ABB ACS 800 Series Installation Manual Download Page 2 | Manualshive

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ACS800 Single Drive Manuals

HARDWARE MANUALS

(appropriate manual is included in the

delivery)

ACS800-01/U1 Hardware Manual 0.55 to 110 kW (0.75 to 150 HP)

3AFE64382101 (English)
ACS800-01/U1 Marine Supplement 3AFE64291275 (English)
ACS800-02/U2 Hardware Manual 90 to 500 kW (125 to 600 HP)

3AFE64567373 (English)
ACS800-11/U11 Hardware Manual 5.5 to110 kW (7.5 to 125 HP)

3AFE68367883 (English)
ACS800-04 Hardware Manual 0.55 to 132 kW

3AFE68372984 (English)
ACS800-04/04M/U4 Hardware Manual 45 to 560 kW (60 to

600 HP) 3AFE64671006 (English)
ACS800-04/04M/U4 Cabinet Installation 45 to 560 kW (60 to

600 HP) 3AFE68360323 (English)
ACS800-07/U7 Hardware Manual 45 to 560 kW (50 to 600 HP)

3AFE64702165 (English)
ACS800-07/U7 Dimensional Drawings 45 to 560 kW (50 to

600 HP) 3AFE64775421
ACS800-07 Hardware Manual 500 to 2800 kW

3AFE64731165 (English)
ACS800-17 Hardware Manual 75 to 1120 kW

3AFE64681338 (English)

• Safety instructions
• Electrical installation planning
• Mechanical and electrical installation
• Motor control and I/O board (RMIO)
• Maintenance
• Technical data
• Dimensional drawings
• Resistor braking

FIRMWARE MANUALS, SUPPLEMENTS AND GUIDES

(appropriate documents are included in the delivery)

Standard Application Program Firmware Manual

3AFE64527592 (English)
System Application Program Firmware Manual

3AFE63700177 (English)
Application Program Template Firmware Manual

3AFE64616340 (English)
Master/Follower 3AFE64590430 (English)
PFC Application Program Firmware Manual

3AFE64649337 (English)
Extruder Control Program Supplement 3AFE64648543 (English)
Centrifuge Control Program Supplement 3AFE64667246 (English)
Traverse Control Program Supplement 3AFE64618334 (English)
Crane Control Program Firmware Manual 3BSE11179 (English)
Adaptive Programming Application Guide

3AFE64527274 (English)

OPTION MANUALS

(delivered with optional equipment)

Fieldbus Adapters, I/O Extension Modules etc.

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Summary of Contents for ACS 800 Series

Page 1: ...ACS800 Rittal TS 8 Cabinet Installation ACS800 04 and ACS800 04M Drive Modules 45 to 560 kW ACS800 U4 Drives 60 to 600 HP ...

Page 2: ... ACS800 17 Hardware Manual 75 to 1120 kW 3AFE64681338 English Safety instructions Electrical installation planning Mechanical and electrical installation Motor control and I O board RMIO Maintenance Technical data Dimensional drawings Resistor braking FIRMWARE MANUALS SUPPLEMENTS AND GUIDES appropriate documents are included in the delivery Standard Application Program Firmware Manual 3AFE64527592...

Page 3: ...ACS800 04 and ACS800 04M Drive Modules 45 to 560 kW ACS800 U4 Drive Modules 60 to 600 HP Rittal TS 8 Cabinet Installation 3AFE68372330 Rev A EN EFFECTIVE 1 2 2005 2005 ABB Oy All Rights Reserved ...

Page 4: ......

Page 5: ...ing the drive module 12 Layout of the installation 13 Installation steps 14 Cable lead through plates 20 Fastening of the back mounting plate 21 Fastening of the RDCU Drive Control Unit to the side mounting plate 22 Drive module of frame size R7 with bottom exit and Rittal cooling unit What this chapter contains 23 Required Rittal parts 23 ACS800 04M parts 23 Additional parts to be provided by the...

Page 6: ...d 40 Fastening of the punched sections 41 Fastening the drive pedestal to the enclosure frame 41 Fastening of the back mounting plate 41 Dimensional drawings What this chapter contains 43 Frame size R7 44 Frame size R8 45 Air baffles for the enclosure with drive module of frame size R7 and Rittal cooling unit 46 Air baffle at the right hand side of the drive module 47 EMC screen for the enclosure ...

Page 7: ...ysical injury or death may follow or damage may occur to the drive motor or driven equipment Read the safety instructions before you work on the unit What this manual contains The manual shows a few installation examples on how to install the drive module into a Rittal TS 8 cabinet The chapters of this manual are briefly described below About this manual introduces the manual Drive module of frame...

Page 8: ...e such as safety moving and unpacking specifications of the drive e g the ratings sizes and technical requirements provisions for fulfilling the requirements for CE and other markings warranty policy etc For installation of ACS800 04M components refer to their manuals ARFI 10 EMC Filter Installation Guide 3AFE68317941 English RDCU Drive Control Unit Hardware Manual 3AFE64636324 English RPMP 11 13 ...

Page 9: ...sufficient cooling When installing the drive module in another position e g by the longer side or in a horizontal position ensure that the cooling air gratings at the front panel of the module will not be covered and the required cooling air flow is achieved For evaluating cooling refer to Rittal Therm calculation program for climate control of enclosures under www rittal com Liability The install...

Page 10: ...About this manual 10 ...

Page 11: ...nd specifications of the parts refer to www rittal com ACS800 04M parts The following ACS800 04M parts are used in the installation drive module of type ACS800 04M xxxx B060 E202 H352 J400 J410 For descriptions of the plus codes refer to ACS800 04 04M U4 Cabinet Installation 3AFE68360323 English chapter The ACS800 04 U4 and ACS800 04M Type code Rittal model no Description Qty pcs TS 8806 500 Enclo...

Page 12: ...page 18 PE busbar of dimensions 70 mm 50 mm 10 mm copper contactor optional auxiliary voltage transformer when a contactor is installed supply disconnecting device and input cable fuses See ACS800 04 04M U4 Hardware Manual 3AFE64671006 English chapters Planning the electrical installation and Technical data terminal for grounding the control cable shields and self adhesive strain reliefs to be mou...

Page 13: ... plate of the enclosure is 50 mm 1 97 in Contactor EMC filter RDCU Switch fuse 635 25 00 970 38 19 EMC compatible air filter SK 3326 267 Cutting in the door 292 292 11 50 11 50 430 95 3 74 from the door edge 1387 54 61 235 9 25 16 93 Note A mirrored layout is advantageous for servicing the drive module EMC screen Air baffle Cutting in the door 115 240 4 53 9 45 PE C rail 600 mm Side mounting plate...

Page 14: ...EMC filter to the contactor with laminated copper bars Connect laminated copper bars to the output of the contactor 7 Fasten the back mounting plate to the enclosure frame 70 mm from the back vertical profile In this location the drive module will face the enclosure door thus allowing no hot air recirculation into the drive module ventilation grating from the inside of the enclosure See also Faste...

Page 15: ...clear plastic busbar shroud to the drive module Step Instruction Photo Remove the protective film Step drill lead throughs for the busbars 9a 9b Press the top cover on the sides inwards to enable its tabs to enter the slots in the lower part of the shroud Top entry busbar shroud installed Pass the laminated copper bars through the lead throughs and the lower part of the shroud 9c 9d 9d 10 11 11 11...

Page 16: ...to Clear plastic shroud included in ACS800 04M bottom exit shroud kit B060 252 9 92 215 8 46 470 18 50 Note Remove the protective film from the shroud surfaces If the EMC screen is not used protect the output terminals against contact at the left hand side also with the clear plastic shroud EMC screen See the dimensional drawing on page 49 ...

Page 17: ... Fasten the back panel of the enclosure 15 Fasten the side panels of the enclosure Step Instruction Photo Cutting for door wires and top front bar Cutting for laminated copper bars The air baffle is needed for preventing hot air from entering the cool area of the cabinet Cooling air flow into the drive module Cooling air flow side view Air baffle 68484871 A ...

Page 18: ...ing Platform Kit Installation Guide 3AFE68400643 English Install the ventilation gratings on the door 1 Cover the edges of the cuttings with copper tape 2 Fasten the metal gratings 2a and the EMC compatible fan and air filter unit 2b 3 Place the metal mesh between the lower grating and the outer louvred grating 4 Push the louvred grating onto its place 18 Fasten the EMC gasket strip to the door as...

Page 19: ...d clamps for cable strain relief 20 Fasten the PE busbar The PE busbar is provided for grounding of the input cable shield and the motor cable shield if the PE terminal of the drive module is not used 21 Fasten shrouds over all live parts Step Instruction Photo P E b u s b a r ...

Page 20: ...s inside the grommets Cut an adequate hole to the rubber grommet Lead the cable through the grommet and the conductive sleeve as shown below In first environment installations 360 degrees grounding must be applied to motor cables and is also recommended for input cables Recommended entry for control cables in first environment installations 360 degrees grounding between the conductive cushions Not...

Page 21: ...he enclosure frame at a distance of 70 mm from the back vertical profiles The attachment in the lower left hand side corner is shown here View of the enclosure ftame when the back mounting plate without the drive module is fastened 70 mm Fastening points of the drive module ProE White Currant acs800 04 rittal_common asm _common_no_heat asm ...

Page 22: ... R7 with bottom exit 22 Fastening of the RDCU Drive Control Unit to the side mounting plate Self adhesive strain relief For grounding of the control cable shields See RDCU Drive Control Unit Hardware Manual 3AFE64636324 English ...

Page 23: ...h chapter The ACS800 04 U4 and ACS800 04M Type code Additional parts to be provided by the installer The following parts in addition to the Rittal and ACS800 04M parts listed above are needed in the installation for first environment installations EMC screen mesh which allows cooling air flow from the cooling unit to the input cable part of the enclosure See page 26 Rittal model no Description Qty...

Page 24: ...lanning the electrical installation and Technical data terminal for grounding the control cable shields and self adhesive strain reliefs to be mounted next to the RDCU Drive Control Unit See page 22 shroud over the input cable terminal connections and output connections of the disconnecting device Moving unpacking and assembling the drive module Follow the instructions given in ACS800 04 04M U4 Ca...

Page 25: ...and side panel Fastening point distances from the bottom of the back mounting plate are shown Contactor EMC filter RDCU Switch fuse Note A mirrored layout is advantageous for servicing the drive module EMC screen Cutting in the door for the control panel mounting platform 115 240 4 53 9 45 PE C rail 600 mm Side mounting plate TS 8614 240 1100 mm 300 mm Punched section TS 8612 160 600 mm Punched se...

Page 26: ...ng See chapter Dimensional drawings for the dimensional drawings of the air baffles The drive module is fastened to the back mounting plate of the enclosure leaving 50 mm 1 97 in free space in front of the module for the air inlet Cooling unit SK 3332 540 Fastening points of the top air baffle Side air baffles Front top air baffle EMC screen mesh needed in first environment installations only see ...

Page 27: ...e side panel of the enclosure for air input and output and power supply wiring of the cooling unit 2 Install the cooling unit 3 Lead the power supply wires through a lead through grommet into the enclosure 4 Connect the power supply wires and secure them with cable ties Connections in the cooling unit Fastening bolt Cutting in the side panel View of the cooling unit power supply wiring inside the ...

Page 28: ...n the enclosure door no air inlet through the door Fasten the back mounting plate at the back of the enclosure frame without moving it 70 mm inwards from the back vertical profile This is needed for allowing air to enter the front grating of the drive module as the front door of the enclosure has no gratings Fasten three air baffles that face the enclosure door one at the front top of the drive mo...

Page 29: ... in a 600 mm deep enclosure to allow the cooling air flow through the drive module In a bookshelf position the drive module would face the enclosure door and block the air flow Layout example with cooling unit on the side Door 1000 mm Output cables are connected to the vertical busbars with cable lugs without the cable terminals Input cables 600 mm Free space for drive module cooling fan replaceme...

Page 30: ... unit 30 Layout example with cooling unit on the door Input cables Door Front view without the door Output cables View from above 1000 mm 600 mm Note The cooling fan of the drive module can be replaced by removing the drive module from the enclosure ...

Page 31: ...idth height depth 800 mm 2000 mm 600 mm 1 TS 8106 235 Side panel for 2000 mm 600 mm 2 TS 8612 180 Punched section with mounting flange outer mounting level for 800 mm horizontal 3 TS 8612 400 Mounting plate 2 TS 8614 640 Mounting plate 500 mm 300 mm 1 TS 8614 840 Mounting plate 700 mm 300 mm 1 DK 7097 000 C rail cable clamp for cable diameters of 18 to 22 mm 4 DK 7099 000 C rail cable clamp for ca...

Page 32: ... page 39 power cable lead throughs An example with rubber grommets and a strain relief bracket is shown on page 40 EMC power cable lead throughs are available from ABB with code 64331116 refer to page 11 control cable lead throughs An example is shown on page 40 PE busbar of dimensions 70 mm 50 mm 10 mm copper contactor optional auxiliary voltage transformer when a contactor is installed supply di...

Page 33: ... SK 3326 607 75 2 95 from the door edge 860 33 86 Note A mirrored layout is advantageous for servicing the drive module Air baffle Cutting in the door 115 240 4 53 9 45 PE Vertical busbar shroud Air filter SK 3326 200 Cutting in the door 292 292 11 50 11 50 Mounting plate TS 8612 400 2 psc C rail 600 mm C rail 600 mm Side mounting plate TS 8614 640 500 mm 300 mm Support rail PS 4944 000 C rail 600...

Page 34: ...asten the pedestal to the enclosure frame See section Fastening the drive pedestal to the enclosure frame on page 41 7 Fasten the contactor and auxiliary voltage transformer to the back mounting plate and fasten the mounting plate to the enclosure frame See section Fastening of the back mounting plate on page 41 8 Fasten the devices to the side mounting plate 9 Slide the drive module onto the pede...

Page 35: ...ect laminated copper bars to the output of the contactor Fasten a C rail to the top of the enclosure frame and support the laminated busbars to the C rail Fastening of the switch fuse Step Instruction Photo Contactor Input terminals of the drive module Cable clamp DK 7099 000 C rail 600 mm DK 7828 060 Spacer brackets PS 4199 000 Front view Side view Punched section PS 4375 000 395 mm Punched secti...

Page 36: ...ough the lead throughs and the lower part of the shroud 13 Connect the laminated copper bars to the input terminals of the drive module 14 Fasten the top entry clear plastic busbar shroud to the drive module Step Instruction Photo Step drill lead throughs for the busbars Top entry busbar shroud fastened Remove the protective film 14 14 14 14 13 13 13 14 12 ...

Page 37: ...tering the cool area of the cabinet Cooling air flow into the drive module and cabinet Cooling air flow side view Air baffle Air baffle fastened Fasten the baffle by its top to the support rail PS 4944 000 which is fastened to the enclosure frame top Fasten the baffle by its bottom to the drive module side top fastening points Cutting for control wiring Cutting for laminated copper bars Cooling ai...

Page 38: ... the output busbars of the drive module Step Instruction Photo Self adhesive strain relief Terminal for grounding of the control cable shields Strain relief clamp Base plate 105 4 13 184 7 24 Control cable route Vertical busbar shroud fastened Note Remove the protective film from the shroud surfaces Cut the corner piece to make space for the PE terminal of the drive module When connecting the powe...

Page 39: ...osure door See page 33 22 Cut openings in the door for the ventilation gratings control panel mounting platform and other devices Fasten and wire the door devices See RPMP 11 13 Control Panel Mounting Platform Kit Installation Guide 3AFE68400643 English Install the ventilation gratings on the door as follows 1 Fasten the gratings 1a and the EMC compatible fan and air filter unit 1b 2 Place the air...

Page 40: ...ain relief 24 Fasten the PE busbar The PE busbar is provided for grounding of the input cable shield and the motor cable shield if the PE terminal of the drive module is not used 25 Fasten shrouds over all live parts Step Instruction Photo P E b u s b a r Input cable lead throughs Control cable lead throughs Motor cable lead throughs ...

Page 41: ...ing of the punched sections Fastening the drive pedestal to the enclosure frame Fastening of the back mounting plate 80 3 15 350 13 78 M8 20 combi screw Support rail PS 4396 000 600 mm Pedestal fastening clamp another clamp at the back side ...

Page 42: ...Drive module of frame size R8 42 ...

Page 43: ... of the fastening points in the drive modules used in the installation examples in this manual Dimensional drawings of air baffles and EMC screens are also shown The dimensions are given in millimetres 1 mm 0 03936996 in For other dimensional drawings refer to ACS800 04 04M U4 Cabinet Installation 3AFE68360323 English ...

Page 44: ...Dimensional drawings 44 Frame size R7 68469091_1 ...

Page 45: ...Dimensional drawings 45 Frame size R8 68469091_2 ...

Page 46: ...rawings 46 Air baffles for the enclosure with drive module of frame size R7 and Rittal cooling unit The air baffles of the layout on page 26 are shown below Air baffle at the front top of the drive module 68484901 A ...

Page 47: ...Dimensional drawings 47 Air baffle at the right hand side of the drive module 68484898 A ...

Page 48: ...Dimensional drawings 48 Air baffle at the left hand side of the drive module 68484910 A ...

Page 49: ...Dimensional drawings 49 EMC screen for the enclosure with drive module of frame size R7 The EMC screen used in the installation on page 16 is shown below 68484936 A ...

Page 50: ...Dimensional drawings 50 EMC screen mesh for the enclosure with drive module of frame size R7 and Rittal cooling unit The EMC screen mesh used in the installation on page 26 is shown below 68484944 A ...

Page 51: ......

Page 52: ...P O Box 184 FI 00381 HELSINKI FINLAND Telephone 358 10 22 11 Fax 358 10 22 22681 Internet http www abb com ABB Inc Automation Technologies Drives and Motors 16250 West Glendale Drive New Berlin WI 53151 USA Telephone 262 785 3200 800 HELP 365 Fax 262 780 5135 ...

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