation and operation check the information on the type designation label of the drive to verify that the unit is of the correc...

Page 46: ...ve module front cover Fastening the cable lug terminals to the output busbars 1 Fasten the grounding terminals to the long side plates of the pedestal with screws 2 Fasten the cable lug terminals to t...

Page 47: ...the output busbars to the insulating supports with M10x20 screws when no cable lug terminal is connected but with M10x25 screws when a cable lug terminal is connected as well Screwing an M10x25 screw...

Page 48: ...base with two screws 3 Place the drive module on the cabinet base and push it so that the tabs of the fastening bracket enter the slots in the drive module pedestal 4 Fasten the front bracket to the...

Page 49: ...ate through the fastening holes in its back or by using a DIN rail The following drawings show the control unit with front cover but units without covers are installed in the same way Mounting through...

Page 50: ...he control unit with four screws 2 Click the control unit to the rail as shown below B Horizontal DIN rail mounting 1 Fasten the latches A to the back of the control unit with four screws 2 Click the...

Page 51: ...regulations ABB does not assume any liability whatsoever for any installation which breaches the local laws and or other regulations Furthermore if the recommendations given by ABB are not followed th...

Page 52: ...ties of the motor cable and the terminals This can cause additional stress on the motor and motor cable insulation Modern variable speed drives with their fast rising voltage pulses and high switching...

Page 53: ...improper installation may shorten motor life or damage the motor bearings and voids the warranty Note The drive is equipped with the common mode filter as standard Motor type Nominal AC line voltage R...

Page 54: ...Reinforced LL 1800 V N or CMF N CMF 600 V UN 690 V Reinforced LL 1800 V du dt du dt N du dt N CMF Reinforced LL 2000 V 0 3 microsecond rise time N CMF N CMF Abbr Definition UN Nominal voltage of the...

Page 55: ...oltage at the motor terminals generated by the drive as well as the voltage rise time depend on the cable length The requirements for the motor insulation system given in the requirements table are wo...

Page 56: ...e is accepted for up to 500 V AC Use symmetrical shielded motor cable see page 58 Ground the shield s of motor cable s 360 at both ends Note When continuous metal conduit is employed shielded cable is...

Page 57: ...ion the cables according to local safety regulations appropriate input voltage and the load current of the drive Copper cables with concentric copper shield Aluminium cables with concentric copper shi...

Page 58: ...ed aluminum armor cable with symmetrical grounds or shielded power cable for the motor cables if metallic conduit is not used For the North American market 600 V AC cable is accepted for up to 500 V A...

Page 59: ...estos Co Gardex Oaknite CLX Shielded power cables are available from Belden LAPPKABEL LFLEX and Pirelli Selecting the control cables Shielding All control cables must be shielded Use a double shielded...

Page 60: ...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 c...

Page 61: ...n a metal enclosure with 360 degrees grounding for the shields of both the incoming and outgoing cable or connect the shields of the cables otherwise together US Install the equipment in a metal enclo...

Page 62: ...to the short circuit capacity of the supply network WARNING Due to the inherent operating principle and construction of circuit breakers independent of the manufacturer hot ionized gases may escape f...

Page 63: ...ction and use of the temperature sensors Protecting the drive against ground faults The drive is equipped with an internal ground fault protective function to protect the unit against ground faults in...

Page 64: ...isconnect the voltage of the main and auxiliary circuits from the drive Therefore maintenance work on electrical parts of the drive or the motor can only be carried out after isolating the drive syste...

Page 65: ...actor 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 volta...

Page 66: ...tor The DTC motor control operates extremely fast much faster than it takes for the contactor to open its contacts When the contactor starts opening while the drive rotates the motor the DTC will try...

Page 67: ...cted 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...

Page 68: ...connected to all digital and analogue inputs of the drive are protected against contact and insulated with basic insulation the same voltage level as the drive main circuit from other low voltage cir...

Page 69: ...Planning the electrical installation 69 Example circuit diagram See page 129...

Page 70: ...70 Planning the electrical installation...

Page 71: ...Ignoring the safety instructions can cause physical injury or death Checking the insulation of the assembly Drive Every drive module has been tested for insulation between the main circuit and the cha...

Page 72: ...each phase conductor 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 ins...

Page 73: ...grounding at the cabinet entry is recommended see page 35 6 Use a separate grounding cable if the conductivity of the cable shield is 50 of the conductivity of the phase conductor and there is no symm...

Page 74: ...the protective covering The protective covering on top of the drive module prevents dust from borings and grindings from entering the module when installing The covering is used because electrically...

Page 75: ...phase conductors to the cable lug terminals U2 V2 and W2 It is recommended to ground the motor cable shield 360 at the cabinet cable entry see page 37 For minimum radio frequency interference ground t...

Page 76: ...ode Contact your local ABB representative for further instructions Checking the settings of the cooling fan transformer The voltage transformer of the cooling fan is located at the top right hand corn...

Page 77: ...ove the cover assembly The numbers refer to the illustrations below Press the tab 1 slightly with a screwdriver Slide the lower cover plate slightly downwards and pull it out 2 Disconnect the panel ca...

Page 78: ...ol unit with four screws as shown below Grounding the control unit If the control unit is not grounded through DIN rail mounting connect the APOW cable grounding wire to the grounding terminal at the...

Page 79: ...ptic cables always grab the connector not the cable itself Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt 1 Lift the control unit from the mounting pla...

Page 80: ...odule to the cable connected to the JRIB board terminals Connecting the control cables See sections Default I O connection diagram and Control cable connection procedure below TXD transmitter RXD rece...

Page 81: ...voltage 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 Dr...

Page 82: ...be connected 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 analo...

Page 83: ...onnect 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 adju...

Page 84: ...ollowers Termination activation jumper T see section Jumpers above next to this terminal block must be set to the ON position on the drives at the ends of the drive to drive link On intermediate drive...

Page 85: ...so that the clamp presses on the bare shield 2 Connect the conductors to the appropriate detachable terminals see page 81 of the control unit At the terminal block use shrink tubing or insulating tape...

Page 86: ...lation Routing the control cables Remove outer jacket of cable at clamp to expose cable shield Tighten clamp to 1 5 N m 13 lbf in Run cables through the cover mounting bracket Use shrink tubing or tap...

Page 87: ...the control unit See page 27 for the available slots Remove the cover assembly if present from on the control unit refer to page 77 Remove the protective cover if present from the connector of the slo...

Page 88: ...88 Electrical installation...

Page 89: ...f structures busbar enclosures and cable entries are correct and completely assembled 1 2 The drive module is fastened properly to the cabinet See Planning the cabinet installation and Mechanical inst...

Page 90: ...Busbar supports and lead in insulators are visually intact and degreased and placed and mounted correctly 3 6 The electrical connections on the main circuit are tightened to required torque and marke...

Page 91: ...s inside the doors are protected against direct contact to at least IP2x if required 7 Labels 7 1 The type designation labels and warning and instruction stickers are made according to the local regul...

Page 92: ...ough a bypass connection Motor connection box and other covers are in place The ambient operating conditions are allowable See Losses cooling data and noise page 112 Ambient conditions page 116 The co...

Page 93: ...scribes the start up procedure of the drive Start up procedure Set up of the drive program according to the start up instructions given in the Quick start up guide or Firmware manual Perform the start...

Page 94: ...94 Start up...

Page 95: ...Ds of the drive module Warning 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...

Page 96: ...96 Fault tracing...

Page 97: ...e dustiness of the environment Checking the cleanliness of the cabinet and the surroundings See Cabinet Heatsink Every 3 years Checking the condition of fiber optic cables See the fault logger If PPCC...

Page 98: ...ean When necessary contact ABB for cleaning of the heatsink Fan The lifespan of the cooling fan of the drive module is about 50 000 hours The actual lifespan depends on the running time of the fan amb...

Page 99: ...er 2 Disconnect the fan capacitor and power supply wires 3 Undo the red fastening screws of the plastic side cover of the fan Shift the cover to the right to free its right hand edge and lift the cove...

Page 100: ...ect the power supply cable and the fibre optic cables from the JCU Control Unit and coil them on the top of the drive module 3 Undo the upper fastening screws of the module if used 4 Undo the screws 2...

Page 101: ...ley is available from ABB The trolley helps in removing heavy drive modules from a cabinet and in replacing the module 6 6 6 6 6 6 7 7 7 8 9 Pedestal when the module is removed M6 16 combi 8 N m 6 lbf...

Page 102: ...a capacitor failure Capacitor failure is usually followed by damage to the unit and an input cable fuse failure or a fault trip Contact ABB if capacitor failure is suspected Replacements are availabl...

Page 103: ...the front cover see 1 on page 99 Remove the profiled side plate 2 Disconnect the discharging resistor wires The upper ones are connected with the same nut as the busbar 3 Undo the fastening screws det...

Page 104: ...unit is located in the JCU Control Unit see page 24 WARNING Do not remove or insert a memory unit when the drive module is powered After power up the drive will scan the memory unit If different para...

Page 105: ...N Icont Imax I P I P A A A A A kW A hp ACQ810 302A 4 G 297 302 340 480 302 250 ACQ810 361A 4 G 355 361 400 568 361 300 ACQ810 414A 4 G 407 414 430 588 354 200 414 350 ACQ810 477A 4 G 459 477 521 588 4...

Page 106: ...ate derating use the DriveSize PC tool Note 1 The ratings apply at an ambient temperature of 40 C 104 F Note 2 To achieve the rated motor power given in the table the rated current of the drive must b...

Page 107: ...can be calculated as follows where Ik2 ph short circuit current in symmetrical two phase short circuit A U network line to line voltage V Rc cable resistance ohm Zk zk UN 2 SN transformer impedance o...

Page 108: ...rrent 9 7 kA is higher than the minimum short circuit current of the drive gG fuse type OFAF3H500 8280 A The 500 V gG fuse ABB Control OFAF3H500 can be used m 0 0273 ohm km 4 641 mohm Xc 170 410 V 2 1...

Page 109: ...melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table 00581898 00581898 Ultrarapid aR fuses Drive type ACS800 04 Input current A Min short circuit current 1 F...

Page 110: ...ration of the fuses In case of any uncertainty regarding the drive protection please contact your local ABB representative Fuses UL UL class T or L fuses for branch circuit protection per NEC are list...

Page 111: ...00 Bussmann JJS 500 T 414A 4 407 500 600 Bussmann JJS 500 T 477A 4 459 600 600 Bussmann JJS 600 T 550A 4 531 800 600 Ferraz A4BY800 L 616A 4 599 800 600 Ferraz A4BY800 L 704A 4 689 800 600 Ferraz A4BY...

Page 112: ...the detailed specification Drive type Frame size Air flow Heat dissipation Noise m3 h ft3 min W dB ACQ810 302A 4 R8 1220 718 5000 72 ACQ810 361A 4 R8 1220 718 6000 72 ACQ810 414A 4 R8 1220 718 6850 72...

Page 113: ...short circuit current IEC 60439 1 65 kA when protected by fuses given in the fuse tables Short circuit current protection UL 508C CSA C22 2 No 14 05 US and Canada The drive is suitable for use on a ci...

Page 114: ...els 0 5 V 1 15 V Rin 2 0 kohm Input type NPN PNP Filtering 0 25 ms Digital inputs outputs DIO1 and DIO2 XDIO 1 and XDIO 2 Input output mode selection by parameters DIO1 can be configured as a frequenc...

Page 115: ...cal layer RS 485 Termination by jumper Safe torque off connection XSTO Connector pitch 3 5 mm wire size 1 5 mm2 For the drive to start both connections OUT1 to IN1 and OUT2 to IN2 must be closed Contr...

Page 116: ...ce of corrosive gases Contamination levels IEC 60721 3 3 IEC 60721 3 2 IEC 60721 3 1 No conductive dust allowed Boards with coating Chemical gases Class 3C2 Solid particles Class 3S2 Boards with coati...

Page 117: ...instructions please contact your local ABB distributor Applicable standards The drive complies with the following standards The compliance with the European Low Voltage Directive is verified accordin...

Page 118: ...ns Tasman Electromagnetic Compatibility Scheme For fulfilling the requirements of the standard see section Compliance with the EN 61800 3 2004 below Compliance with the EN 61800 3 2004 Definitions EMC...

Page 119: ...ive emission is propagated to neighboring low voltage networks In some cases the inherent suppression in transformers and cables is sufficient If in doubt the supply transformer with static screening...

Page 120: ...r installation in Canada branch circuit protection must be provided in accordance with the Canadian Electrical Code and any applicable provincial codes To fulfill this requirement use the UL classifie...

Page 121: ...Dimension drawings 121 13 Dimension drawings What this chapter contains This chapter contains dimension drawings of the drive modules as well as auxiliary components...

Page 122: ...122 Dimension drawings Frame without pedestal mm 64801082_3 6 E Center of gravity...

Page 123: ...Dimension drawings 123 Frame with busbars on the left side mm 64801082_5 6 E...

Page 124: ...124 Dimension drawings Drive control unit JCU Can be mounted on a DIN rail EN 50022 35 mm x 7 5 mm...

Page 125: ...Dimension drawings 125 Package...

Page 126: ...126 Dimension drawings Dimension drawings USA Frame without pedestal inches 68440513_3 6 A 64801082 asm E Center of gravity...

Page 127: ...Dimension drawings 127 Frame with busbars on the left side inches 68440513_5 6 A 64801082 asm E...

Page 128: ...128 Dimension drawings...

Page 129: ...Example circuit diagrams 129 14 Example circuit diagrams What this chapter contains This chapter shows an example circuit diagram for a cabinet installed drive module...

Page 130: ...ot included in a basic delivery other than plus code options to be acquired by the customer Motor temperature supervision ACS CP U Control Panel Switch fuse disconnector Main contactor Supply Alarm Dr...

Page 131: ...ive page 58 Selection table du dt filter types for the drive module types are given below Description installation and technical data of the FOCH filters See FOCH du dt Filters Hardware Manual 3AFE685...

Page 132: ...132 du dt filters and sine filters Sine filters Contact your local ABB representative...

Page 133: ...ct 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 w...

Page 134: ...drives ABB Inc Automation Technologies Drives Motors 16250 West Glendale Drive New Berlin WI 53151 USA Telephone 262 785 3200 800 HELP 365 Fax 262 780 5135 www abb com drives ABB Beijing Drive System...

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