ABB ACS800-04 Hardware Manual Download Page 75

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Maintenance

Layout

The layout stickers of the drive 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 are listed below:

Designation

Component

Y41

Cooling fan

Capacitors

Code: 64572261

Code: 64601423

Summary of Contents for ACS800-04

Page 1: ...ACS800 Hardware Manual ACS800 04 and ACS800 04M Drive Modules 45 to 560 kW ACS800 U4 Drive Modules 60 to 600 HP ...

Page 2: ...2800 kW 3AFE64731165 English ACS800 17 Hardware Manual 55 to 2500 kW 75 to 2800 HP 3AFE68397260 English ACS800 37 Hardware Manual 55 to 2700 kW 75 to 3000 HP 3AFE68557925 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 AN...

Page 4: ......

Page 5: ...fety 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 voltage which ca...

Page 6: ...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 power is on regardless of whether the motor ...

Page 7: ...otective earth PE ACS800 01 ACS800 11 ACS800 31 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 disturbances In addition connect the cable shields to protective earth PE in order to meet safety regulations ACS800 04 45 to 560 kW and ACS800 02 in first en...

Page 8: ...rive is heavy Lift the drive by the lifting lugs only Do not tilt the unit The unit will overturn from a tilt of about 6 degrees Use extreme caution when manoeuvring a drive that runs on wheels An overturning unit can cause physical injury Beware of hot surfaces Some parts such as heatsinks of power semiconductors remain hot for a while after disconnection of the electrical supply Make sure that d...

Page 9: ...ding wrist band when handling the boards Do not touch the boards unnecessarily WARNING Ignoring the following instructions can cause equipment malfunction and damage to the fibre optic cables Handle the fibre optic cables with care When unplugging optic cables always grab the connector not the cable itself Do not touch the ends of the fibres with bare hands as the fibre is extremely sensitive to d...

Page 10: ...angerous situations can occur When activated these functions will reset the drive 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 maximum allowed number of charging cycles of the DC capacitors i e power ups by applying power is five in ten minutes Note...

Page 11: ...draulic crawling drives are able to rotate the motor directly or through any mechanical connection like felt nip rope etc Ensure that there is no voltage on the drive power terminals Alternative 1 Disconnect the motor from the drive with a safety switch or by other means Measure that there is no voltage present on the drive input or output terminals U1 V1 W1 U2 V2 W2 UDC UDC Alternative 2 Measure ...

Page 12: ...Safety instructions 12 ...

Page 13: ...11 Start up and operation 11 Table of contents About this manual What this chapter contains 19 Target audience 19 Common chapters for several products 19 Categorization according to the frame size 19 Categorization according to the plus code 19 Contents 20 Other related manuals 20 Installation commissioning and operating flowchart 20 Product and service inquiries 21 Product training 21 Providing f...

Page 14: ...ion 40 Disconnecting device disconnecting means 40 ACS800 01 ACS800 U1 ACS800 11 ACS800 U11 ACS800 31 ACS800 U31 ACS800 02 and ACS800 U2 without enclosure extension ACS800 04 ACS800 U4 40 ACS800 02 and ACS800 U2 with enclosure extension ACS800 07 and ACS800 U7 40 EU 40 US 40 Fuses 40 Main contactor 40 Thermal overload and short circuit protection 41 Thermal overload protection of the drive and the...

Page 15: ...o the drive I O 52 Installation sites above 2000 metres 6562 feet 52 Routing the cables 52 Control cable ducts 53 Electrical installation What this chapter contains 55 Warnings 55 Checking the insulation of the assembly 55 Drive 55 Input cable 55 Motor and motor cable 55 IT ungrounded systems 56 Installation of optional EMC filter E202 56 Example wiring diagram 57 Power cable connection diagram 58...

Page 16: ...ernal control connections US 68 RMIO board specifications 69 Analogue inputs 69 Constant voltage output 69 Auxiliary power output 69 Analogue outputs 69 Digital inputs 69 Relay outputs 70 DDCS fibre optic link 70 24 VDC power input 70 Maintenance What this chapter contains 73 Safety 73 Maintenance intervals 74 Layout 75 Heatsink 76 Fan 76 Replacing the fan R7 77 Replacing the fan R8 78 Capacitors ...

Page 17: ...5 Sizing 95 Derating 95 Fuses 95 UL class T and L fuses 96 Cable types 97 Cable Entries 97 Dimensions weights and noise 98 Input power connection 99 Motor connection 99 Efficiency 99 Cooling 99 Degrees of protection 99 Prevention of Unexpected Start AGPS 21 board 100 Ambient conditions 100 Materials 101 Applicable standards 101 US patents 101 CE marking 102 Definitions 102 Compliance with the EMC ...

Page 18: ... chapter applies 107 Availability of brake choppers and resistors for the ACS800 107 How to select the correct drive chopper resistor combination 107 Optional brake chopper and resistor s for the ACS800 01 U1 108 Optional brake chopper and resistor s for the ACS800 02 U2 ACS800 04 04M U4 and ACS800 07 U7 111 Resistor installation and wiring 113 ACS800 07 U7 114 Protection of frame sizes R2 to R5 A...

Page 19: ...mmon chapters for several products Chapters Planning the electrical installation Motor control and I O board RMIO and Resistor braking apply to the ACS800 01 U1 ACS800 02 U2 ACS800 04 04M U4 and ACS800 07 U7 types up to 0610 x Safety instructions apply to the ACS800 01 U1 ACS800 02 U2 and ACS800 04 04M U4 Categorization according to the frame size The instructions technical data and dimensional dr...

Page 20: ...cal specifications of the drive e g the ratings sizes and technical requirements provisions for fulfilling the requirements for CE and other markings and warranty policy Resistor braking describes how to select protect and wire optional brake choppers and resistors The chapter also contains technical data Other related manuals Refer to ACS800 04 04M U4 Cabinet Installation 3AFE68360323 English for...

Page 21: ...one year the converter DC link capacitors need to be reformed Ask ABB for instructions Check the installation site Technical data If the drive is about to be connected to an IT ungrounded system check that the drive is not equipped with EMC filter E202 The ACS800 04 U4 and ACS800 04M Type code For instructions on how to disconnect the EMC filtering contact ABB Route the cables Planning the electri...

Page 22: ...his manual 22 Providing feedback on ABB Drives manuals Your comments on our manuals are welcome Go to www abb com drives then select successively Drives Document Library Manuals feedback form on the right pane ...

Page 23: ...unit The unit is delivered pre assembled with mounting pedestal and output busbars Front cover Pedestal Motor cable terminals Input cable terminals Optional brake and DC busbars and terminals PE terminal Slots for cables going to the RMIO board in the RDCU unit The cables are coiled on the top of the module Alternative output cable terminals when no vertical busbars are used Fastening bracket Fast...

Page 24: ...g side of the module and DC busbars on the left hand side Output busbars on the short side of the module Motor and brake busbars on the left hand long side of the module and DC busbars on the right hand side Frame size R8 Output busbars on the short side of the module Frame size R7 Frame size R7 with bottom exit optional top entry busbar shroud and bottom exit shroud included Output busbars are lo...

Page 25: ...on 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 same serial number The type designation label is located on the front cover and the serial number label inside the unit Example labels are show...

Page 26: ...he Standard Control Program three wire start stop as default setting common mode filter in frame size R8 boards without coating pedestal with output on the long side output busbar set for motor base and wall mounting brackets one set of manuals Pre assembled unit Size Refer to Technical data IEC ratings or NEMA ratings in Hardware Manual 3AFE68360323 Engllish Voltage range nominal rating in bold 2...

Page 27: ... limits E210 EMC RFI filter for second environment TN IT grounded ungrounded system E208 common mode filter Pedestal and output busbars H352 bottom exit kit for frame size R7 H354 pedestal with output on the long side bookshelf H355 vertical busbars and support brackets for AC output connection H356 pedestal and adapter with H360 busbar kit for brake resistor and DC connection H360 pedestal with o...

Page 28: ...tor control and I O board RMIO External control via analogue digital inputs and outputs Input power Output power R UDC UDC R Optional module 1 RMBA RAIO RDIO RDNA RLON RIBA RPBA RCAN RCNA RMBP RETA RRIA or RTAC Optional module 2 RTAC RAIO RRIA or RDIO DDCS communication option module RDCO 01 RDCO 02 or RDCO 03 Brake chopper optional ...

Page 29: ...ntermediate circuit DC voltage six pulse IGBT inverter converts the DC voltage to AC voltage and vice versa The motor operation is controlled by switching the IGBTs Control panel mounting platform kit RPMP 11 optional Control panel CDP312R optional 3 m 118 in Drive control unit RDCU which contains motor control and I O board RMIO External control connections to RMIO board To RMIO Shielded 6 pin mo...

Page 30: ...nput bridge protection board AIBP which includes snubbers for the thyristors and varistors power supply board APOW gate driver control board AGDR diagnostics and panel interface board ADPI 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...

Page 31: ... check The drive delivery contains drive cabinet including factory installed options such as optional modules inserted onto the RMIO board in the RDCU unit residual voltage warning stickers hardware manual appropriate firmware manuals and guides appropriate optional module manuals delivery documents Requirements for the installation site Check the installation site according to the requirements be...

Page 32: ...binet cannot be used proceed 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 the welding circuit may damage electronic circuits in the cabinet Ensure that the welding fumes are not inhaled Example cabinet frame viewed from above With heavy cabinets s...

Page 33: ...the warranty does not cover To which products this chapter applies This chapter applies to the ACS800 01 U1 ACS800 11 U11 ACS800 31 U31 ACS800 02 U2 ACS800 04 U4 and ACS800 07 U7 types up to 0610 x Note All options described in this chapter are not available for all products Check the availability from section Type code on page 26 Motor selection and compatibility 1 Select the motor according to t...

Page 34: ...hen the supply voltage is 440 V and the drive is equipped with an IGBT supply the maximum peak voltage in the motor terminals can be approximated as follows 440 V 1 41 2 1241 V Check that the motor insulation system withstands this voltage If the drive is equipped with and then the motor voltage rating should be diode supply ACS800 01 U1 02 U2 04 04M U4 07 U7 no resistor braking is in use UN frequ...

Page 35: ...d drives with their fast rising voltage pulses and high switching frequencies can generate current pulses that flow through the motor bearings which can gradually erode the bearing races and rolling elements The stress on motor insulation can be avoided by using optional ABB du dt filters du dt filters also reduce bearing currents To avoid damage to motor bearings the cables must be selected and i...

Page 36: ...e Requirement for Motor insulation system ABB du dt filter insulated N end bearing and ABB common mode filter PN 100 kW and frame size IEC 315 100 kW PN 350 kW or frame size IEC 315 PN 350 kW or frame size IEC 400 PN 134 HP and frame size NEMA 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 Standar...

Page 37: ...du dt N du dt N CMF or du dt CMF or Reinforced ÛLL 1800 V N or CMF N CMF 600 V UN 690 V Reinforced ÛLL 1800 V du dt du dt N du dt N CMF Reinforced ÛLL 2000 V 0 3 microsecond rise time N CMF N CMF Abbreviation Definition UN nominal voltage of the supply network ÛLL peak line to line voltage at motor terminals which the motor insulation must withstand PN motor nominal power du dt du dt filter at the...

Page 38: ...election criteria given for non ABB motors Note 6 Resistor braking of the drive When the drive is in braking mode for a large part of its operation time the intermediate circuit DC voltage of the drive increases the effect being similar to increasing the supply voltage by up to 20 percent The voltage increase should be taken into consideration when determining the motor insulation requirement Exam...

Page 39: ...proximately 20 higher Note 9 Sine filters protect the motor insulation system Therefore du dt filter can be replaced with a sine filter The peak phase to phase voltage with the sine filter is approximately 1 5 UN Note 10 Common mode filter is available as a plus code option E208 or as a separate kit one box including three rings for one cable Permanent magnet synchronous motor Only one permanent m...

Page 40: ...he AC power Therefore during installation and maintenance work on the drive the input cables and busbars must be isolated from the input power with a disconnector at the distribution board or at the supplying transformer EU To meet the European Union Directives according to standard EN 60204 1 Safety of Machinery the disconnecting device must be one of the following types switch disconnector of ut...

Page 41: ... off when overload is detected The drive includes a motor thermal protection function that protects the motor and switches off the current when necessary Depending on a drive parameter value the function either monitors a calculated temperature value based on a motor thermal model or an actual temperature indication given by motor temperature sensors The user can tune the thermal model further by ...

Page 42: ...de the drive Circuit diagram Drive type Short circuit protection DRIVE IS NOT EQUIPPED WITH INPUT FUSES ACS800 01 ACS800 U1 ACS800 02 ACS800 U2 0C111 ACS800 11 ACS800 U11 ACS800 31 ACS800 U31 ACS800 04 ACS800 U4 Protect the drive and input cable with fuses or a circuit breaker See footnotes 1 and 2 DRIVE IS EQUIPPED WITH INPUT FUSES ACS800 02 C111 ACS800 U2 ACS800 07 ACS800 U7 Protect the input ca...

Page 43: ...rt circuit inside the drive Ground fault protection The drive is equipped with an internal ground fault protective function to protect the unit against ground faults in the motor and motor cable This is not a personal safety or a fire protection feature The ground fault protective function can be disabled with a parameter refer to the appropriate ACS800 Firmware Manual The EMC filter of the drive ...

Page 44: ...E CTRL is set to ON default in Standard Control Program ACS800 07 U7 units without line contactor The power loss ride through funtion is not in use ACS800 07 U7 units with line contactor F250 The power loss ride through funtion is enabled by connecting RMIO board terminals X22 8 and X22 11 with a jumper X22 1 2 3 4 5 6 7 8 9 10 11 X2 RMIO board K13 21 22 ...

Page 45: ...ention 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 lamp on starting the drive is prevented off drive is operative ACS800 01 U1 ACS800 04 U4 ACS800 11 U11 ACS800 31 U31 saf...

Page 46: ...ystem can be used up to frame size R4 with up to 30 kW 40 HP motors but shielded symmetrical motor cable is always recommended The shield s of motor cable s must have 360 bonding at both ends Note When continuous metal conduit is employed shielded cable is not required The conduit must have bonding at both ends as with cable shield A four conductor system is allowed for input cabling but shielded ...

Page 47: ...per tape or copper wire 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 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 p...

Page 48: ...ium armor cable or shielded cable is not required A dedicated ground cable is always required Note Do not run motor wiring from more than one drive in the same conduit Armored cable shielded power cable Six conductor 3 phases and 3 ground type MC continuous corrugated aluminum armor cable with symmetrical grounds is available from the following suppliers trade names in parentheses Anixter Wire Cab...

Page 49: ...nnection boxes or similar equipment are installed in the motor cable between the drive and the motor EU Install the equipment in 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 enclosure in a way that the conduit or motor cable shielding runs consistently...

Page 50: ...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 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 protectiv...

Page 51: ...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 V AC signals in the same cable Relay cable The cable type with braided metallic screen e g ÖLFLEX by LA...

Page 52: ...t of the drive For connection see ACS800 Firmware Manual Installation sites above 2000 metres 6562 feet WARNING Protect against direct contact when installing operating and servicing the RMIO board wiring and optional modules attached to the board The Protective Extra Low Voltage PELV requirements stated in EN 50178 are not fulfilled at altitudes above 2000 m 6562 ft Routing the cables Route the m...

Page 53: ...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 230 V Lead 24 V and 230 V 120 V control cables in separate ducts inside the cabinet Not allowed unless the 24 V cable is insulated for 230 V 120 V or insulated with an insulation sleeving for 230 V 120 V 120 V 230 V 120 V ...

Page 54: ...Planning the electrical installation 54 ...

Page 55: ... 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 megger on any part of the drive Input cable Check the insulation of the input cable according to local regulations before connecting it to the drive Motor and motor cable Check the insulation of the motor and motor cable as follows 1 Check that the moto...

Page 56: ...tailed instructions on how to do this please contact your local ABB representative WARNING If a drive with EMC filter E202 is installed on an IT system an ungrounded power system or a high resistance grounded over 30 ohms power system the system will be connected to earth potential through the EMC filter capacitors of the drive This may cause danger or damage the unit Installation of optional EMC ...

Page 57: ...marked and equipment not available as plus code options marked Motor temperature supervision CDP312R control panel Switch fuse disconnector Main contactor Supply Temperature sensors for motor protection Alarm Signal control Brake resistor ACS800 04 drive module RDCU RMIO 3 Motor Cabinet 360 degrees grounding in first environment installations Common mode filter du dt filter or Line filter sine fil...

Page 58: ...le 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 3 360 degrees grounding recommended at the cabinet entry if shielded cable 4 360 degrees grounding required at the cabinet entry in first environment installations 5 Use a separate grounding cable if the conductivity of the cable shield is 50 of the conductivity of ...

Page 59: ...terminal of the cabinet or drive module Strain relief To power terminals Example cable lead through Grommet EMI conductive Lead through Side view cushion plate Strain relief required for motor cables in first environment installations First environment EMC compliance is defined in chapter Technical data CE marking Recommended for control cables ...

Page 60: ...Electrical installation 60 Fastening US cable lugs Example mounting US cable lugs can be connected directly to the output busbars or to the terminals as follows 1 3 4 1 2 bolt ...

Page 61: ...not the cable itself Do not touch the ends of the fibres with bare hands as the fibre is extremely sensitive to dirt Note The lowest pin ExtPower is not in use Even when the RMIO board is powered from an external power supply do not use the ExtPower pin but upper pins TXD transmitter RXD receiver X34 Ffibre optic cables coming from the drive module to the RMIO board Internal power supply cable com...

Page 62: ...ble Connect the inner shields and the 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 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 w...

Page 63: ... 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 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 if the supply frequency...

Page 64: ...the cover of the drive module 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 encoder cable at the drive end only If the encoder is galvanically isolated from the motor shaft and the stator frame ground the encoder cable shield at the drive and the encoder end Note 2 Twist the pair cable w...

Page 65: ... with enclosure extension and the ACS800 07 The connections for the RMIO board shown below apply also to optional terminal block X2 available for the ACS800 02 and 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 for screw terminals is 0 4 to 0 8 Nm 0 3 to 0 6 lbf ft For disconnectin...

Page 66: ...nd X34 The internal power supply to terminal X34 can be left connected when using terminal X23 WARNING If the RMIO board is supplied from an external power source via terminal X34 the loose end of the cable removed from the RMIO board terminal must be secured mechanically to a location where it cannot come into contact with electrical parts If the screw terminal plug of the cable is removed the wi...

Page 67: ...ration 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 and input non isolated 24 VDC 250 mA 5 2 2 GND X25 X25 1 1 RO1 Relay output 1 ready 2 2 RO1 3 3 RO1 X26 X26 1 1 RO2 Relay output 2 running 2 2 RO2 3 3 RO2 ...

Page 68: ...tion 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 and input non isolated 24 VDC 250 mA 5 2 2 GND X25 X25 1 1 RO1 Relay output 1 ready 2 2 RO1 3 3 RO1 X26 X26 1 1 RO2 Relay output 2 running 2 2 RO2 3 3 RO2 X2...

Page 69: ...ble potentiometer 1 kohm to 10 kohm Auxiliary power output Voltage 24 VDC 10 short circuit proof Maximum current 250 mA shared between this output and optional modules installed on the RMIO 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 Sta...

Page 70: ...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 stated in EN 50178 provided that the extern...

Page 71: ...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 insulation voltage 50 V Ground Test voltage 4 kV A...

Page 72: ...Motor control and I O board RMIO 72 ...

Page 73: ...pment Ignoring the safety instructions can cause injury or death WARNING The drive module is heavy frame size R7 100 kg 220 lb frame size R8 200 kg 441 lb Lift the module by the upper part using the lifting lugs attached to the top of the unit Do not tilt the drive module 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 p...

Page 74: ...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 6 years Cooling fan change See Fan Every 10 years Capacitor change See Capacitors ...

Page 75: ...own 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 are listed below Designation Component Y41 Cooling fan C_ Capacitors Code 64572261 Code 64601423 R7 R8 ...

Page 76: ...n 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 ambient temperature and dust concentration See the appropriate ACS800 firmware manual for the actual signal which indicates the running time of the cooling fan For resetting the running time signal after a fan ...

Page 77: ...an 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 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 above 3 3 3 4 7 7 8 8 9 2 DC DC 5 3 6 2 pcs in 690...

Page 78: ...res 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 5 Lift the fan out of the cabinet 6 Install the new fan and fan capacitor in reverse order to the above 5 4 4 2 2 3 3 ...

Page 79: ...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 80: ...iled side plate 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 81: ...pedestal from the module by undoing the fastening a and busbar connecting b screws Secure the module from the lifting hooks at the top Pull the module from the cabinet onto a pallet truck Install the new module in reverse order to the above Frame size R8 M10x25 combi screws Tightening torque 30 44 Nm 22 32 lbf ft b b b b b b a a M6x16 combi screws Tightening torque 5 Nm 3 7 lbf ft a M6 combi screw...

Page 82: ...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 83: ...326 55 211 55 170 45 R7 540 2900 0100 2 253 404 75 248 75 202 55 R7 540 3450 0120 2 295 432 90 290 90 240 4 55 R7 540 4050 0140 2 405 588 110 396 110 316 90 R8 1220 5300 0170 2 447 588 132 440 132 340 90 R8 1220 6100 0210 2 528 588 160 516 160 370 110 R8 1220 6700 0230 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 20...

Page 84: ... 284 200 224 160 R7 540 4500 0320 5 440 588 250 435 250 340 200 R8 1220 6850 0400 5 515 588 315 510 315 370 250 R8 1220 7800 0440 5 550 840 355 545 355 490 315 R8 1220 7600 0490 5 602 840 400 590 400 515 2 355 R8 1220 8100 0550 5 684 1017 450 670 450 590 2 400 R8 1220 9100 0610 5 718 1017 500 704 500 632 3 450 R8 1220 9700 Three phase supply voltage 525 V 550 V 575 V 600 V 660 V or 690 V 0140 7 13...

Page 85: ...e range of 40 C 104 F to 50 C 122 F the rated output current is decreased by 1 for every additional 1 C 1 8 F The output current is calculated by 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 al...

Page 86: ...ircuit current 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 ohm zk transformer impedance UN transformer rated voltage V SN nominal apparent power of the transformer kVA Xc cable reactance ohm Calculation example Drive ACS800 04 0260 3 supply volta...

Page 87: ...210 2 506 10200 630 4 000 000 500 ABB Control OFAF3H630 3 0230 2 599 10200 630 4 000 000 500 ABB Control OFAF3H630 3 0260 2 677 13500 800 7 400 000 500 ABB Control OFAF3H800 3 0300 2 707 13500 800 7 400 000 500 ABB Control OFAF3H800 3 Three phase supply voltage 380 V 400 V or 415 V 0140 3 196 3820 250 550 000 500 ABB Control OFAF1H250 1 0170 3 237 4510 315 1 100 000 500 ABB Control OFAF2H315 2 021...

Page 88: ... Control OFAA2GG250 2 0320 7 298 4510 315 820 000 690 ABB Control OFAA2GG315 2 0400 7 333 6180 400 1 300 000 690 ABB Control OFAA3GG400 3 0440 7 377 8280 500 3 800 000 690 ABB Control OFAA3H500 3 0490 7 423 8280 500 3 800 000 690 ABB Control OFAA3H500 3 0550 7 468 8280 500 3 800 000 690 ABB Control OFAA3H500 3 0610 7 533 10800 630 10 000 000 690 Bussmann 630NH3G 690 3 rated breaking capacity only ...

Page 89: ... 8850 1400 3 900 000 690 Bussmann 170M8555 DIN3 0490 3 705 8850 1400 3 900 000 690 Bussmann 170M8555 DIN3 Three phase supply voltage 380 V 400 V 415 V 440 V 460 V 480 V or 500 V 0170 5 191 1810 400 105 000 690 Bussmann 170M3819 DIN1 0210 5 243 2210 500 145 000 690 Bussmann 170M5810 DIN2 0260 5 291 2620 550 190 000 690 Bussmann 170M5811 DIN2 0320 5 424 4000 800 465 000 690 Bussmann 170M6812 DIN2 04...

Page 90: ...installations install only one fuse per phase not one fuse per conductor Note 3 Larger fuses than the recommended ones must not be used Note 4 Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table PDM code 00096931 G 00556489 A Ultrarapid aR fuses ACS800 04 size Input current A Min ...

Page 91: ...0 310 200 200 200 0260 3 3 3 70 Cu 3 3 120 Al 430 460 560 310 310 310 0320 3 3 3 95 Cu 2 3 240 Al 530 600 750 350 350 440 0400 3 3 3 120 Cu 3 3 185 Al 530 600 750 410 470 660 0440 3 3 3 150 Cu 3 3 240 Al 700 770 930 470 530 730 0490 3 3 3 150 Cu 3 3 240 Al 700 770 930 490 530 730 Three phase supply voltage 380 V 400 V 415 V 440 V 460 V 480 V or 500 V 0170 5 3 120 Cu 3 150 Al 250 270 310 200 200 20...

Page 92: ...life time and lead to unnecessary operation of the fuses In case of any uncertainty regarding the drive protection please contact your local ABB Cable types The table below gives copper and aluminium cable types for different load currents Cable sizing is based on max 9 cables laid on a cable ladder side by side ambient temperature 30 C PVC insulation surface temperature 70 C EN 60204 1 and IEC 60...

Page 93: ...ith fastening brackets is 571 mm W3 width of the basic unit with PE terminal busbar flat W4 width with the cable connection terminal plates flat H height without top and bottom exit busbar shrouds W width D depth weight without top entry and bottom exit shrouds Frame size U1 V1 W1 U2 V2 W2 UDC R UDC R Earthing PE Number of holes per phase Max cable Screw Tightening torque Screw Tightening torque m...

Page 94: ... 200 R8 718 26750 0300 2 1017 704 250 635 3 250 R8 718 28300 Three phase supply voltage 380 V 400 V 415 V 440 V 460 V 480 V 0170 5 326 192 150 162 125 R7 318 10100 0210 5 384 240 200 192 150 R7 318 12900 0260 5 432 289 1 250 2 224 150 R7 318 15300 0270 5 480 316 250 240 200 R8 718 15350 0300 5 568 361 300 302 250 R8 718 18050 0320 5 588 435 350 340 250 R8 718 23250 0400 5 588 510 400 370 300 R8 71...

Page 95: ...ed in the USA Check from the fuse time current curve that the operating time of the fuse is below 0 1 seconds The operating time depends on the supply network impedance and the cross sectional area and length of the supply cable The short circuit current can be calculated as shown on page 86 Imax maximum output current Available for 10 s at start otherwise as long as allowed by drive temperature N...

Page 96: ...600 T 0440 5 501 800 600 Ferraz A4BY800 L 0490 5 542 800 600 Ferraz A4BY800 L 0550 5 614 900 600 Ferraz A4BY900 L 0610 5 661 900 600 Ferraz A4BY900 L Three phase supply voltage 525 V 575 V or 600 V 0140 7 117 200 600 Bussmann JJS 200 T 0170 7 146 200 600 Bussmann JJS 200 T 0210 7 184 250 600 Bussmann JJS 250 T 0260 7 199 300 600 Bussmann JJS 300 T 0320 7 273 500 600 Bussmann JJS 500 T 0400 7 325 5...

Page 97: ...oncentric 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 1 251 300 MCM or 2 1 0 273 350 MCM or 2 2 0 295 400 MCM or 2 2 0 334 500 MCM or 2 3 0 370 600 MCM or 2 4 0 or 3 1 0 405 700 MCM or 2 4 0 or 3 2 0 449 2 250 MCM or 3 2 0 502 2 300 MCM or 3 3 0 546 2 350 MCM or 3 4 0 590 2 400 MCM or 3 4 0 669 2 500 MCM or 3 250...

Page 98: ...n terminal plates on the left side only bookshelf D depth without fastening brackets R7 bookshelf depth with fastening brackets is 20 32 in R8 bookshelf depth with fastening brackets is 22 48 mm Frame size UL type open chassis Weight Noise Height W1 W2 Depth in in in in lb dB R7 44 13 13 15 16 36 18 31 220 71 R8 61 57 16 35 22 14 22 36 441 72 ...

Page 99: ...ield weakening point Frequency DTC mode 0 to 3 2 fFWP Maximum frequency 300 Hz 120 Hz with du dt or sine filter 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 section IEC data Power limit 1 5 Phd 1 1 PN or Pcont max whichever value is greatest Field weakening point 8 t...

Page 100: ...8 F Relative humidity 5 to 95 Max 95 Max 95 No condensation 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 Chemical gases Class 3C1 Solid particles Class 3S2 Boards with coating Chemical gases Class 3C2 Solid particles Class 3S2 Boards without coating...

Page 101: ...peed electrical power drive systems Part 5 1 Safety requirements electrical thermal and energy EN 60204 1 2006 Safety of machinery Electrical equipment of machines Part 1 General requirements Provisions for compliance The final assembler of the machine is responsible for installing an emergency stop device a supply disconnecting device the ACS800 04 04M U4 into a cabinet EN 60529 1991 IEC 529 Degr...

Page 102: ...ended for use in the second environment and not intended for use in the first environment Drive of category C4 drive of rated voltage equal to or above 1000 V or rated current equal to or above 400 A or intended for use in complex systems in the second environment Compliance with the EMC Directive The EMC Directive defines the requirements for immunity and emissions of electrical equipment used wi...

Page 103: ...gated to neighbouring low voltage networks In some cases the inherent suppression in transformers and cables is sufficient If in doubt the supply transformer with static screening between the primary and secondary windings can be used 2 An EMC plan for preventing disturbances is drawn up for the installation A template is available from the local ABB representative 3 The motor and control cables a...

Page 104: ...ve of rated voltage less than 1000 V and intended to be installed and commissioned only by a professional when used in the first environment Note A professional is a person or organisation having necessary skills in installing and or commissioning power drive systems including their EMC aspects Drive of category C3 drive of rated voltage less than 1000 V and intended for use in the second environm...

Page 105: ... can be met as follows 1 It is ensured that no excessive emission is propagated to neighbouring low voltage networks In some cases the inherent suppression in transformers and cables is sufficient If in doubt the supply transformer with static screening between the primary and secondary windings is strongly recommended 2 An EMC plan for preventing disturbances is drawn up for the installation A te...

Page 106: ... months after installation or twenty four 24 months from date of manufacturing whichever first occurs The local ABB office or distributor may grant a warranty 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 ...

Page 107: ...kits For 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 co...

Page 108: ...ax 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 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 ACS800 01 type ACS800 U1 type Braking power of the chopper and the drive Brake resistor s Pbrcont kW T...

Page 109: ...2 7 5400 13 5 0165 3 132 SAFUR200F500 2 7 5400 13 5 500 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 0009 5 4 0 SACE08RE44 44 210 1 0011 5 5 5 SACE08RE44 44 210 1 0016 5 7 5 SACE15RE22 22 420 2 0020 5 11 SACE15RE22 22 420 2 0025 5 15 SACE15RE22 22 420 2 0030 5 28 SACE15RE13 13 435 2 0040 5 33 SACE15RE13 13 435 2 0050 5 45 SAFUR90F575 8 1800 4...

Page 110: ...ith standard 22 ohm resistor and 33 kW with 32 37 ohm resistor All braking resistors must be installed outside the converter module The SACE brake resistors are built in an IP 21 metal housing The SAFUR brake resistors are built in an IP 00 metal frame Note The SACE and SAFUR resistors are not UL listed 690 V units 0011 7 8 SACE08RE44 44 210 1 0016 7 11 SACE08RE44 44 210 1 0020 7 16 SACE08RE44 44 ...

Page 111: ...4 3600 9 0130 3 R6 113 SAFUR125F500 4 3600 9 0140 3 R7 135 135 100 80 SAFUR200F500 2 70 5400 13 5 0170 3 R7 165 150 100 80 SAFUR200F500 2 70 5400 13 5 0210 3 R7 165 150 100 80 SAFUR200F500 2 70 5400 13 5 0260 3 R8 240 240 240 173 2XSAFUR210F575 1 70 8400 21 0320 3 R8 300 300 300 143 2xSAFUR200F500 1 35 10800 27 0400 3 R8 375 375 273 130 4xSAFUR125F500 1 00 14400 36 0440 3 R8 473 355 237 120 4xSAFU...

Page 112: ...er will withstand this continuous braking power The braking is considered continuous if the braking time exceeds 30 s Note Check that the braking energy transmitted to the specified resistor s in 400 seconds does not exceed ER R Resistance 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 withsta...

Page 113: ...lowed once every minute After Pbrcont braking there has to be a pause of 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 within a total braking time of 30 seconds Pbr10 braking is not acceptable after Pbr5 braking Combined braking cycles for R8 After Pbr5 Pbr10 or Pbr30 brakin...

Page 114: ...the drive will not otherwise be able to interrupt the main supply if the chopper remains conductive in a fault situation Below is a simple example wiring diagram Protection of frame 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 instruc...

Page 115: ...rameter 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 brake r...

Page 116: ...Resistor braking 116 ...

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Page 118: ...ernet www abb com 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 ABB Beijing Drive Systems Co Ltd No 1 Block D A 10 Jiuxianqiao Beilu Chaoyang District Beijing P R China 100015 Telephone 86 10 5821 7788 Fax 86 10 5821 7618 Internet www abb com ...

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