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Maintenance

83

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 fan (R7)

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Summary of Contents for ACS800-02

Page 1: ...ACS800 Hardware Manual ACS800 02 Drives 45 to 500 kW ACS800 U2 Drives 60 to 600 HP ...

Page 2: ...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 3AFE 64527592 English System Application Program Firmware Manual 3AFE 63700177 English Application Program Template Firmware Manual 3AFE 64616340 English...

Page 3: ...ACS800 02 Drives 45 to 500 kW ACS800 U2 Drives 60 to 600 HP Hardware Manual 3AFE 64567373 Rev C EN EFFECTIVE 18 11 2003 ã 2003 ABB Oy All Rights Reserved ...

Page 4: ......

Page 5: ...two types of safety instructions throughout this manual warnings and notes Warnings caution you about conditions which can result 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 symbols are used as follows Dangerous voltage warning warns of high v...

Page 6: ...uits 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 motor cable always check that the phase order is correct Note The motor cable terminals on the drive are at a dangerously high voltage when the input po...

Page 7: ... and pick up Make sure that grounding conductors are adequately sized as required by safety regulations In a multiple drive installation connect each drive separately to protective earth PE ACS800 01 In European CE compliant installations and in other installations where EMC emissions must be minimized make a 360 high frequency grounding of cable entries in order to suppress electromagnetic distur...

Page 8: ...quipment 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 automatic fault reset functions of the Standard Application Program if dangerous situations can occur When activated these functions will reset the drive an...

Page 9: ... feeds power to the intermediate circuit of the drive and the supply connections become live Installation and maintenance work Disconnect the motor from the drive with a safety switch and additionally if possible lock the motor shaft and ground the motor connection terminals temporarily by connecting them together as well as to the PE Operation Do not run the motor over the rated speed Motor overs...

Page 10: ...Safety instructions 10 ...

Page 11: ...Operation 9 Table of contents About this manual What this chapter contains 17 Intended audience 17 Common chapters for two products 17 Categorization according to the frame size 17 Contents 17 Installation and commissioning flowchart 18 Inquiries 19 The ACS800 02 U2 What this chapter contains 21 The ACS800 02 U2 21 Enclosure extension 22 Type code 22 Main circuit and control 24 Diagram 24 Operatio...

Page 12: ... Emergency stop devices 32 ACS800 02 U2 with enclosure extension and ACS800 07 U7 32 Restarting after an emergency stop 33 Prevention of Unexpected Start ACS800 07 U7 only 33 Selecting the power cables 34 General rules 34 Alternative power cable types 35 Motor cable shield 35 Additional US requirements 36 Conduit 36 Armored cable shielded power cable 36 Power factor compensation capacitors 36 Equi...

Page 13: ...side the cubicle 64 Units without an enclosure extension 64 Units with an enclosure extension 65 Connecting the control cables 66 Connecting the shield wires at RMIO board 66 Securing the control cables mechanically 66 Settings of the cooling fan transformer 67 Setting of the auxiliary voltage transformer of the line contactor option 67 Installation of optional modules and PC 67 Cabling of I O and...

Page 14: ...lacing the fan of the enclosure extension 80 Replacing the fan R7 81 Replacing the fan R8 82 Capacitors 83 Reforming 83 Replacing the capacitor pack R7 83 Replacing the capacitor pack R8 84 Module replacement of units with the enclosure extension 85 LEDs 86 Technical data What this chapter contains 87 IEC ratings 87 Symbols 88 Sizing 88 Derating 89 Temperature derating 89 Altitude derating 89 Main...

Page 15: ...SA markings 105 UL 105 Dimensional drawings Frame size R7 108 Frame size R8 109 Frame size R7 with enclosure extension bottom entry 110 Frame size R7 with enclosure extension top entry 112 Frame size R8 with enclosure extension bottom entry 114 Frame size R8 with enclosure extension top entry 116 Resistor braking What this chapter contains 119 To which products this chapter applies 119 Availabilit...

Page 16: ...Table of contents 16 Protection of frame size R6 ACS800 01 ACS800 07 and frame sizes R7 and R8 ACS800 02 ACS800 04 ACS800 07 125 Brake circuit commissioning 126 ...

Page 17: ... the United States that must be installed per the National Electrical Code and local codes are marked with US Common chapters for two products Three chapters of this manual Safety instructions Planning the electrical installation Motor control and I O board RMIO and Resistor braking apply to the ACS800 01 U1 the ACS800 02 U2 the ACS800 04 U4 and the ACS800 07 U7 Categorization according to the fra...

Page 18: ... select protect and wire optional brake choppers and resistors The chapter also contains technical data Installation and commissioning flowchart Task See Identify the frame size of your drive R7 or R8 Technical data IEC ratings or US tables NEMA ratings Plan the installation Check the ambient conditions ratings required cooling air flow input power connection compatibility of the motor motor conne...

Page 19: ...o be connected to an IT ungrounded system check that the drive is not equipped with EMC filter E202 The ACS800 02 U2 Type code For instructions on how to disconnect the EMC filtering contact ABB Route the cables Planning the electrical installation Routing the cables For compliance with the European Union EMC Directive see Technical data CE marking Install the drive Connect the power cables Connec...

Page 20: ...About this manual 20 ...

Page 21: ...g drive for controlling AC motors In the basic unit the cabling direction is from below When an optional enclosure extension is connected next to the basic unit the cables can also be led from above The ACS800 U2 is a US version of the drive Front covers Lead through plate ACS800 02 Enclosure extension Pedestal inside the unit Alternative slot for the control panel Control panel CDP312R ACS800 U2 ...

Page 22: ...ies Type 02 free standing When no options are selected 6 pulse diode input bridge IP 21 Control Panel CDP312R no EMC filter Standard Application Program no enclosure extension cabling from below boards without coating one set of manuals Size Refer to Technical data IEC ratings Voltage range nominal rating in bold 2 208 220 230 240 VAC 3 380 400 415 VAC 5 380 400 415 440 460 480 500 VAC options Con...

Page 23: ...l rating in bold 2 208 220 230 240 VAC 5 380 400 415 440 460 480 VAC options Construction 0C111 no enclosure extension bottom entry exit of cables Resistor braking D150 brake chopper Filter E202 EMC RFI filter for first environment TN grounded system restricted the A limits E210 EMC RFI filter for second environment TN IT grounded ungrounded system E208 common mode filter for frame size R7 E209 li...

Page 24: ...ons for the ACS800 U2 Selection Alternatives Motor control and I O board RMIO External control via analogue digital inputs and outputs Input power Output power Optional module 1 RMBA RAIO RDIO RDNA RLON RIBA RPBA RCAN RCNA RMBP RETA or RTAC Optional module 2 RTAC RAIO or RDIO Optional module 3 RDCO 01 RDCO 02 or RDCO 03 R UDC UDC R Brake chopper in frame sizes R2 and R3 optional in other frame siz...

Page 25: ... diagnostics and panel interface board ADPI EMC filter boards NRFC with option E202 brake chopper control board ABRC with option D150 Motor control The motor control is based on the Direct Torque Control DTC method Two phase currents and DC link voltage are measured and used for the control The third phase current is measured for earth fault protection Component Description six pulse rectifier con...

Page 26: ...The ACS800 02 U2 26 ...

Page 27: ... 1 2 of the drive nominal input voltage The allowed range of the 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 Protecting the motor winding and bearings The output of the drive comprises regardless of output frequency pulses of approximately 1 35 times the mains network voltage with a very short rise...

Page 28: ...e consulted regarding the construction of the motor insulation and additional requirements for explosion safe EX motors Failure of the motor to fulfil the following requirements or improper installation may shorten motor life or damage the motor bearings Manufacturer Motor type Nominal mains voltage AC line voltage Requirement for Motor insulation system ABB du dt filter insulated N end bearing an...

Page 29: ...eviation 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 output of the drive CMF common mode filter E208 3 toroidal cores LCMF light common mode filter E209 1 toroidal core N N end bearing insulated motor non driven end bearing n a Motors of this power ran...

Page 30: ...aken into consideration when determining the motor insulation requirement Example Motor insulation requirement for a 400 V application must be selected as if the drive were supplied with 480 V Permanent magnet synchronous motor Only one permanent magnet motor can be connected to the inverter output Install a safety switch between a permanent magnet synchronous motor and the motor cable The switch ...

Page 31: ...f the drive No additional thermal protection devices are needed WARNING If the drive is connected to multiple motors a separate thermal overload switch or a circuit breaker must be used for protecting each cable and motor These devices may require a separate fuse to cut off the short circuit current The drive protects the motor cable and the motor in a short circuit situation when the motor cable ...

Page 32: ...ection The drive is equipped with an internal ground fault protective function to protect the unit against ground faults in the motor and the 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 appropriate ACS800 Firmware Manual The EMC filter of the drive includes capacitors connected between the...

Page 33: ...nction by opening a switch on a control desk An indicating lamp on the control desk will light signalling 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 to prevent inadvertent and or mistaken closure of the disconnecting device EN 60204 1 1997 indicating l...

Page 34: ...um 1 kV For drive 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 motors but shielded symmetrical motor cable is recommended A four conductor system is allowed for input cabling but shielded symmetrical cable is recommended To operate as a protective ...

Page 35: ... helix of copper tape The better and tighter the shield the lower the emission level and the bearing currents Symmetrical shielded cable three phase conductors and a concentric or otherwise symmetrically constructed PE conductor and a shield Recommended PE conductor and shield Shield Shield A separate PE conductor is required if the conductivity of the cable shield is 50 of the conductivity of the...

Page 36: ...le 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 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 Shielde...

Page 37: ...r 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 bypassing is required employ mechanically connected switches or contactors Mains line voltage applied to the output can result in permanent damage to the unit Before opening a contactor DTC control mode ...

Page 38: ...ads 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 to other conductors in the control cable and form a risk of malfunction in other parts of the system Install the protective component as close to the inductive load as possible Do not install protecti...

Page 39: ...sable 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 signals It is recommended that the relay controlled signals be run as twisted pairs Never mix 24 VDC and 115 230 VAC signals in the same cable Relay cable The cable type with braided metallic screen e g ÖLFLEX by LAP...

Page 40: ...om other low voltage 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 the cables Route the motor cable away from other cable routes Motor cables of several drives can be run in parallel installed next to each other It is recommended that the motor c...

Page 41: ...20 in Motor cable Input power cable Control cables min 200 mm 8 in min 300 mm 12 in Motor cable Power cable Drive 230 V 24 V 24 V 230 V Lead 24 V and 230 V control cables in separate ducts inside the cabinet Not allowed unless the 24 V cable is insulated for 230 V or insulated with an insulation sleeving for 230 V ...

Page 42: ...Planning the electrical installation 42 ...

Page 43: ...ed electricians are allowed to carry out the work described in this chapter Follow the Safety instructions on the first pages of this manual Ignoring the safety instructions can cause injury or death Moving the unit Move the transport package by pallet truck to the installation site Unpack the package as shown below Lifting when the enclosure extension is included ...

Page 44: ...erturn from a tilt of about 6 degrees Do not wheel the drive except for installation the front direction is preferable because the front wheels are steadier The drive frame may be deformed from wheeling when the pedestal is removed If the drive is moved over long distances place it on its back on a pallet and move it by fork lift Do not lift by the lower part of the frame M a x 3 0 Front Back Do n...

Page 45: ... type The label includes an IEC and NEMA rating UL C UL CSA and CE markings a type code and a serial number which allow individual recognition of each unit The first digit of the serial number refers to the manufacturing plant The next four digits refer to the unit s manufacturing year and week respectively The remaining digits complete the serial number so that there are no two units with the sam...

Page 46: ...o vertical as possible and strong enough to carry the weight of the unit The drive must not be installed without the pedestal and a support shelf on wall refer to ACS800 02 U2 Application Note on Wall Mounting 68250013 English Floor The floor material below the installation should be non flammable The floor must be horizontal Free space around the unit See section Installation procedure Choose the...

Page 47: ... in extension bar 19 mm 3 4 in socket for frame size R7 13 mm 1 2 in magnetic end socket for frame size R8 17 mm 11 16 in magnetic end socket Checking the insulation of the assembly Every drive has been tested for insulation between the main circuit and the chassis 2500 V rms 50 Hz for 1 second at the factory Therefore do not make any voltage tolerance or insulation resistance tests e g hi pot or ...

Page 48: ...ity of the shield is 50 of the conductivity of the phase conductor use a separate PE cable 1 or a cable with a grounding conductor 2 Ground the other end of the input cable shield or PE conductor at the distribution board 3 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 symmetrically constructed grounding cond...

Page 49: ...0 7 9 lifting space lifting space R8 a d 600 24 300 12 b 600 24 300 12 c 300 12 lifting space lifting space Make holes in the wall recommended 1 Lift the unit against the wall into the mounting place 2 Mark the locations for the two fixing points in the wall not for mounting orientation a if the unit is subjected to sideways vibration 3 Mark the bottom edges of the unit to the floor With enclosure...

Page 50: ...t fix the pedestal to the frame from front 3 Undo the red M8 combi screws 8 pcs or 9 pcs with D150 that connect the busbars of the pedestal to the upper frame Use a torque wrench with an extension bar 4 Wheel the drive frame out by using the handle 4 Wheeling the frame out 1 2 2 1 3 3 3 3 ProE ACS800 02 R7_manual2 drw 2 2 3 3 3 2 pcs 3 ...

Page 51: ...aside in the same way The legs will prevent the unit from falling down during the installation 3 Undo the screws that fix the pedestal to the frame from front 4 Undo the screws that connect the busbars of the pedestal to the upper frame Use a torque wrench with an extension bar 5 Wheel the drive frame out by using the handle 1 2 1 3 4 5 Red M10 combi screws 8 pcs or 9 pcs Pedestal disconnected 3 w...

Page 52: ...be fastened after leading the cables through it if the cabling procedure is more convenient in that way Lead the power input motor and optional brake cables through the lead through plate 1 Make adequate holes in the grommets to fit them tightly on the cables 2 Lead the cables through the holes and slide the grommets onto the cables These brackets can be removed for the time of the installation Fr...

Page 53: ...of the cable lug is 38 mm 1 5 in Wider cable lugs may cause a short circuit 6 Connect the twisted shields of the cables to the PE terminal Note 360 degrees grounding is not needed at the cable entry The short twisted shield provides in addition to the protective grounding also sufficient disturbance suppression Frame size R7 Terminal U1 U2 V1 V2 W1 W2 UDC R R UDC A hole 1 mm in 159 6 3 262 10 3 36...

Page 54: ...nto the cables Terminal A B A B hole 1 hole 2 hole 3 hole 1 hole 2 hole 3 mm mm mm mm in in in in Frame size R8 U1 432 387 342 40 17 0 15 2 13 5 1 6 V1 148 5 8 W1 264 10 4 U2 284 239 194 40 11 2 9 4 7 6 1 6 V2 148 5 8 W2 264 10 4 UDC 136 91 46 40 5 4 3 6 1 8 1 6 R 148 5 8 UDC R 264 10 4 PE terminal hole 1 2 3 4 5 6 7 8 9 C mm in 24 0 9 56 2 2 88 3 5 120 4 7 152 6 0 184 7 2 216 8 5 248 9 8 280 11 0...

Page 55: ...1 W1 U2 V2 W2 and PE optional brake resistor cable lugs to UDC R and R 5 Tighten the connections WARNING It is not allowed to connect the cables directly to the drive module terminals The leadthrough insulation material is not strong enough to carry the mechanical stress exerted by the cables The cable connections must be performed in the pedestal Wheel the drive frame back on the pedestal See ste...

Page 56: ...emove the pedestal 1 Fix the fastening screws WARNING The fixing is important because the screws are required for the grounding of the drive 2 Connect the terminals at the top of the pedestal to the terminals at the bottom of the upper part of the drive frame WARNING Be careful not to drop screws inside the pedestal Loose metal pieces inside the unit may cause damage 3 Tighten the connections Fast...

Page 57: ...rive pedestal is fastened to the base plate of the enclosure extension Fastening the unit See Dimensional drawings for the locations of the fastening points Fasten the unit to the floor with four screws using the holes provided in the base plate It is recommended to fasten the unit to the rear wall as well Use the holes at the top of the enclosure extension and at the top of the drive cubicle The ...

Page 58: ...ent disturbance suppression Slide the grommets onto the cables Cut the cables to appropriate length Terminate the conductors with cable lugs or connectors Connect the cable shields to the PE busbar Connect the phase conductors of the motor cable to the U2 V2 and W2 terminals Connect the phase conductors of the supply cable to the U1 V1 and W1 terminals Connect the optional brake conductors to the ...

Page 59: ...tch fuse Start Stop Stop switch Control voltage fuses Thermistor Pt100 relays Line contactor control relays Terminal block for line contactor control Terminal block for motor temp supervision Power cable entries Denotes optional equipment not present on all units 64530151 B Cabinet fan Emergency Stop switch Signal cable entries ...

Page 60: ...e Start Stop Stop switch Thermistor Pt100 relays Line contactor control relays Terminal block for line contactor control Terminal block for motor temp supervision Power cable entries Denotes optional equipment not present on all units 64530186 B Cabinet fan Emergency Stop switch Signal cable entries Control voltage fuses ...

Page 61: ...se Start Stop Stop switch Control voltage fuses Thermistor Pt100 relays Line contactor control relays Terminal block for line contactor control Terminal block for motor temp supervision Power cable entries Denotes optional equipment not present on all units 64660250 B Cabinet fans Emergency Stop switch Signal cable entries ...

Page 62: ...e Start Stop Stop switch Control voltage fuses Thermistor Pt100 relays Line contactor control relays Terminal block for line contactor control Terminal block for motor temp supervision Power cable entries Denotes optional equipment not present on all units 64660225 C Cabinet fans Emergency Stop switch Signal cable entries ...

Page 63: ...ked which are not always included in the delivery Enclosure extension ACS800 02 drive cubicle X2 terminal block Motor temperature supervision X4 CDP 312R control panel Switch fuse disconnector Main contactor F250 3 motor Supply Temperature sensors for motor protection Alarm Signal control Brake resistor Common mode filter Drive module RMIO RDCU L505 or L506 X1 ...

Page 64: ...ecure the cables with cable ties to the holes in the side bracket of the capacitor pack Lead the cables through the cushions This is for mechanical support only No 360 degrees EMC grounding is needed here Place for user s motor temperature relay RMIO Opening the top front cover R7 Disconnect the control panel cables Place for user s motor temperature relay Frame size R8 ...

Page 65: ...losure extension Cable entries with grommets for multiple cable diameters are provided The following diagram gives an example of signal control cabling routing inside the cubicle X2 RMIO Secure the cables with cable ties to these holes ...

Page 66: ...es to the same grounding clamp Leave the other end of the shield unconnected or ground it indirectly via a few nanofarads high frequency capacitor e g 3 3 nF 630 V The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points Keep the signal wire pairs twisted as close to the terminals as possible Twisting the wire...

Page 67: ...er I O extension module and the pulse encoder interface is inserted in the optional module slot of the RMIO board and fixed with two screws See the appropriate optional module manual for cable connections Cabling of I O and fieldbus modules Set according to the supply voltage 380 V 400 V 415 V 440 V 480 V or 500 V or 525 V 575 V 600 V 660 V or 690 V Note No need to set for 230 V units Set to 220 V...

Page 68: ... Resistor braking Connect the resistor as shown in section Power cable connection diagram above Parameter settings To enable dynamic braking certain drive parameters must be adjusted For further information refer to the Firmware Manual Strain relief with a cable tie 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 encode...

Page 69: ...for the RMIO board shown below apply also to optional terminal block X2 available for the ACS800 02 and the ACS800 07 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 0 4 to 0 8 Nm 0 3 to 0 6 lbf ft Note for external power supply WARNING If the RMIO board is supplied from an external power sou...

Page 70: ... Reverse 1 3 3 DI3 Not in use 4 4 DI4 Acceleration 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 DGND1 Digital ground 10 10 DGND2 Digital ground 11 11 DIIL Start interlock 0 stop 4 X23 X23 1 1 24V Auxiliary voltage output non isolated 24 VDC 250 mA 2 2 GND X25 X25 1 1 RO1 Relay output 1 ready 2 2 RO1 3 3 RO1 X26 X26 1 ...

Page 71: ...p 3 3 DI3 Forward Reverse 1 4 4 DI4 Acceleration 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 DGND1 Digital ground 10 10 DGND2 Digital ground 11 11 DIIL Start interlock 0 stop 4 X23 X23 1 1 24V Auxiliary voltage output non isolated 24 VDC 250 mA 2 2 GND X25 X25 1 1 RO1 Relay output 1 ready 2 2 RO1 3 3 RO1 X26 X26 1 1 ...

Page 72: ...Applicable potentiometer 1 kohm to 10 kohm Auxiliary power output Voltage 24 VDC 10 short circuit proof Maximum current 250 mA without any optional modules inserted onto slots 1 and 2 Analogue outputs Two programmable current outputs 0 4 to 20 mA RL 700 ohm Resolution 0 1 10 bit Inaccuracy 1 Full Scale Range at 25 C 77 F Temperature coefficient 200 ppm C 111 ppm F max Digital inputs With Standard ...

Page 73: ...cation adapter module RDCO Protocol DDCS ABB Distributed Drives Communication System 24 VDC power input Voltage 24 VDC 10 Typical current consumption without optional modules 250 mA Maximum current consumption 1200 mA with optional modules inserted The terminals on the RMIO board as well as on the optional modules attachable to the board fulfil the Protective Extra Low Voltage PELV requirements st...

Page 74: ...ND1 5 DI5 6 DI6 7 24VD 8 24VD 11 DIIL 10 DGND2 X23 1 24 V 2 GND X25 1 RO1 2 RO1 3 RO1 X26 1 RO2 2 RO2 3 RO2 X27 1 RO3 2 RO3 3 RO3 Common mode voltage between channels 15 V J1 Test voltage 500 V AC or Jumper J1 settings All digital inputs share a common ground This is the default setting Grounds of input groups DI1 DI4 and DI5 DI6 DIIL are separate isolation voltage 50 V Ground Test voltage 4 kV AC...

Page 75: ...MC 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 Capacitor Reforming Guide 64059629 English The drive is grounded properly The mains input power voltage matches the drive nominal input voltage The mains input power connections at U1 V1 and W1 and their tightening torques are OK Approp...

Page 76: ...Installation checklist 76 ...

Page 77: ...aintenance intervals If installed in an appropriate environment the drive requires very little maintenance This table lists the routine maintenance intervals recommended by ABB Interval Maintenance Instruction Every year when stored Capacitor reforming See Reforming Every 6 to 12 months depending on the dustiness of the environment Heatsink temperature check and cleaning See Heatsink Every 7 years...

Page 78: ...shown below The stickers show all possible components Not all of them are present in each delivery or described here Designation Component A49 Control panel A41 Motor control and I O board RMIO Y41 Cooling fan C_ Capacitors Code 64572261 B Code 64601423 B R7 R8 ...

Page 79: ...se a vacuum cleaner at the air outlet to trap the dust Note Prevent dust from entering adjoining equipment 3 Replace the cooling fan Fan The lifespan of the cooling fan of the drive is about 50 000 R7 and 60 000 R8 hours The actual lifespan depends on the running time of the fan ambient temperature and dust concentration See the appropriate ACS800 firmware manual for the actual signal which indica...

Page 80: ...s of the fan cassette 3 Shift the fan cassette sideways and pull it out of the enclosure extension 4 Undo the screws that fasten the fan to the base of the cassette 5 Undo the screws that fasten the fingerguard 6 Install the new fan in reverse order to the above 4 2 2 2 2 2 2 4 4 1 Views from below Front side in frame size R7 units 3 5 5 5 5 4 Front side in frame size R8 units 64669800 C ...

Page 81: ...4 Disconnect the fan supply wires detachable connector 5 Disconnect the fan capacitor wires and remove the fan capacitor 6 Disconnect the AINP board wires from connectors X1 and X2 7 Undo the red fixing screws of the fan cassette 8 Press the snap on holders to release the side cover 9 Lift the handle and pull the fan cassette out 10 Install the new fan and fan capacitor in reverse order to the abo...

Page 82: ...ct the power supply a fibre optic b and control panel c cables from the RMIO board Units with enclosure extension move the wires in front of the fan aside 5 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 6 Undo the red fastening screws of the fan 7 Lift the fan out 8 Install the new fan and fan capa...

Page 83: ...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 ...

Page 84: ...side plate equipped with the control panel mounting slot 2 Disconnect the discharging resistor wires 3 Undo the fastening screws 4 Lift the capacitor pack out 5 Install the new capacitor pack in reverse order to the above 3 3 2 2 M10 M6 2 pcs M6x12 combi screw 3 3 3 3 3 4 At the rear side view from below 2 pcs in 690 V units 2 3 ...

Page 85: ...and b 5 Undo the two screws that fasten the unit to the enclosure extension 6 Disconnect the power supply wire of the RMIO board and the enclosure extension fan 7 Disconnect the fibre optic cables of the RMIO board from the AINT board and mark down the terminals for reconnecting 8 Pull cables 6 and 7 carefully down inside the pedestal and roll them aside so that they will not get damaged when the ...

Page 86: ...ly 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 board is OK V309 red Prevention of unexpected start is ON V310 green IGBT control signal transmission to the gate driver control boards is enabled ...

Page 87: ...30 2 613 840 160 598 160 480 132 R8 1220 7600 0260 2 693 1017 200 679 200 590 2 160 R8 1220 7850 0300 2 720 1017 200 704 200 635 3 200 R8 1220 8300 Three phase supply voltage 380 V 400 V or 415 V 0140 3 206 326 110 202 110 163 90 R7 540 3050 0170 3 248 404 132 243 132 202 110 R7 540 3700 0210 3 289 432 160 284 160 240 1 132 R7 540 4300 0260 3 445 588 200 440 200 340 160 R8 1220 6600 0320 3 521 588...

Page 88: ...que and current are automatically restricted The function protects the input bridge of the drive against overload Note 2 The ratings apply in ambient temperature of 40 C 104 F In lower temperatures the ratings are higher except Imax Note 3 Use the DriveSize PC tool for a more accurate dimensioning if the ambient temperature is below 40 C 104 F or the drive is loaded cyclically Nominal ratings Icon...

Page 89: ...y multiplying the current given in the rating table by the derating factor Example If the ambient temperature is 50 C 122 F the derating factor is 100 1 10 C 90 or 0 90 The output current is then 0 90 I2N 0 90 I2hd or 0 90 Icont max Altitude derating At altitudes from 1000 to 4000 m 3281 to 13123 ft above sea level the derating is 1 for every 100 m 328 ft For a more accurate derating use the Drive...

Page 90: ...00 2 900 000 500 ABB Control OFAF3H500 3 0210 2 506 630 4 000 000 500 ABB Control OFAF3H630 3 0230 2 599 630 4 000 000 500 ABB Control OFAF3H630 3 0260 2 677 800 7 400 000 500 ABB Control OFAF3H800 3 0300 2 707 800 7 400 000 500 ABB Control OFAF3H800 3 Three phase supply voltage 380 V 400 V or 415 V 0140 3 196 250 550 000 500 ABB Control OFAF1H250 1 0170 3 237 315 1 100 000 500 ABB Control OFAF2H3...

Page 91: ... Bussmann 170M3819 DIN1 0170 3 237 500 145 000 690 Bussmann 170M5810 DIN2 0210 3 286 550 190 000 690 Bussmann 170M5811 DIN2 0260 3 438 800 465 000 690 Bussmann 170M6812 DIN3 0320 3 501 1000 945 000 690 Bussmann 170M6814 DIN3 0400 3 581 1250 1 950 000 690 Bussmann 170M8554 DIN3 0440 3 674 1600 3 900 000 690 Bussmann 170M8557 DIN3 0490 3 705 1600 3 900 000 690 Bussmann 170M8557 DIN3 Three phase supp...

Page 92: ... copper shield Aluminium cables with concentric copper shield Max load current A Cable type mm2 Max load current A Cable type mm2 62 3x16 61 3x25 79 3x25 75 3x35 98 3x35 91 3x50 119 3x50 117 3x70 153 3x70 143 3x95 186 3x95 165 3x120 215 3x120 191 3x150 249 3x150 218 3x185 284 3x185 257 3x240 335 3x240 274 3 x 3x50 358 3 x 3x50 285 2 x 3x95 371 2 x 3x95 331 2 x 3x120 431 2 x 3x120 351 3 x 3x70 459 ...

Page 93: ... 15 22 R8 3 58 M12 50 75 M8 15 22 Frame size IP 21 W3 W4 Noise H W1 W2 Depth mm mm mm mm kg kg dB R7 1507 250 602 524 100 195 71 R8 2024 347 793 622 230 375 72 Input power connection Voltage U1 208 220 230 240 VAC 3 phase 10 for 230 VAC units 380 400 415 VAC 3 phase 10 for 400 VAC units 380 400 415 440 460 480 500 VAC 3 phase 10 for 500 VAC units 525 550 575 600 660 690 VAC 3 phase 10 for 690 VAC ...

Page 94: ...300 Hz Switching frequency 3 kHz average In 690 V units 2 kHz average Maximum recommended motor cable length Type code EMC equipment Max motor cable length DTC control Scalar control 300 m 984 ft 300 m 984 ft E202 E210 100 m 328 ft 100 m 328 ft Motor cable longer than 100 m 328 ft is allowed but then the EMC Directive requirements may not be fulfilled Efficiency Approximately 98 at nominal power l...

Page 95: ...d particles Class 3S2 Boards with coating Chemical gases Class 3C2 Solid particles Class 3S2 Boards without coating Chemical gases Class 1C2 Solid particles Class 1S3 Boards with coating Chemical gases Class 1C2 Solid particles Class 1S3 Boards without coating Chemical gases Class 2C2 Solid particles Class 2S2 Boards with coating Chemical gases Class 2C2 Solid particles Class 2S2 Atmospheric press...

Page 96: ...aste within the EU They must be removed and handled according to local regulations For further information on environmental aspects and more detailed recycling 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 according to standards EN 50178 and EN 60204 1 EN...

Page 97: ...ion in which the manufacturer restricts the supply of equipment to suppliers customers or users who separately or jointly have technical competence in the EMC requirements of the application of drives Unrestricted distribution mode of sales distribution in which the supply of equipment is not dependent on the EMC competence of the customer or user for the application of drives Compliance with the ...

Page 98: ...networks In some cases the natural 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 specified in the Har...

Page 99: ...t environment includes establishments connected to a low voltage network which supplies buildings used for domestic purposes Second environment includes establishments connected to a network not supplying domestic premises Restricted distribution mode of sales distribution in which the manufacturer restricts the supply of equipment to suppliers customers or users who separately or jointly have tec...

Page 100: ...rranty period different to the above and refer to local terms of liability as defined in the supply contract The manufacturer is not responsible for any costs resulting from a failure if the installation 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 101: ...hree phase supply voltage 208 V 220 V 230 V or 240 V 0080 2 326 211 75 170 60 R7 318 9900 0100 2 404 248 100 202 75 R7 318 11750 0120 2 432 290 100 240 4 75 R7 318 13750 0140 2 588 396 150 316 125 R8 718 16450 0170 2 588 440 150 340 125 R8 718 20800 0210 2 588 516 200 370 150 R8 718 22750 0230 2 840 598 200 480 200 R8 718 25900 0260 2 1017 679 250 590 2 200 R8 718 26750 0300 2 1017 704 250 635 3 2...

Page 102: ...ote 3 Fuses from other manufacturers can be used if they meet the ratings Imax maximum output current Available for 10 s ar start otherwise as long as allowed by drive 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 NEMA rated motors 230 V or 460 V ...

Page 103: ...0 105 690 Bussmann 170M3169 1 0100 2 239 500 145 690 Bussmann 170M5160 2 0120 2 285 550 190 690 Bussmann 170M5161 2 0140 2 391 800 465 690 Bussmann 170M6162 3 0170 2 428 800 465 690 Bussmann 170M6162 3 0210 2 506 1000 945 690 Bussmann 170M6164 3 0230 2 599 1250 1950 690 Bussmann 170M6166 3 0260 2 677 1600 3900 690 Bussmann 170M6169 3 0300 2 707 1600 3900 690 Bussmann 170M6169 3 Three phase supply ...

Page 104: ...tension two hole cable lugs 1 2 inch diameter can be used Copper cables with concentric copper shield Max load current A Cable type AWG kcmil 57 6 75 4 88 3 101 2 114 1 132 1 0 154 2 0 176 3 0 202 4 0 224 250 MCM or 2 x 1 251 300 MCM or 2 x 1 0 273 350 MCM or 2 x 2 0 295 400 MCM or 2 x 2 0 334 500 MCM or 2 x 3 0 370 600 MCM or 2 x 4 0 or 3 x 1 0 405 700 MCM or 2 x 4 0 or 3 x 2 0 449 2 x 250 MCM or...

Page 105: ...ovides overload protection in accordance with the National Electrical Code US See ACS800 Firmware Manual for setting Default setting is off must be activated at start up The drives are to be used in a heated indoor controlled environment See section Ambient conditions for specific limits Brake chopper ABB has brake choppers that when applied with appropriately sized brake resistors will allow the ...

Page 106: ...Technical data 106 ...

Page 107: ...Dimensional drawings 107 Dimensional drawings The dimensions are given in milllimetres and inches ...

Page 108: ...Dimensional drawings 108 Frame size R7 US gland conduit plate 64579746 H ...

Page 109: ...Dimensional drawings 109 Frame size R8 3AFE 64564161 D US gland conduit plate ...

Page 110: ...Dimensional drawings 110 Frame size R7 with enclosure extension bottom entry 64625942 1 2 B ...

Page 111: ...Dimensional drawings 111 64625942 2 2 C ...

Page 112: ...Dimensional drawings 112 Frame size R7 with enclosure extension top entry 64626264 1 2 C ...

Page 113: ...Dimensional drawings 113 64626264 2 2 C ...

Page 114: ...Dimensional drawings 114 Frame size R8 with enclosure extension bottom entry 3AFE 64626388 1 2 B ...

Page 115: ...Dimensional drawings 115 3AFE 64626388 2 2 B ...

Page 116: ...Dimensional drawings 116 Frame size R8 with enclosure extension top entry 3AFE 64626370 1 2 C ...

Page 117: ...Dimensional drawings 117 3AFE 64626370 2 2 C ...

Page 118: ...Dimensional drawings 118 ...

Page 119: ...or the ACS800 07 U7 resistors are available as factory installed How to select the correct drive chopper resistor combination 1 Calculate the maximum power Pmax generated by the motor during braking 2 Select a suitable drive brake chopper brake resistor combination for the application according to the following tables take account of other factors in the drive selection also The following conditio...

Page 120: ... over the resistor during braking e g 1 35 1 2 415 VDC when supply voltage is 380 to 415 VAC 1 35 1 2 500 VDC when supply voltage is 440 to 500 VAC or 1 35 1 2 690 VDC when supply voltage is 525 to 690 VAC R resistor resistance ohm ACS 800 01 type Braking power of the chopper and the drive Brake resistor s Pbrcont kW Type R ohm ER kJ PRcont kW 230 V units 0001 2 0 55 SACE08RE44 44 248 1 0002 2 0 8...

Page 121: ... 420 2 0020 3 11 SACE15RE22 22 420 2 0025 3 23 SACE15RE13 13 435 2 0030 3 28 SACE15RE13 13 435 2 0040 3 33 SAFUR90F575 8 1800 4 5 0050 3 45 SAFUR90F575 8 1800 4 5 0060 3 56 SAFUR90F575 8 1800 4 5 0070 3 68 SAFUR80F500 6 2400 6 0100 3 83 SAFUR125F500 4 3600 9 0120 3 113 SAFUR125F500 4 3600 9 500 V units 0004 5 1 5 SACE08RE44 44 210 1 0005 5 2 2 SACE08RE44 44 210 1 0006 5 3 0 SACE08RE44 44 210 1 000...

Page 122: ...800 42 0490 3 R8 500 355 237 120 4xSAFUR210F575 0 85 16800 42 500 V units 0100 5 R6 83 SAFUR125F500 4 3600 9 0120 5 R6 113 SAFUR125F500 4 3600 9 0140 5 R6 135 SAFUR125F500 4 3600 9 0170 5 R7 165 132 2 120 80 SAFUR200F500 2 70 5400 13 5 0210 5 R7 198 132 2 120 80 SAFUR200F500 2 70 5400 13 5 0260 5 R7 198 1 132 2 120 80 SAFUR200F500 2 70 5400 13 5 0270 5 R8 240 240 240 240 2xSAFUR125F500 2 00 7200 1...

Page 123: ...value for the resistor assembly Note This is also the minimum allowed resistance for the brake resistor ER Short energy pulse that the resistor assembly withstands every 400 seconds This energy will heat the resistor element from 40 C 104 F to the maximum allowable temperature PRcont Continuous power heat dissipation of the resistor when placed correctly Energy ER dissipates in 400 seconds ACS800 ...

Page 124: ...e drive Combined braking cycles for R7 After Pbr5 Pbr10 or Pbr30 braking the drive and the chopper will withstand Pbrcont continuously Pbr5 Pbr10 or Pbr30 braking is allowed once every minute After Pbrcont braking there has to be at least 30 seconds without any braking if the subsequent braking power is greater than Pbrcont After Pbr5 or Pbr10 braking the drive and the chopper will withstand Pbr30...

Page 125: ...rame size R6 ACS800 01 ACS800 07 and frame sizes R7 and R8 ACS800 02 ACS800 04 ACS800 07 A main contactor is not required for protecting against resistor overheating when the resistor is dimensioned according 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 exter...

Page 126: ...ve parameter 20 05 Check the resistance value setting parameter 27 03 Frame sizes R6 R7 and R8 Check the setting of parameter 21 09 If stop by coasting is required select OFF2 STOP For the use of the brake resistor overload protection parameters 27 02 27 05 consult an ABB representative WARNING If the drive is equipped with a brake chopper but the chopper is not enabled by parameter setting the br...

Page 127: ......

Page 128: ... P O Box 184 FIN 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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