ABB ACS800-07-0610-3 User Manual Download

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ACS800

Hardware Manual
ACS800-07 Drives (500 to 2800 kW)

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

Summary of Contents for ACS800-07-0610-3

Page 1: ...ACS800 Hardware Manual ACS800 07 Drives 500 to 2800 kW Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 2: ...anual 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 AND GUIDES appropriate documents are included in th...

Page 3: ...ACS800 07 Drives 500 to 2800 kW Hardware Manual 3AFE64731165 REV E EN EFFECTIVE 15 2 2008 2008 ABB Oy All Rights Reserved Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 4: ...Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 5: ...059446 Rev A Valid from 01 02 2010 until the release of the next revision of the manual Contents The headings in this update notice refer to the modified subsections in the original English manual Each heading also includes a page number and a classifier NEW CHANGED or DELETED The page number refers to the page number in the original English manual The classifier describes the type of the modifica...

Page 6: ...N 62061 2005 The function also corresponds to an uncontrolled stop in accordance with category 0 of EN 60204 1 and prevention of unexpected start up of EN 1037 The STO may be used where power removal is required to prevent an unexpected start The function disables the control voltage of the power semiconductors of the drive output stage thus preventing the inverter from generating the voltage requ...

Page 7: ...Update Notice 3 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 8: ...e wiring in the drive safety circuits ensure that the appropriate standards e g IEC 61800 5 1 EN 62061 EN ISO 13849 1 and 2 and the ABB guidelines are met NEW page 101 On load checks The following information has been added to the procedure NEW page 101 On load checks The following information has been added to the procedure Action Additional information Check the correct operation of the emergenc...

Page 9: ...and check that the motor runs normally Test the operation of the STO function when the motor is running Start the drive and ensure that the motor is running Activate the STO circuit Ensure that the motor stops and the drive trips Reset the fault and try to start the drive Ensure that the motor stays at standstill Deactivate the STO circuit Restart the drive and check that the motor runs normally L...

Page 10: ...Update Notice 6 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 11: ...t conditions which can result in serious injury or death and or damage to the equipment and advise on 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 voltages which can cause physical injury and or damage to the equipment General warning warns about condit...

Page 12: ...r is applied to the drive or to the external control circuits Externally supplied control circuits may cause dangerous voltages to exist inside the drive even when the main power of 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 When joining shipping splits ...

Page 13: ...recommended However if welding is necessary ensure the return wire is properly connected in order not to damage the electronic equipment in the cabinet Also ensure that welding fumes are not inhaled Ensure sufficient cooling of the unit Cooling fans may continue to rotate for a while after the disconnection of the electrical supply Some parts inside the drive cabinet such as heatsinks of power sem...

Page 14: ...ective earth PE Do not install a drive equipped with an EMC line filter to an ungrounded power system or a high resistance grounded over 30 ohms power system Note Power cable shields are suitable for equipment grounding conductors only when adequately sized to meet safety regulations As the normal leakage current of the drive is higher than 3 5 mA AC or 10 mA DC stated by EN 50178 5 2 11 1 a fixed...

Page 15: ... 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 and resume operation after a fault Do not control the motor with the disconnecting device means instead use the control panel keys and or commands vi...

Page 16: ...or 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 above the rated speed Motor overspeed leads to overvoltage which may result in explosion of the capacitors in the intermediate circuit of the drive Application program Controlli...

Page 17: ...ducts 17 Categorization according to the frame size 17 Contents 17 Installation and commissioning flowchart 18 Product and service inquiries 19 Product training 19 Providing feedback on ABB Drives manuals 19 Terms and abbreviations 20 Hardware description What this chapter contains 21 The ACS800 07 21 Cabinet line up 21 Swing out frame 23 Cabling direction 24 Single line circuit diagram of the dri...

Page 18: ...dure 44 Fastening the cabinet to the floor Non marine units 45 Clamping 45 Holes inside the cabinet 46 Fastening the unit to the floor and wall Marine units 47 Joining the shipping splits 48 Procedure 48 Connecting the DC busbars and the PE busbar 49 DC busbars 50 PE busbar 50 Miscellaneous 51 Cable duct in the floor below the cabinet 51 Cooling air intake through bottom of cabinet 52 Example 52 E...

Page 19: ...ith Advant Controllers AC 80 AC 800 67 Connection of a motor temperature sensor to the drive I O 68 Installation sites above 2000 metres 6562 feet 68 Routing the cables 68 Control cable ducts 69 Electrical installation What this chapter contains 71 Before installation 71 Checking the insulation of the assembly 71 Motor and motor cable 71 IT ungrounded systems 72 Setting the earth fault ground faul...

Page 20: ... RMIO What this chapter contains 91 To which products this chapter applies 91 Note on cabinet installed ACS800 drives 91 Note on terminal labelling 91 Note on external power supply 92 Parameter settings 92 External control connections non US 93 External control connections US 94 RMIO board specifications 95 Analogue inputs 95 Constant voltage output 95 Auxiliary power output 95 Analogue outputs 95...

Page 21: ...e actions 112 Power module replacement 112 Fault tracing What this chapter contains 113 Supply unit status fault and warning LEDs 113 Other LEDs of the drive 115 Technical data What this chapter contains 117 Ratings 117 Symbols 118 Derating 118 Temperature derating 118 Altitude derating 118 ACS800 07 frame sizes and power module types 119 Internal AC fuses 120 DC fuses at inverter module input 121...

Page 22: ... 153 Frame size 2 D4 3 R8i 156 Frame size 2 D4 3 R8i with load switch disconnector 159 Frame size 2 D4 3 R8i with air circuit breaker 163 Frame size 3 D4 4 R8i 167 Frame size 3 D4 4 R8i with load switch disconnector 170 Frame size 3 D4 4 R8i with air circuit breaker 174 Common motor terminal cubicle 178 300 mm 178 400 mm 179 600 mm 180 Resistor braking What this chapter contains 181 Resistor braki...

Page 23: ...s manual apply to several products including the ACS800 07 Other product types may be mentioned in these chapters Categorization according to the frame size Some instructions technical data and dimensional drawings which concern only certain drive frame sizes are marked with the symbol of the frame size such as 1 D4 2 R8i etc The frame size is not marked on the drive designation label To identify ...

Page 24: ... cables Technical data Planning the electrical installation Option manuals if optional equipment is included Unpack and check the units Check the type code indicated by the type designation label with the original order If the drive is about to be connected to an IT ungrounded system check that the drive is not equipped with EMC RFI filtering E202 Check that all necessary optional modules and equi...

Page 25: ...s Providing feedback on ABB Drives manuals Your comments on our manuals are welcome Go to ABB website and select Document Library Manuals feedback form LV AC drives Connect the power cables Connect the control and the auxiliary control cables Mechanical installation Planning the electrical installation Electrical installation Resistor braking optional Check the installation Installation checklist ...

Page 26: ... with different power ratings may have the same basic construction and this term is used in reference to all those drive types With the ACS800 07 500 kW the frame size of the drive indicates the quantity and frame size of the supply modules plus the quantity and frame size of the inverter modules e g 2 D4 4 R8i To determine the frame size of a drive type see the rating tables in the chapter Techni...

Page 27: ...bicle is not present 4 Chassis socket for quick supply module connection behind module 5 Supply module switch disconnector Not present if the drive is equipped with an optional load switch disconnector cubicle 6 Supply unit control board DSSB mounted sideways Contains an actual value display and status LEDs 7 Inverter DC fuses 8 Inverter modules 9 Chassis socket for inverter module output connecti...

Page 28: ...utput cable lead throughs Not used if optional common motor terminal cubicle is present 6 Supply modules 15 Swing out frame Contains the drive control unit with I O terminals and provides space for standard and optional electrical equipment 7 Chassis socket for quick supply module connection behind each module 16 Auxiliary voltage transformer accessible by opening the swing out frame 8 Supply modu...

Page 29: ...ed by removing the two locking screws arrowed in the picture below and moving the swing out frame aside Depending on selected options actual equipment of the drive may differ from what is depicted below Mounting rails for additional equipment Remove screws arrowed to release swing out frame Drive control unit RDCU with I O terminal blocks Space for optional terminal block X2 Terminal block X1 Auxi...

Page 30: ...cuit breaker not for IP54 4 Main supply Top entry with load switch disconnector or air circuit breaker 5 Motor output Bottom exit at each inverter module without common motor terminal cubicle 6 Motor output Top exit at each inverter module without common motor terminal cubicle Added depth 130 mm 7 Motor output Bottom exit with common motor terminal cubicle 8 Motor output Top exit with common motor...

Page 31: ...2 D4 2 R8i drive with 2 brake chopper resistor units optional and without load switch disconnector air circuit breaker or common motor output cubicles The supply modules are not equipped with internal contactors if an air circuit breaker is ordered The supply modules are not equipped with internal switch disconnectors if a load switch disconnector or air circuit breaker is ordered Phone 800 894 04...

Page 32: ...s within the supply module s is closed Auxiliary voltage switch The auxiliary voltage switch controls the voltage supply to the auxiliary voltage transformer Earthing Grounding switch An earthing grounding switch for temporary grounding is optionally available Other door controls The following switches are mounted on the door of the control and I O cubicle Emergency stop button optional Operating ...

Page 33: ...supply module s via the quick connectors at the back of the modules The DSSB contains the following LEDs Actual value display Status LEDs See chapter Fault tracing DSU_DISPLAY TIF Display selection keys Unit display Displayed actual value Three phase voltages Six phase currents DC link voltage DC link current DC link power default READY LED Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Em...

Page 34: ...2 Select ON or OFF down key Press up key Press down key Press up and down keys simultaneously Direction of display change Setting accepted 1 For more information see section Power loss ride through function on page 34 2 For more information see section Earth ground current function on page 33 Display Mode autoexit 2s Activating earth current func tion and setting wake up level 2 Select NONE 1 2 A ...

Page 35: ...allel mod ules continued from previous page LED on LED off 3 No of modules 1 5 DSSB needs the value for scaling the current output signal connected to current meters on cabinet door optional equipment 4 Displays earth current peak value 5 Displays module count set in AOS 6 Displays VAC phase balance Display Mode autoexit 2s Select ON or OFF down key module count 5 Display Mode Phone 800 894 0412 F...

Page 36: ... input and relay output terminals on page 31 X8 Emergency stop input See Emergency stop input on page 32 X9 Phase current output for an external display device e g a meter on the cabinet door For scaling see Reading and setting of values page 2 of 2 on page 29 Use single phase meters Connect the meter between the current output terminal and ground cabinet frame Type tested and used by ABB BQ307 by...

Page 37: ... rectifying and opens contactors 3 24 V 24 VDC 4 RESET 0 1 Reset 5 RESET LED Ground for reset button LED 6 24 V 24 VDC X5 Remote digital inputs 2 1 2 ON 1 DSU is rectifying 1 0 DSU stops rectifying and opens contactors Note If start command was given through local START input DSU stops only after local ON input is switched off 3 4 START 0 1 DSU closes main contactors and starts rectifying Note Loc...

Page 38: ...eset Note Emergency stop according to category 0 and category 1 controlled emergency stop are available as factory installed options The category 1 option requires additional wirings that are not visible in the figure below See the circuit diagrams delivered with the unit for more information DSSB board terminals Note The DSSB board terminals are wired to a separate terminal block to which the use...

Page 39: ... fault illuminates earth fault LED and energizes relay output earth current fault DSU continues operation and energizes relay output earth current warning Yes START No DSU does not monitor earth current No Yes Yes Is fault trip selection ON for the earth current function 3 No 1 Function is inactive when the wake up level is set to NONE default setting See page 28 2 See page 28 for setting checking...

Page 40: ...he CDP 312R is the user interface of the inverters of the drive providing the essential controls such as Start Stop Direction Reset Reference and the parameter settings for the drive application program See the Firmware Manual for further information Duration of the break What happens during the break What happens after the break Shorter than power loss ride through time If the DC voltage drops le...

Page 41: ...ration using the remaining modules albeit at reduced power For directions contact your local ABB representative Motor control and I O board RMIO External control via analogue digital inputs and outputs Input power To motor Optional module 1 I O extension RAIO RDIO pulse encoder interface RTAC or fieldbus adapter e g RMBA RDNA RPBA Optional module 2 I O extension RAIO RDIO or pulse encoder interfac...

Page 42: ... range nominal rating in bold 3 380 400 415 VAC 5 380 400 415 440 460 480 500 VAC 7 525 575 600 690 VAC options I O options Refer to ACS800 Ordering Information 3AFY64556568 English Fieldbus adapter Application program Degree of protection B053 IP22 UL Type 1 B054 IP42 UL Type 1 B055 IP54 UL Type 12 Not available with C134 B059 IP54R with connection to air outlet duct Construction C121 Marine cons...

Page 43: ... or F255 H353 top exit H358 US UK gland conduit plate standard with C129 and C134 H359 common motor terminal cubicle Auxiliary voltage G304 115 VAC auxiliary voltage standard with C129 and C134 Cabinet options G300 cabinet heaters external supply Not available with C129 or C134 G313 motor heater output external supply G307 terminals for external control voltage UPS G317 busbar supply conductors 6 ...

Page 44: ...Hardware description 38 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 45: ...deviation from the surface level is 5 mm in every 3 metres The installation site should be levelled if necessary as the cabinet is not equipped with adjustable feet The wall behind the unit should be of non flammable material Provide the drive with the amount of fresh cooling air given in Technical data Note Very wide cabinet line ups are delivered as shipping splits Required tools The tools requi...

Page 46: ...fting lugs The lifting lugs can be removed not mandatory once the cabinet is in its final position If the lifting lugs are removed the bolts must be refastened to retain the degree of protection of the cabinet IP54 units Allowed minimum height of lifting ropes or slings for IP54 units is 2 metres Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 47: ...s part of the shipment Lay the unit on the rollers and move it carefully until close to its final location Remove the rollers by lifting the unit with a crane fork lift pallet truck or jack as described above If the cabinet needs to be laid on its back it must be supported from below beside the cubicle seams as shown Notes Transportation of a unit on its back is only allowed if the unit is equippe...

Page 48: ...be moved into its final position with an iron bar and a wooden piece at the bottom edge of the cabinet Care is to be taken to properly place the wooden piece so as not to damage the cabinet frame Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 49: ...el of the drive to verify that the unit is of the correct type The label includes an IEC and NEMA rating C UL US and CSA 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 ser...

Page 50: ...ight hand sides of the line up A to allow the doors to open sufficiently Note Any height adjustment must be done before fastening the units or shipping splits together Height adjustment can be done by using metal shims between the bottom frame and floor 2 Remove the lifting bars if present In marine units also replace the lifting lugs with L profiles see below Use the original bolts to block any u...

Page 51: ...n the clamps is 800 mm 31 5 If there is not enough working space behind the cabinet for mounting replace the lifting lugs at the top with L brackets not included and fasten the top of the cabinet to the wall Clamp dimensions in millimetres Cabinet frame Distances between slots Cubicle Width mm Distance in millimetres and inches 300 150 5 9 400 250 9 85 600 450 17 7 700 550 21 65 800 650 25 6 Cabin...

Page 52: ...he top of the cabinet to the wall Fastening holes inside the cabinet arrowed 0 5 IP 54 IP 20 42 25 mm 0 985 Added width Side panels of the cabinet 15 mm 0 6 Back panel of the cabinet 10 mm 0 4 Gap between cubicles mm Distances between fastening holes Bolt size M10 to M12 3 8 to 1 2 Cubicle Width Distance between holes 300 150 mm 5 9 400 250 9 85 600 450 17 7 700 550 21 65 800 650 25 6 Outer Ø31 mm...

Page 53: ...the base of the cabinet using M10 or M12 screws If there is not enough room behind the cabinet for installation clamp the rear ends of the flat bars as shown in figure 2 Fasten the top of the cabinet to the rear wall and or roof using brackets Fastening the cabinet at the top with brackets side view Cabinet M16 bolt L bracket Clamping the cabinet to the floor at the back Back panel of cabinet Flat...

Page 54: ...astening the shipping splits together are enclosed in a plastic bag inside the rightmost cubicle of the first shipping split The threaded bushings are already mounted on the post Procedure Fasten the front post of the joining section with 7 screws to the front frame post of the next cubicle Threaded bushing Maximum tightening torque 5 Nm 3 ft lbs 7 7 Phone 800 894 0412 Fax 888 723 4773 Web www clr...

Page 55: ...cted from the front of the joining cubicle All necessary materials are located in the joining cubicle Remove the front metal partitioning plate located in the busbar joining cubicle Unscrew the bolts of the joint pieces Connect the busbars with the joint pieces see figure below For aluminium busbars suitable anti oxidant joint compound must be used to avoid corrosion and to ensure good electrical ...

Page 56: ...oor at the back The connection is shown below No separate nuts are needed Tighten the bolts to 55 70 Nm 40 50 ft lbs Side view of single busbar connection Joint pieces 1 1 1 1 1 1 Shipping split A Shipping split B Top view PE busbar Tighten the screws to 55 70 Nm 40 50 ft lbs Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 57: ...iew This area can be used for a cable duct With heavy cabinets support the structural C sections from below Prevent the cooling air flow from the cable duct to the cabinet by bottom plates To ensure the degree of protection for the cabinet use the original bottom plates delivered with the unit With user defined cable entries take care of the degree of protection fire protection and EMC compliance ...

Page 58: ...lets This area may or may not be consistent through the width of the whole line up Example Notes The plinth of the cabinet must be supported all round The air duct must be able to supply a sufficient volume of cooling air The minimum air flow values are given in the Technical data section of the Hardware Manual The cubicles of diode supply units require a larger air inlet area than other cubicles ...

Page 59: ... never the cabinet frame itself Clamp the welding electrode onto the flat bar about to be welded or onto the floor 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 The thickness of the zinc coating of the cabinet frame is 100 to 200 micrometres on the flat bars the coating is approxim...

Page 60: ...Mechanical installation 54 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 61: ...inal 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 Check that the motor voltage rating meets the application requirements The motor voltage is selected according to the AC voltage feeding the drive when the drive is equipped with a diode input bridge a non regenerat...

Page 62: ...e 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 This in turn can cause additional stress on the motor and motor cable insulation Modern variable speed drives with their fast rising voltage pulses and high switching frequencies can cause current pulses that flow through the motor bearings...

Page 63: ... 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 N CMF 600 V UN 690 V Reinforced du dt du dt N du dt N CMF Form wound HX_ and AM_ 380 V UN 690 V Standard n a N CMF PN 500 kW N CMF PN 500 kW N CMF du dt Old form wound HX_ and modular 380 V UN 690 V Check with the motor manufactu...

Page 64: ...rting 1 1 1998 have form wound windings Note 5 ABB motors of types other than M2_ M3_ HX_ and AM_ Use the selection 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...

Page 65: ...ect the motor insulation system Therefore a du dt filter can be replaced with a sine filter The peak phase to phase voltage with a sine filter is approximately 1 5 UN Permanent magnet synchronous motor Only one permanent magnet motor can be connected to the inverter output It is recommended to install a safety switch between a permanent magnet synchronous motor and the motor cable The switch is ne...

Page 66: ... with internal AC fuses option code F260 install external protection such as fuses at the supply to protect the input cable If the drive is not equipped with AC input fuses install external fuses at the supply to protect the input cable and the drive Use the AC fuse types listed in the chapter Technical data on page 120 or equivalent fuses Six fuses are needed for each DSU module WARNING Circuit b...

Page 67: ...954 1 Category 3 The function is achieved by disconnecting the control voltage to the power semiconductors of the inverters of the drive Thus it is not possible for the power semiconductors to switch and generate the AC voltage needed to rotate the motor In case of faulty main circuit components the DC voltage from the busbars can be conducted to the motor but an AC motor cannot rotate without the...

Page 68: ...d symmetrical motor cable is recommended Note When continuous conduit is employed shielded cable is not required A four conductor system is allowed for input cabling but shielded symmetrical cable is recommended To operate as a protective conductor the shield conductivity must be as follows when the protective conductor is made of the same metal as the phase conductors Compared to a four conductor...

Page 69: ... must be used for the motor cables if metallic conduit is not used For the North American market 600 VAC cable is accepted for up to 500 VAC 1000 VAC cable is required above 500 VAC below 600 VAC For drives rated over 100 amperes the power cables must be rated for 75 C 167 F Symmetrical shielded cable three phase conductors and a concentric or otherwise symmetrically constructed PE conductor and a...

Page 70: ...from more than one drive in the same conduit 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 Six conductor 3 phases and 3 ground type MC continuous corrugated aluminum armor cable with symmetrical grounds is available from the following suppliers tra...

Page 71: ...tems the compensation unit should typically be equipped with a blocking reactor or harmonic filter Equipment connected to the motor cable Installation of safety switches contactors connection boxes etc To minimize the emission level when safety switches contactors connection boxes or similar equipment are installed in the motor cable between the drive and the motor EU Install the equipment in a me...

Page 72: ... highly recommended to equip inductive loads 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...

Page 73: ...oes 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 LAPPKABEL Germany has been tested and approved by ABB Control panel cable In remote use the cable connecting the control pa...

Page 74: ... 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 motor cable away from other cable routes ...

Page 75: ...les min 200 mm 8 in min 300 mm 12 in Motor cable Power cable Drive 230 120 V 24 V 24 V 230 120 V Lead 24 V and 230 120 V control cables in separate ducts inside the cabinet Not allowed unless the 24 V cable is insulated for 230 120 V or insulated with insulation sleeving for 230 120 V Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 76: ...Planning the electrical installation 70 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 77: ...ion 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 megger on any part of the drive When checking the insulation of the assembly proceed in the following manner WARNING Check the insulation before connecting the drive to the supply Make sure that the drive is disconnected ...

Page 78: ...r 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 Setting the earth fault ground fault trip level Grounded systems See page 28 IT ungrounded systems On ungrounded systems an external monitoring u...

Page 79: ...wo supply modules in parallel L11 L21 L31 L12 L22 L32 PE Notes No parallel cabling is shown here Each input terminal of the supply modules must be fed through a dedicated fuse The fuses are specified in Technical data Contactors are optional L11 L21 L31 L12 L22 L32 L1 L2 L3 PE Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 80: ... inside a single module do not form a 12 pulse connection any more This means that the benefits of the 12 pulse connection are not available during a temporary operation with one module out of use e g for maintenance Each input terminal of the supply modules must be fed through a dedicated fuse The fuses are specified in Technical data The secondaries of the transformer must not be grounded Contac...

Page 81: ...of the cabinet Make the 360 earthing arrangement at the cable entries as shown below Connect the cables as follows Twist the cable shields to bundles and connect to cabinet PE ground busbar Connect the separate ground conductors cables to cabinet PE ground busbar Connect the phase conductors to the input power terminals U1 1 Depending on the cable size use cable lugs or dual cable screw lug connec...

Page 82: ...ectrical installation 76 Use of the dual cable screw lug connector Removal of the dual cable screw lug connector 1 2 3 4 1 2 3 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 83: ...rrent The cable lead through details number and size of holes and cable connection details number and dimensions of busbars tightening torque are given in chapter Technical data section Input power connection There are no contactors inside the supply module s when the drive is equipped with an air circuit breaker PE Incoming cubicle Supply module cubicle L1 L2 L3 1L1 1L2 1L3 Switching breaking dis...

Page 84: ...s b the drive is UL listed or c the incoming cubicle is designed for a busbar connection The cable lead through details number and size of holes and cable connection details number and dimensions of busbars tightening torque are given in chapter Technical data section Input power connection There are no contactors inside the modules when the drive is equipped with air circuit breakers PE Incoming ...

Page 85: ... Cut the cables to suitable length Strip the cables and conductors Twist the cable screens into bundles and connect to cabinet PE ground busbar Connect the separate ground conductors cables to cabinet PE ground busbar Connect the phase conductors to the input terminals using the torques given in chapter Technical data section Input power connection Refit the shrouds removed earlier Close the door ...

Page 86: ...ows a drive with a single inverter module 360 earthing is to be used at cable entries Whenever the inverter unit consists of parallel connected inverter modules all the modules two are shown below are to be cabled separately to the motor U2 V2 W2 PE The recommended cable types are given in chapter Planning the electrical installation M 3 U1 W1 V1 PE Inverter unit cubicle U2 V2 W2 PE The recommende...

Page 87: ...all inverter modules to the motor must be physically identical considering cable type cross sectional area and length PE Inverter unit cubicle U2 V2 W2 U2 V2 W2 M 3 U1 W1 V1 PE Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 88: ...fibre optic cables Move the cables aside 4 Remove the L shaped DC busbars on top of the module 5 Disconnect the terminal block X50 next to the DC busbars 6 Remove the two module fastening screws 6a at the top At the base of the module loosen the two fastening screws 6b but leave them in place lift the bracket 6c into the up position 7 Insert the module pull out ramp under the two screws at the bas...

Page 89: ... Push the module back into the cubicle mind your fingers 3 Refasten the module fixing screws at the top reconnect the DC busbars 4 Reconnect the cables X50 fibre optic cables 5 Loosen the module fastening screws at the base of the module and remove the pull out ramp Flip the module fastening bracket into the down position and tighten the screws Close the doors At the motor connect the cables accor...

Page 90: ... Connection procedure See the connection procedure on page 83 U2 V2 W2 PE The recommended cable types are given in chapter Planning the electrical installation M 3 U1 W1 V1 PE Inverter unit cubicle Common motor terminal cubicle Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 91: ...control the supply unit through the remote control inputs On Start Reset External fault halt the supply unit by an external emergency stop button if the unit is equipped with a local emergency stop button read supply unit s status information through the relay outputs Fault Running External 48 VDC supply on Earth fault emergency stop feed the supply unit s control boards from an external 48 VDC su...

Page 92: ...this location to enable proper connection of the bare shield and the cushions Tighten the cushions firmly onto the cable shields If the outer surface of a cable shield is non conductive turn the shield inside out as shown below and apply copper foil to keep the shielding continuous Do not cut the grounding wire if present On top entry units sort the cables so that the thinnest and thickest cables ...

Page 93: ...ables to suitable length Strip the cables and conductors Twist the cable shields into bundles and connect them to the ground terminal nearest to the terminal block Keep the unshielded portion of the cables as short as possible Connect the conductors to appropriate terminals see the chapter Motor control and I O board RMIO and the circuit diagrams delivered with the unit Close the swing out frame r...

Page 94: ...lour coding when installing fibre optic cables Blue connectors go to blue terminals and grey connectors to grey terminals When installing multiple modules on the same channel connect them in a ring Shield Module 2 3 4 1 Keep unshielded portion as short as possible To nearest PE terminal 2 3 4 1 Note 1 If the encoder is of unisolated type ground the encoder cable at the drive end only If the encode...

Page 95: ...3 600 V a3 n1 230 a4 n1 115 a1 b1 c1 a2 b2 c2 575 V A1 B1 C1 C3 A3 B3 575 V a3 n1 230 a4 n1 115 a1 b1 c1 a2 b2 c2 525 V A1 B1 C1 C4 A4 B4 525 V a3 n1 230 a4 n1 115 a1 b1 c1 a2 b2 c2 500 V A1 B1 C1 C4 A4 B4 500 V a3 n1 230 a4 n1 115 a1 b1 c1 a2 b2 c2 480 V A1 B1 C1 C5 A5 B5 480 V a3 n1 230 a4 n1 115 a1 b1 c1 a2 b2 c2 460 V A1 B1 C1 C5 A5 B5 460 V a3 n1 230 a4 n1 115 a1 b1 c1 a2 b2 c2 440 V A1 B1 C1...

Page 96: ...Electrical installation 90 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 97: ...ptionally wired to terminal block X2 The connections shown below apply also to terminal block X2 the markings are identical to the ones on the RMIO board Terminals of X2 accept cables from 0 5 to 4 0 mm2 22 to 12 AWG The tightening torque for screw terminals is 0 4 to 0 8 Nm 0 3 to 0 6 lbf ft For disconnecting wires from spring terminals use a screwdriver with a blade thickness of 0 6 mm 0 024 and...

Page 98: ...ot come into contact with electrical parts If the screw terminal plug of the cable is removed the wire ends must be individually insulated WARNING If the RMIO board is powered from two power supplies connected to X23 and X34 and the external power supply connected to X23 is also used to power external equipment equip the RMIO branch of the circuit with a diode as shown below The diode ensures that...

Page 99: ...lect 2 5 DI5 Constant speed select 3 6 DI6 Constant speed select 3 7 24VD 24 VDC max 100 mA 8 24VD 9 DGND1 Digital ground 10 DGND2 Digital ground 11 DIIL Start interlock 0 stop 4 X23 1 24V Auxiliary voltage output and input non isolated 24 VDC 250 mA 5 2 GND X25 1 RO1 Relay output 1 ready 2 RO1 3 RO1 X26 1 RO2 Relay output 2 running 2 RO2 3 RO2 X27 1 RO3 Relay output 3 fault 1 2 RO3 3 RO3 Fault A ...

Page 100: ...ct 2 5 DI5 Constant speed select 3 6 DI6 Constant speed select 3 7 24VD 24 VDC max 100 mA 8 24VD 9 DGND1 Digital ground 10 DGND2 Digital ground 11 DIIL Start interlock 0 stop 4 X23 1 24V Auxiliary voltage output and input non isolated 24 VDC 250 mA 5 2 GND X25 1 RO1 Relay output 1 ready 2 RO1 3 RO1 X26 1 RO2 Relay output 2 running 2 RO2 3 RO2 X27 1 RO3 Relay output 3 fault 1 2 RO3 3 RO3 Fault A rp...

Page 101: ...xiliary 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 Standard Application Program six programm...

Page 102: ...stem 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 external circuits connected to the terminals ...

Page 103: ...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 Phone 800 894 0412 Fax 888 723 4773 W...

Page 104: ...Motor control and I O board RMIO 98 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 105: ...ungrounded system The drive is grounded properly The supply input power voltage matches the nominal input voltage of the drive The supply input power connection to the input terminals are OK and the phase order is correct Appropriate supply input power fuses and disconnector are installed The motor connections at the output terminals are OK The motor cable is routed away from other cables Settings...

Page 106: ...Disconnect any unfinished or unchecked 230 115 VAC cables that lead from the terminal blocks to the outside of the equipment Locate the PPCS branching unit APBU xx Enable memory backup battery by setting actuator 6 of switch S3 to ON By default memory backup is switched off to save the battery Connecting voltage to input terminals and auxiliary circuit WARNING When voltage is connected to the inpu...

Page 107: ... after a short power supply break See chapter Hardware description Check the settings of the earth fault ground fault monitoring device See chapter Electrical installation 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 Prevention of Unexpected Start function if installed works Start and S...

Page 108: ...Installation checklist and start up 102 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 109: ... isolate the drive from the supply note that the switch disconnector on the door does not switch off the voltage from the input terminals wait for 5 minutes to let the intermediate circuit capacitors discharge open the cabinet doors ensure there is no dangerous voltage present by measuring the voltage of the input terminals and the intermediate circuit terminals Phone 800 894 0412 Fax 888 723 4773...

Page 110: ...replacement if necessary See Replacing the PPCS branching unit APBU xx memory backup battery Every year IP54 units Air filter replacement Every 3 years Cooling fan check replacement if necessary See Cooling fans Every 3 years Power connections check and cleaning See Power connections Every 6 years Cooling fan change See Cooling fans Every 6 years PPCS branching unit APBU xx Memory backup battery r...

Page 111: ...ackup battery 1 Switch off the power to the unit 2 Open the screws on the cover 3 pcs 3 Slide off the cover 4 Remove the battery 5 Insert the new CR 2032 battery and reattach the cover 2 3 4 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 112: ...and a vacuum cleaner 5 Close the cabinet doors Power connections 1 Read and repeat the steps in section Safety instructions above 2 Open the cabinet doors 3 Extract one supply or inverter module from the cabinet as described in the connection procedures in the chapter Electrical installation 4 Check the tightness of the cable connections at the quick connector Use the tightening torque table in Te...

Page 113: ... ABB specified spare parts The application program keeps track of the running time of the cooling fan of the inverter modules See the Firmware Manual delivered with the drive for the actual signal which indicates the running time Supply module fan replacement 1 Read and repeat the steps in section Safety instructions above 2 Open the supply cubicle doors 3 Loosen the locking screw 1 4 Disconnect t...

Page 114: ...Safety instructions above 2 Open the inverter cubicle doors 3 Disconnect the fan wiring plug 1 4 Remove the locking screws 2 5 Pull the fan out along its sliding rails 3 6 Install a new fan in reverse order 3 2 1 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 115: ... 3 Detach the wiring from each fan AC plug and grounding wire 4 Undo the four fastening screws of the fan assembly and pull the assembly outwards to gain access to the fan fastening screws 5 Undo the fastening screws of the fans there are four for each fan from below Remove the fans 6 Install new fans in reverse order Before fastening the fans make sure the airflow arrow on both fans is pointed up...

Page 116: ...crews of the side top cover of the fan 4 Lift the side top cover of the fan off 5 Disconnect the fan supply wire connector from the cabinet roof on top and inside the cabinet 6 Undo the fastening screws of the fan cassette at each corner 7 Lift the fan cassette off 8 Undo the cable ties on the top of the fan cassette 9 Disconnect the cables detachable terminals 10 Remove the fan capacitor by undoi...

Page 117: ...Maintenance 111 1 2 3 2 2 2 3 4 5 5 7 6 8 8 9 8 8 9 11 10 11 12 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 118: ...fespan 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 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 Reforming Reform re a...

Page 119: ...Supply Unit has blown main circuit AC fuse of branches L1 1 L2 1 or L3 1 of the first DSU module has blown or input power terminal is loose Change blown auxiliary circuit AC fuse Change blown main circuit AC fuse Check and tighten input power terminals LED on DSU overload or faulty DSSB control board Check load Are all parallel connected supply modules in place Decrease load or replace missing mod...

Page 120: ...r DSSB board receives false contactor status signal auxiliary contact Check operation of contactors optional Check status signal Check tighten signal connections Replace module or contactor Reset DSU and restart EARTH FAULT Supply load imbalance due to earth fault leakage current in drive motor cable or motor Check motor and motor cable Ensure there are no power factor correction capacitors or sur...

Page 121: ...L_ _ Missing See SUPPLY MISSING above See SUPPLY MISSING above Location LED Indication RMIO board RDCU drive control unit Red Drive in fault state Green The power supply on the board is OK Control panel mounting platform with the control panel removed Red Drive in fault state Green The main 24 V power supply for the control panel and the RMIO board is OK AINT board visible through the transparent ...

Page 122: ...Fault tracing 116 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 123: ...V 440 V 460 V 480 V or 500 V ACS800 07 0760 5 883 1321 630 848 630 660 500 14 0 3120 73 ACS800 07 0910 5 1050 1524 710 1008 710 785 560 17 2 3840 74 ACS800 07 1090 5 1258 1882 900 1208 900 941 630 19 9 3840 74 ACS800 07 1210 5 1372 1991 1000 1317 1000 1026 710 23 8 3840 74 ACS800 07 1540 5 1775 2655 1250 1704 1200 1328 900 29 4 5040 75 ACS800 07 1820 5 2037 2956 1450 1956 1400 1524 1120 35 0 5760 ...

Page 124: ...an 2000 m 6600 ft above sea level please contact your local ABB distributor or office for further information Nominal ratings Icont max Continuous RMS output current No overloadability at 40 C Imax Maximum output current Allowable for 10 seconds at start otherwise as long as allowed by drive temperature Typical ratings for no overload use Pcont max Typical motor power The power ratings apply to mo...

Page 125: ...CS800 07 1210 5 2 D4 2 R8i 2 ACS800 704 0910 7 2 ACS800 104 0610 5 ACS800 07 1540 5 2 D4 3 R8i 2 ACS800 704 0910 7 3 ACS800 104 0610 5 ACS800 07 1820 5 3 D4 3 R8i 3 ACS800 704 0910 7 3 ACS800 104 0610 5 ACS800 07 2310 5 3 D4 4 R8i 3 ACS800 704 0910 7 4 ACS800 104 0610 5 Three phase supply voltage 525 V 550 V 575 V 600 V 660 V or 690 V ACS800 07 0750 7 1 D4 2 R8i 1 ACS800 704 0640 7 2 ACS800 104 04...

Page 126: ...65000 0910 5 944 12 1090 5 1131 12 1210 5 1233 12 1540 5 1596 12 1820 5 1831 18 2310 5 2400 18 UN 690 V Range 525 690 V 0750 7 565 6 170M4417 Bussmann 700 690 69500 465000 0870 7 655 6 1060 7 795 6 1160 7 856 12 1500 7 1131 12 1740 7 1271 12 2120 7 1595 12 2320 7 1678 18 2900 7 2086 18 3190 7 2396 18 3490 7 2490 24 If the drive is not equipped with internal AC fuses option code F260 install specif...

Page 127: ...4 170M8547 Bussmann 170M6216 Bussmann 1250 690 0770 3 999 4 0870 3 1128 4 170M8550 Bussmann 170M6219 Bussmann 1600 690 1030 3 1305 4 1230 3 1591 6 1540 3 1938 6 1850 3 2394 8 UN 500 V Range 380 500 V 0760 5 793 4 170M8547 Bussmann 170M6216 Bussmann 1250 690 0910 5 944 4 1090 5 1131 4 170M8550 Bussmann 170M6219 Bussmann 1600 690 1210 5 1233 4 1540 5 1596 6 1820 5 1831 6 2310 5 2400 8 UN 690 V Range...

Page 128: ...o phase input voltage Fundamental power factor cos phi1 0 98 at nominal load Transformer for 12 pulse supply Connection Dy 11 d0 or Dyn 11 d0 Phase shift between secondaries 30 electrical Voltage difference between secondaries 0 5 Short circuit impedance of secondaries 5 Short circuit impedance difference between secondaries 10 of short circuit impedance Other No grounding of the secondaries allow...

Page 129: ... with delivery 15 Nm US Cabling 300 350 MCM 2 350 MCM 2 1 7 16 30 lbf ft Busbar dimensions No of busbars 2 Bolt size Tightening torque See below M12 or 70 Nm 50 lb ft Number of input busbars 6 pulse units No of supply modules n D4 No of busbars per connection point 1L1 1L2 1L3 1 1 1 1 2 2 2 2 3 3 3 3 4 3 3 3 Number of input busbars 12 pulse units No of supply modules n D4 No of busbars per connect...

Page 130: ...tor frequency Frequency resolution 0 01 Hz Current See section Ratings Power limit 2 Phd After approximately 2 minutes at 2 Phd the limit is set at Pcont max Field weakening point 8 to 300 Hz Switching frequency 2 kHz average Motor cable lead throughs 3 Ø60 mm at each inverter module units without common motor terminal cubicle Units with common motor terminal cubicle See the chapter Dimensions UNm...

Page 131: ...ft Motor cables up to 500 m 1640 ft long are allowed but EMC filtering within the specified limits will not be realised Efficiency Approximately 98 at nominal power level Bottom exit Side view Bolt size M12 or Tightening torque 70 Nm 52 lbf ft Cabling direction Top exit Side view Bolt size M12 or Tightening torque 70 Nm 52 lbf ft Cabling direction cabinet_400_generic asm 68265631 A0 Phone 800 894 ...

Page 132: ...ve 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 Chemical gases Class 1C2 Solid particles Class 1S3 Boards with coating Chemical gases Class 1C2 Solid particles Class 1S3 Boards with...

Page 133: ... and handled according to local regulations For further information on environmental aspects and more detailed recycling instructions please contact your local ABB distributor Tightening torques for power connections Screw size Torque M5 3 5 Nm 2 6 lbf ft M6 9 Nm 6 6 lbf ft M8 20 Nm 14 8 lbf ft M10 40 Nm 29 5 lbf ft M12 70 Nm 52 lbf ft M16 180 Nm 133 lbf ft Applicable standards The drive complies ...

Page 134: ...endent on the EMC competence of the customer or user for the application of drives Compliance with the EMC Directive The EMC Directive defines the requirements for immunity and emissions of electrical equipment used within the European Union The EMC product standard EN 61800 3 Amendment A11 2000 covers requirements stated for drives Compliance with the EN 61800 3 Amendment A11 2000 First environme...

Page 135: ... 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 drive manuals 4 The drive is installe...

Page 136: ...lies 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 technical competence in the EMC requirements of the application of drives Unrestricted...

Page 137: ...ply transformer with static screening between the primary and secondary windings is strongly recommended 2 The drive is installed according to the instructions given in the drive manuals 3 The motor and control cables used are selected as specified in the drive manuals Low voltage Equipment Low voltage Equipment Equipment victim Supply transformer Medium voltage network Static screen Point of meas...

Page 138: ...Technical data 132 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 139: ...standard depth of the cabinet line up is 650 mm excluding door equipment such as switches and air inlet gratings This is increased by 130 millimetres 5 1 with top entry exit models as well as units with cooling air intake through the bottom of the cabinet The measurements given apply to 6 pulse input non UL CSA units For dimensions of 12 pulse input or UL CSA units contact your local ABB represent...

Page 140: ...00 400 600 200 400 800 400 800 1900 2400 4300 1280 800 700 600 300 400 800 400 800 1600 2400 4000 1060 800 700 300 400 600 300 400 800 400 800 2300 2400 4700 1660 800 700 400 600 300 400 800 400 800 2000 2400 4400 1360 800 700 600 400 400 400 2500 2500 1430 700 300 400 600 400 400 400 3200 3200 2030 700 400 600 400 400 400 2900 2900 1730 700 600 300 400 400 400 2800 2800 1600 700 300 400 600 300 4...

Page 141: ...0 400 600 600 600 200 400 800 400 800 2400 2400 4800 1990 800 400 600 600 300 400 800 400 800 1900 2400 4300 1370 800 400 500 600 600 300 400 800 400 800 2400 2400 4800 1750 800 400 600 600 600 300 400 800 400 800 2500 2400 4900 2070 800 400 600 600 400 400 400 2800 2800 1740 400 500 600 600 400 400 400 3100 3100 2120 400 600 600 600 400 400 400 3400 3400 2440 400 600 600 300 400 400 400 3100 3100...

Page 142: ... split widths Line up width Net weight kg approx 400 800 800 2000 2000 1540 400 600 800 800 2600 2600 1940 400 600 800 800 2600 2600 2240 400 800 800 400 2400 2400 1730 400 600 800 800 400 3000 3000 2130 400 600 800 800 400 3000 3000 2430 3 D4 4 R8i Control I O cubicle Load switch disconnector Air circuit breaker Supply unit Inverter unit 1 Common motor terminal cubicle Inverter unit 2 Shipping sp...

Page 143: ...800 4000 4000 2790 400 600 800 800 600 800 4000 4000 3090 4 D4 6 R8i Control I O cubicle Load switch disconnector Air circuit breaker Supply unit Inverter unit 1 Common motor terminal cubicle Inverter unit 2 Shipping split widths Line up width Net weight kg approx 400 600 600 800 800 3200 3200 2520 400 600 600 600 800 800 3800 3800 2920 400 600 600 600 800 800 3800 3800 3220 400 600 600 800 600 80...

Page 144: ...Dimensions 138 Frame size 1 D4 2 R8i Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 145: ...Dimensions 139 Frame size 1 D4 2 R8i continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 146: ...Dimensions 140 Frame size 1 D4 2 R8i continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 147: ...Dimensions 141 Frame size 1 D4 2 R8i with load switch disconnector Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 148: ...Dimensions 142 Frame size 1 D4 2 R8i with load switch disconnector continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 149: ...Dimensions 143 Frame size 1 D4 2 R8i with load switch disconnector continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 150: ...Dimensions 144 Frame size 1 D4 2 R8i with load switch disconnector continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 151: ...Dimensions 145 Frame size 1 D4 2 R8i with load switch disconnector continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 152: ...Dimensions 146 Frame size 1 D4 2 R8i with load switch disconnector continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 153: ...Dimensions 147 Frame size 1 D4 2 R8i with top entry exit Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 154: ...Dimensions 148 Frame size 1 D4 2 R8i with top entry exit continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 155: ...Dimensions 149 Frame size 1 D4 2 R8i with top entry exit continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 156: ...Dimensions 150 Frame size 2 D4 2 R8i Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 157: ...Dimensions 151 Frame size 2 D4 2 R8i continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 158: ...Dimensions 152 Frame size 2 D4 2 R8i continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 159: ...Dimensions 153 Frame size 2 D4 2 R8i with load switch disconnector Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 160: ...Dimensions 154 Frame size 2 D4 2 R8i with load switch disconnector continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 161: ...Dimensions 155 Frame size 2 D4 2 R8i with load switch disconnector continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 162: ...Dimensions 156 Frame size 2 D4 3 R8i Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 163: ...Dimensions 157 Frame size 2 D4 3 R8i continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 164: ...Dimensions 158 Frame size 2 D4 3 R8i continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 165: ...Dimensions 159 Frame size 2 D4 3 R8i with load switch disconnector Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 166: ...Dimensions 160 Frame size 2 D4 3 R8i with load switch disconnector Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 167: ...Dimensions 161 Frame size 2 D4 3 R8i with load switch disconnector Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 168: ...Dimensions 162 Frame size 2 D4 3 R8i with load switch disconnector Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 169: ...Dimensions 163 Frame size 2 D4 3 R8i with air circuit breaker Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 170: ...Dimensions 164 Frame size 2 D4 3 R8i with air circuit breaker continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 171: ...Dimensions 165 Frame size 2 D4 3 R8i with air circuit breaker continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 172: ...Dimensions 166 Frame size 2 D4 3 R8i with air circuit breaker continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 173: ...Dimensions 167 Frame size 3 D4 4 R8i Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 174: ...Dimensions 168 Frame size 3 D4 4 R8i continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 175: ...Dimensions 169 Frame size 3 D4 4 R8i continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 176: ...Dimensions 170 Frame size 3 D4 4 R8i with load switch disconnector Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 177: ...Dimensions 171 Frame size 3 D4 4 R8i with load switch disconnector continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 178: ...Dimensions 172 Frame size 3 D4 4 R8i with load switch disconnector continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 179: ...Dimensions 173 Frame size 3 D4 4 R8i with load switch disconnector continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 180: ...Dimensions 174 Frame size 3 D4 4 R8i with air circuit breaker Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 181: ...Dimensions 175 Frame size 3 D4 4 R8i with air circuit breaker continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 182: ...Dimensions 176 Frame size 3 D4 4 R8i with air circuit breaker continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 183: ...Dimensions 177 Frame size 3 D4 4 R8i with air circuit breaker continued Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 184: ...Depending on the drive size the common motor terminal cubicle is either 300 400 or 600 mm wide Refer to the cabinet line up tables at the beginning of this chapter 300 mm Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 185: ...Dimensions 179 400 mm Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 186: ...Dimensions 180 600 mm Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 187: ...ype D151 400 V ACS800 07 0610 3 2 NBRA 659 2 2 SAFUR180F460 ACS800 07 0770 3 2 NBRA 659 2 2 SAFUR180F460 ACS800 07 0870 3 3 NBRA 659 3 2 SAFUR180F460 ACS800 07 1030 3 3 NBRA 659 3 2 SAFUR180F460 500 V ACS800 07 0760 5 2 NBRA 659 2 2 SAFUR200F500 ACS800 07 0910 5 2 NBRA 659 2 2 SAFUR200F500 ACS800 07 1090 5 3 NBRA 659 3 2 SAFUR200F500 ACS800 07 1210 5 3 NBRA 659 3 2 SAFUR200F500 690 V ACS800 07 075...

Page 188: ... 1815 862 1065 500 618 690 V 1 NBRA 669 2 SAFUR200F500 1 35 404 54 835 287 355 167 206 2 NBRA 669 2 2 SAFUR200F500 1 35 807 108 1670 575 514 333 298 3 NBRA 669 3 2 SAFUR200F500 1 35 1211 162 2505 862 771 500 447 UN Nominal voltage R Resistance of specified resistors per chopper Pbrmax Maximum short term 1 min every 10 mins braking power Pcont Maximum continuous braking power Imax Maximum peak curr...

Page 189: ... two in series The ER value of the four resistor assembly is four times the value specified for the standard resistor Custom resistors Resistors other than the standard resistors can be used provided that the resistance is not lower than with the standard resistors WARNING Never use a brake resistor with a resistance below the value specified for the particular drive brake chopper resistor combina...

Page 190: ...ed continuous braking power is 10 of the Maximum Braking Power Pbrmax Example 2 Duration of a braking cycle is three minutes The braking time is 40 seconds Result The maximum allowed braking power for the cycle is 37 of the rated value given for the reference cycle n Pbr tbr Pbrmax 60 s n Number of braking pulses during a ten minute period Pbr Maximum allowed braking power kW tbr Braking time s Pb...

Page 191: ...The maximum allowed braking power for the cycle is equal to the Maximum Braking Power Pbrmax given for the reference cycle T Duration of the braking cycle tbr Pbrmax t Pbr 600 s Pbr Pbrmax 60 s 4 10 s 1 5 Pbrmax 1 2 Pbr Pbrmax Not allowed Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 192: ...ainst overheating resistors with thermal circuit breakers standard in ABB resistors should be used The circuit breakers should be wired to the ENABLE inputs of the brake choppers WARNING The ENABLE input terminal blocks of the choppers are at intermediate circuit potential when the supply unit of the ACS800 07 is running This voltage is extremely dangerous and may cause serious damage or injuries ...

Page 193: ... In the drive application program overvoltage control of the drive must be disabled for correct operation of the brake chopper This has been done at the factory for units with brake choppers R R R R 1 2 3 t Brake chopper Brake resistor 1 2 X1 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

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