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75

Maintenance

Capacitors

The drive intermediate circuit employs several electrolytic capacitors. Their lifespan
is at least 90 000 hours depending on the operating time of the drive, loading and
ambient temperature. Capacitor life can be prolonged by lowering the ambient
temperature.

It is not possible to predict 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 available from ABB. Do not use
other than ABB specified spare parts.

Reforming

Reform (re-age) spare part capacitors once a year according to

ACS 600/800

Capacitor Reforming Guide

[code: 64059629 (English)].

Replacing the Capacitor Pack (R7)

Replace the capacitor pack as described in section "Replacing the Drive Module Fan
(R7)".

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Summary of Contents for ACS 800 Series

Page 1: ...ACS800 Hardware Manual ACS800 PC Drives 150 to 600 HP...

Page 2: ...lication Program Firmware Manual 3AFE64527592 English System Application Program Firmware Manual 3AFE63700177 English Application Program Template Firmware Manual 3AFE64616340 English Master Follower...

Page 3: ...ACS800 PC Drives 150 to 600 HP Hardware Manual 3AUA0000010601 Rev C EFFECTIVE 10 16 2009 2009 ABB Inc All Rights Reserved...

Page 4: ......

Page 5: ...in serious injury or death and or damage to the equipment They also tell you how to avoid the danger Notes draw attention to a particular condition or fact or give information on a subject The warning...

Page 6: ...trol 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 Wh...

Page 7: ...amage or lead to malfunction Ensure sufficient cooling Welding of the cabinet frame is not recommended However if electric welding is the only way to mount the cabinet follow the instructions given in...

Page 8: ...d the drive the motor and adjoining equipment to ensure personnel safety in all circumstances and to reduce electromagnetic emission and pick up Make sure that grounding conductors are adequately size...

Page 9: ...ve and resume operation after a fault Do not control the motor with the disconnecting device disconnecting means instead use the control panel keys and or commands via the I O board of the drive The m...

Page 10: ...the supply connections become live Installation and Maintenance Work Before installation and maintenance work on the drive Disconnect the motor from the drive with a safety switch and additionally if...

Page 11: ...he Code 14 Contents 15 Installation and Commissioning Flowchart 16 Inquiries 17 The ACS800 PC What this Chapter Contains 18 The ACS800 PC 18 Type Code 19 Product Ordering Special Note 20 Main Circuit...

Page 12: ...king the Insulation of the Assembly 46 Warning Sticker 46 Example Wiring Diagram 47 Power Cable Connection Diagram 48 Connecting the Power Cables 49 Connecting the Control Cables 50 Installation of Op...

Page 13: ...cable Standards 90 CE Marking 91 Equipment Warranty and Liability 92 Dimensional Drawings Resistor Braking What this Chapter Contains 95 To Which Products this Chapter Applies 95 Availability of Brake...

Page 14: ...e National Electrical Code and local codes are marked with US Common Chapters for Products Chapters Planning the Electrical Installation Motor Control and I O Board RMIO and Resistor Braking apply to...

Page 15: ...nstructs how to wire the drive Motor Control and I O Board RMIO shows external control connections to the motor control and I O board and its specifications Installation Checklist and Start Up helps i...

Page 16: ...capacitors need to be reformed Ask ABB for instructions Check the installation site Mechanical Installation Before Installation Technical Data If the drive is about to be connected to an IT ungrounde...

Page 17: ...s Address any inquiries about the product to the local ABB representative quoting the type code and the serial number of the unit If the local ABB representative cannot be contacted address inquiries...

Page 18: ...net installed drive for controlling AC motors Control Panel Emergency Stop Drive Control Unit RDCU RMIO Switch Handle Circuit Breaker Cabinet Filter Drive Module Swing frame with options Circuit Break...

Page 19: ...Environment EMC filter in frame R8 boards with coating one set of manuals Size Refer to Technical Data NEMA Ratings Voltage range nominal rating in bold 5 460 480 500 VAC 7 525 575 600 690 VAC options...

Page 20: ...always supplied with exhaust fan and are not available without the exhaust fan Main Circuit and Control Door Switches The following switches are mounted on the cabinet door when option F250 Q951 is in...

Page 21: ...torage which stabilizes the intermediate circuit DC voltage six pulse IGBT inverter converts the DC voltage to AC voltage The motor operation is controlled by switching the IGBTs Motor control and I O...

Page 22: ...e protection board AIBP which includes varistors and snubbers for the thyristors Power supply board APOW Gate driver control board AGDR Diagnostics and panel interface board ADPI Brake chopper control...

Page 23: ...of the drive Moving the Unit Move the transport package by truck and pallet truck to the installation site WARNING The ACS800 PC is to be handled and shipped standing up ONLY This unit is not designe...

Page 24: ...t The first digit of the serial number refers to the manufacturing plant The next four digits refer to the unit s manufacturing year and week respectively The remaining digits complete the serial numb...

Page 25: ...of protection NEMA 1 UL Type 1 enclosures typically are not the best selection for installation on industrial factory floors NEMA 12 NEMA Standard 7 15 1991 Type 12 enclosures are intended for indoor...

Page 26: ...t can be fastened against a wall or back to back with another cabinet Refer to Dimensional Drawings for the horizontal and vertical fastening points Height adjustment can be done by using metal shims...

Page 27: ...et Through the Holes Inside the Cabinet The cabinet can be fastened to the floor using the fastening holes inside the cabinet The maximum allowed distance between the fastening points is 800 mm 31 50...

Page 28: ...as follows Connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0 5 metres of the welding point WARNING If the welding return wire is connected improperly t...

Page 29: ...ram Motor nominal voltage is 1 2 2 UN of the drive Motor nominal current is 1 6 2 I2hd of the drive in DTC control and 0 2 I2hd in scalar control The control mode is selected by a drive parameter 3 Ch...

Page 30: ...ng modern IGBT inverter technology The voltage of the pulses can be almost double at the motor terminals depending on the attenuation and reflection properties of the motor cable and the terminals Thi...

Page 31: ...500 134 HP PN 469 HP or frame size NEMA 500 PN 469 HP or frame size NEMA 580 A B B Random wound M2_ and M3_ UN 500 V Standard N N CMF 500 V UN 600 V Standard du dt du dt N du dt N CMF or Reinforced N...

Page 32: ...100 kW Apply the requirements of range PN 350 kW to motors within the range 100 kW PN 350 kW In other cases consult the motor manufacturer Note 4 HXR and AMA motors All AMA machines manufactured in H...

Page 33: ...us motor and the motor cable The switch is needed to isolate the motor during any maintenance work on the drive Supply Connection Disconnecting Device Disconnecting Means ACS800 01 ACS800 U1 ACS800 02...

Page 34: ...sted in Technical Data The fuses restrict drive damage and prevent damage to adjoining equipment in case of a short circuit inside the drive Operating Time of the Fuses Check that the operating time o...

Page 35: ...tial ACS800 02 U2 with Enclosure Extension ACS800 07 U7 and ACS800 PC An emergency stop function is optionally available for stopping and switching off the whole drive Two stop categories according to...

Page 36: ...nalling that the prevention is active The switch can be locked out The user must install on a control desk near the machinery Switching disconnecting device for the circuitry Means shall be provided t...

Page 37: ...e frame size R5 and larger or motors larger than 30 kW 40 HP symmetrical shielded motor cable must be used figure below A four conductor system can be used up to frame size R4 with up to 30 kW 40 HP m...

Page 38: ...n helix of copper tape The better and tighter the shield the lower the emission level and bearing currents Symmetrical shielded cable three phase conductors and a concentric or otherwise symmetrically...

Page 39: ...Armored Cable Shielded Power Cable The motor cables can be run in the same cable tray as other 460 V or 600 V power wiring Control and signal cables must not be run in the same tray as power cables S...

Page 40: ...motor cable shielding runs consistently without breaks from the drive to the motor Bypass Connection WARNING Never connect the supply power to the drive output terminals U2 V2 and W2 If frequent bypa...

Page 41: ...ds with noise attenuating circuits varistors RC filters AC or diodes DC in order to minimize the EMC emission at switch off If not suppressed the disturbances may connect capacitively or inductively t...

Page 42: ...ure b is also usable Run analogue and digital signals in separate shielded cables Relay controlled signals providing their voltage does not exceed 48 V can be run in the same cables as digital input s...

Page 43: ...circuits 3 An external thermistor relay is used The insulation of the relay must be rated for the same voltage level as the main circuit of the drive For connection see ACS800 Firmware Manual Routing...

Page 44: ...otor cable Input power cable Control cables min 200 mm 8 in min 300 mm 12 in Motor cable Power cable Drive 24 V 24 V 120 V Lead 24 V and 230 V control cables in separate ducts inside the cabinet Not a...

Page 45: ...s A drive equipped with no EMC filter or with EMC filter E210 is suitable for IT ungrounded systems If the drive is equipped with EMC filter E200 or E202 disconnect the filter before connecting the dr...

Page 46: ...insulation before connecting the drive to the mains Make sure that the drive is disconnected from the mains input power 1 Check that the motor cable is disconnected from the drive output terminals U2...

Page 47: ...marked which are not always included in the delivery Motor temperature supervision CDP312R control panel Circuit Breaker Main contactor Supply Temperature sensors for motor protection Alarm Signal co...

Page 48: ...the phase conductor Ground the other end of the input cable shield or PE conductor at the distribution board 360 degrees grounding recommended if shielded cable 360 degrees grounding required Use a s...

Page 49: ...ires and proper grounding from motor to cabinet 6 Connect ground cable and power cable shield to ground bar at top of cabinet inside at back 7 Connect motor phase conductors to the output power blocks...

Page 50: ...cabinet The Control cables must be in separate conduit from the power cables Use protective sleeve wherever the cables are against sharp edges Allow for slack in the cable at any hinge location to al...

Page 51: ...grounding wires of the outer shield to the nearest grounding clamp Do not connect shields of different cables to the same grounding clamp Leave the other end of the shield unconnected or ground it ind...

Page 52: ...d the pulse encoder interface is inserted in the optional module slot of the RMIO board in the RDCU unit and fixed with two screws See the appropriate optional module manual for the cable connections...

Page 53: ...ct them in a ring 2 3 4 1 Clamp as close to the terminals as possible As short as possible Note1 If the encoder is of unisolated type ground the encoder cable at the drive end only If the encoder is g...

Page 54: ...control X6 G313 Output for Motor Heater Supply and output X7 M600 M605 Starter for Aux Motor Fan X8 L505 or 2L505 Thermistor or L506 PT100 L515 AIMA 01 I O Expansion option Customer connection Termin...

Page 55: ...7 and ACS800 PC The terminals of the RMIO board are wired to terminal block X2 internally Terminals of X2 accept cables from 0 5 to 4 0 mm2 22 to 12 AWG Tightening torque for screw terminals is 0 4 to...

Page 56: ...leration deceleration select 2 5 5 DI5 Constant speed select 3 6 6 DI6 Constant speed select 3 7 7 24VD 24 VDC max 100 mA 8 8 24VD 9 9 DGND Digital ground 10 10 DGND Digital ground 11 11 DIIL Start in...

Page 57: ...0 V 10 V input 0 5 11 bit for the 0 10 V and 0 20 mA inputs Inaccuracy 0 5 Full Scale Range at 25 C 77 F Temperature coefficient 100 ppm C 56 ppm F max Constant voltage output Voltage 10 VDC 0 10 VDC...

Page 58: ...I6 5 mA Filtering time constant 1 ms Relay outputs Three programmable relay outputs Switching capacity 8 A at 24 VDC or 250 VAC 0 4 A at 120 VDC Minimum continuous current 5 mA rms at 24 VDC Maximum c...

Page 59: ...D1 5 DI5 6 DI6 7 24VD 8 24VD 11 DIIL 10 DGND2 X23 1 24 V 2 GND X25 1 RO1 2 RO1 3 RO1 X26 1 RO2 2 RO2 3 RO2 X27 1 RO3 2 RO3 3 RO3 Common mode voltage between channels 15 V J1 Test voltage 500 V AC or J...

Page 60: ...Motor Connection The E202 EMC filter capacitors are disconnected if the drive is connected to an IT ungrounded system The capacitors are reformed if stored over one year refer to ACS 600 800 Capacito...

Page 61: ...seconds Leave the switch to ON position Application program set up Follow the instructions in the Firmware Manual to start up the drive and to set the drive parameters On load checks Check that the Pr...

Page 62: ...filter media the white side must face the outside of the cabinet and the colored side must face the inside of the cabinet Interval Maintenance For instruction see section Every 3 months UL Type 12 Che...

Page 63: ...ay be accessed and replaced by the following procedure 1 While holding the top of the filter frame pull up on the bottom of the frame The filter frame will slide up approximately 3 4 inch and can then...

Page 64: ...ce the outside of the cabinet and the colored side must face the inside of the cabinet 4 Reinstall the 3 filter restraining brackets These will prevent the filter from being pulled out of the filter f...

Page 65: ...the cabinet door The hooks should be pointing down Press in at the center of the filter frame with your knee and gently press down with your hands at the top of the frame The filter frame will slide d...

Page 66: ...accessed and replaced by the following procedure 1 There are 2 filter frames attached to the filter fan box on top of the UL Type 12 cabinet To remove the filter frames lift up on the filter frame unt...

Page 67: ...n installing the filter media the white side must face the outside of the cabinet and the colored side must face the inside of the cabinet 4 Reinstall the filter restraining bracket Insert the solid e...

Page 68: ...liness of the cabinet and the surroundings When necessary clean the interior of the cabinet with a soft brush and a vacuum cleaner The module heatsink fins pick up dust from the cooling air The drive...

Page 69: ...nance Replacing the Cabinet Fan 1 Remove the left and right filter frames of the exhaust fan box by lifting them upwards 2 Disconnect the fan supply connector from the cabinet roof top right Inside th...

Page 70: ...en and remove the four fastening screws at the corners of the fan frame The screw are through bolts with nuts on the inside of the cabinet Do not drop the hardware into the drive 4 Remove the fan and...

Page 71: ...hen remove the four screws attaching the fan to the fan frame Remove the old fan 6 Install the new fan and capacitor with the replacement part for ABB in the reverse order of the above Ensure the fan...

Page 72: ...he drive module are shown below The stickers show all possible components Not all of them are present in each delivery Components that need to be changed regularly are listed below Designation Compone...

Page 73: ...the fan supply wires detachable connector 5 Disconnect the fan capacitor wires 6 Disconnect the AINP board wires from connectors X1 and X2 7 Undo the red fixing screws of the fan cassette 8 Press the...

Page 74: ...ly 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 cover off 4 Undo the red fastening screws of the fan...

Page 75: ...ct 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 availa...

Page 76: ...the front cover Remove the profiled side plate 3 Disconnect the discharging resistor wires 4 Undo the red fastening screws 5 Lift the capacitor pack out 6 Install the new capacitor pack in reverse ord...

Page 77: ...onnect ground cable at top back left of module 5 Disconnect low voltage RMIO power supply cable see step 2 picture 6 On the left side of the cabinet open the lower swing panel if it is there Disconnec...

Page 78: ...the grommets and be very careful not to kink or touch the ends of the fiber optic cables Any contaminants on the fiber optic cables will reduce signal integrity and may result in failure Recommendati...

Page 79: ...rack frame in the cabinet Recommendation Be very careful removing the module Frame R7 modules weigh 200 lbs and frame R8 modules weigh 450 lbs Both are top heavy The module may be slid onto a forklif...

Page 80: ...y on the board is OK Control panel mounting platform Red Drive in fault state Green The main 24 V power supply for the control panel and the RMIO board is OK AINT board V204 green 5 V voltage of the b...

Page 81: ...rature is 40 C 104 F ACS800 PC Imax Normal use Heavy duty use Frame size Air flow Heat dissipation A I2N A PN HP I2hd A Phd HP ft3 min BTU Hr Three phase supply voltage 380 V 400 V 415 V 440 V 460 V 4...

Page 82: ...temperature Normal use 10 overload capability I2N continuous rms current 10 overload is typically allowed for one minute every 5 minutes PN typical motor power The power ratings apply to most 4 pole N...

Page 83: ...ote 1 In multi cable installations install only one fuse per phase not one fuse per conductor Note 2 Larger fuses must not be used Note 3 Fuses from other manufacturers can be used if they meet the ra...

Page 84: ...d Lugs D150 Brake Resistor Terminals BR BR 150 ACS800 PC 0170 5 R7 2 x 250 MCM 274 in lbs 350 MCM 350 in lbs 5 Bus Bar Holes 13 32 Bolts 500 MCM 500 in lbs 200 ACS800 PC 0210 5 R7 250 ACS800 PC 0270 5...

Page 85: ...irmware Manual for setting Default setting is off the setting must be activated at start up The drives are to be used in a heated indoor controlled environment See section Ambient Conditions for speci...

Page 86: ...e ambient temperature is below 40 C 104 F or the drive is loaded cyclically Derating The load capacity current and power decreases if the installation site altitude exceeds 1000 metres 3281 ft or if t...

Page 87: ...e of the cabinet top Space requirement for the door opening Frame size Required free space around the unit for cooling Front Side Above in in in R6 6 15 R7 6 15 R8 6 15 Top clearance UL Type 12 UL Typ...

Page 88: ...mum frequency 300 Hz fFWP fFWP frequency at field weakening point UNmains mains input power voltage UNmotor rated motor voltage fNmotor rated motor frequency Frequency resolution 0 01 Hz Current See s...

Page 89: ...allowed Maximum allowed relative humidity is 60 in the presence of corrosive gases Contamination levels IEC 60721 3 3 IEC 60721 3 2 IEC 60721 3 1 No conductive dust allowed Boards without coating Che...

Page 90: ...ither 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 electro...

Page 91: ...EC as amended by 93 68 EEC and Directive 89 336 EEC as amended by 93 68 EEC The ACS800 PC drive with circuit breaker package is intended for use in North America and has been qualified to only the app...

Page 92: ...ion commissioning repair alternation or ambient conditions of the drive do not fulfil the requirements specified in the documentation delivered with the unit and other relevant documentation Units sub...

Page 93: ...wings UL Type 1 Dimensional Drawing 0170 5 through 0440 5 UL Type 1 Example dimensional drawings with dimensions in millimeters and inches Frame Height Width Depth Weight R7 85 9 in 31 7 in 25 9 in 69...

Page 94: ...rough 0610 5 UL Type 12 Note 0490 5 through 0610 5 are only available in UL Type 12 enclosure Example dimensional drawings with dimensions in millimeters and inches Frame Height Width Depth Weight R7...

Page 95: ...ly available as built in units indicated in the type code by D150 Resistors are available as add on kits How to Select the Correct Drive Chopper Resistor Combination 1 Calculate the maximum power Pmax...

Page 96: ...he connections see the power connection diagram of the drive Pmax maximum power generated by the motor during braking UDC voltage over the resistor during braking e g 1 35 1 2 415 VDC when supply volt...

Page 97: ...to the instructions and the internal brake chopper is in use The drive will disable power flow through the input bridge if the chopper remains conductive in a fault situation Note If an external brak...

Page 98: ...ive parameter 20 05 Check the resistance value setting parameter 27 03 Frame sizes R7 and R8 Check the setting of parameter 21 09 If stop by coasting is required select OFF2 STOP For the use of the br...

Page 99: ...99 Resistor Braking...

Page 100: ......

Page 101: ...58 10 22 11 Telefax 358 10 22 22681 Internet http www abb com ABB Inc Drives and Power Electronics 16250 West Glendale Drive New Berlin WI 53151 USA Telephone 262 785 3200 800 243 4384 Telefax 262 780...

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