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ABB ACS800-11, Hardware Manual

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Table of contents

17

Capacitors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Reforming  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

LEDs  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Technical data

What this chapter contains   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
IEC ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Symbols  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Sizing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Derating   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Temperature derating   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Altitude derating  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Mains cable fuses  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Cable types  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Cable entries  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Dimensions, weights and noise   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Input power connection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Efficiency  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Cooling   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Degrees of protection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Ambient conditions   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Materials  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Applicable standards  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
CE marking  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Compliance with the EMC Directive  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Compliance with the EN 61800-3 + Amendment A11 (2000) . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

First environment (restricted distribution) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Second environment   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Machinery Directive   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

 “C-tick” marking   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Compliance with IEC 61800-3   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

First environment (restricted distribution) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Second environment   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Equipment warranty and liability  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
US tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

NEMA ratings  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Symbols  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Input cable fuses   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Cable Entries   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Dimensions and weights   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
UL/CSA markings  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

UL   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Summary of Contents for ACS800-11

Page 1: ...ACS800 Hardware Manual ACS800 11 Drives 5 5 to 110 kW ACS800 U11 Drives 7 5 to 125 HP ...

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

Page 3: ...ACS800 11 Drives 5 5 to 110 kW ACS800 U11 Drives 7 5 to 125 HP Hardware Manual 3AFE68367883 Rev A EN EFFECTIVE 5 1 2005 2005 ABB Oy All Rights Reserved ...

Page 4: ......

Page 5: ...otes There are two types of safety instructions throughout this manual warnings and notes Warnings caution you about conditions which can result in serious injury or death and or damage to the equipment They also tell you how to avoid the danger Notes draw attention to a particular condition or fact or give information on a subject The warning symbols are used as follows Dangerous voltage warning ...

Page 6: ...o the drive or to the external control circuits Externally supplied control circuits may cause dangerous voltages inside the drive even when the main power on the drive is switched off Do not make any insulation or voltage withstand tests on the drive or drive modules When reconnecting the motor cable always check that the phase order is correct Note The motor cable terminals on the drive are at a...

Page 7: ...tallations 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 environment make a 360 high frequency grounding of motor cable entries at the cabinet lead through Do not...

Page 8: ... drive 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...

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: ... 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 Do not use the optional Prevention of Unexpected Start function for stoppin...

Page 11: ...o 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 Alternative 2 Measure that there is no voltage present on the drive input or output terminals U1 V1 W1 U2 V2 W2 Ground the drive output terminals temporarily by connecting th...

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

Page 13: ...and operation 11 Table of contents About this manual What this chapter contains 19 Intended audience 19 Other related manuals 19 Common chapters for several products 20 Categorization according to the frame size 20 Categorization according to the plus code 20 Contents 20 Installation and commissioning flowchart 21 Inquiries 22 The ACS800 11 U11 What this chapter contains 23 The ACS800 11 U11 23 Te...

Page 14: ...1 ACS800 U1 ACS800 11 ACS800 U11 ACS800 02 ACS800 U2 without enclosure extension ACS800 04 ACS800 U4 42 ACS800 U2 with enclosure extension ACS800 07 and ACS800 U7 42 EU 42 US 42 Fuses 42 Thermal overload and short circuit protection 43 Mains cable AC line cable short circuit protection 43 ACS800 01 U1 ACS800 11 U11 ACS800 02 U2 without enclosure extension and ACS800 04 U4 43 Drive AC fuses ACS800 ...

Page 15: ...the power cables 57 Diagram 57 Conductor stripping lengths 58 Allowed wire sizes tightening torques 58 Wall installed units European version 58 Power cable installation procedure 58 Wall installed units US version 61 Warning sticker 62 Cabinet installed units IP 00 UL type open 62 Connecting the control cables 63 Terminals 63 360 degrees grounding 64 When the outer surface of the shield is covered...

Page 16: ... and ACS800 17 77 ACS800 11 U11 specific parameters in the application program 78 Terms and abbreviations 78 Actual signals and parameters of the line converter in the motor side converter control program 78 09 ACTUAL SIGNALS 78 95 HARDWARE SPECIF 78 Fieldbus control interface 79 Block diagram reference select 79 Connection diagram of the RMIO board in the line side converter 80 Fault tracing 81 F...

Page 17: ...ient conditions 92 Materials 93 Applicable standards 93 CE marking 94 Definitions 94 Compliance with the EMC Directive 94 Compliance with the EN 61800 3 Amendment A11 2000 94 First environment restricted distribution 94 Second environment 95 Machinery Directive 95 C tick marking 96 Definitions 96 Compliance with IEC 61800 3 96 First environment restricted distribution 96 Second environment 97 Equi...

Page 18: ...wings Frame size R5 IP 21 UL type open 104 Frame size R6 IP 21 UL type open 105 External 24 V power supply for the RMIO board What this chapter contains 107 When to use 107 Parameter settings 107 Connecting 24 V external power supply 108 ...

Page 19: ...dwide Both SI and imperial units are shown Special US instructions for installations within the United States that must be installed per the National Electrical Code and local codes are marked with US Other related manuals Refer to ACS800 IGBT Supply Control Program Firmware Manual 3AFE68315735 English for the line side converter program features actual signals and parameters fault tracing fieldbu...

Page 20: ...certain optional selections are marked with plus codes e g E202 The options included in the drive can be identified from the plus codes visible on the type designation label of the drive The plus code selections are listed in chapter The ACS800 11 U11 under Type code Contents The chapters of this manual are briefly described below Safety instructions give safety instructions for the installation c...

Page 21: ...ditions ratings required cooling air flow input power connection compatibility of the motor motor connection and other technical data Select the cables Technical data Planning the electrical installation For compliance with the European Union EMC Directive see Technical data CE marking Option manual if optional equipment is included Unpack and check the units Check that all necessary optional modu...

Page 22: ...ance with the European Union EMC Directive see Technical data CE marking Check the insulation of the motor and the motor cable Electrical installation Checking the insulation of the installation Connect the power cables Electrical installation Connect the control and auxiliary control cables Electrical installation Motor control and I O board RMIO and the optional module manual delivered with the ...

Page 23: ...in short The ACS800 11 U11 The ACS800 1 U11 is a four quadrant wall mountable drive for controlling AC motors The main circuit consists of two IGBT converters a line side converter and a motor side converter integrated into the same frame Heat sink Control panel CDP312R Front cover Cooling fan IP 21 UL type 1 Frame size R6 Connection box cover ...

Page 24: ... Location of the motor side converter RMIO board Frame size R6 without front and connection box covers IP 00 UL type open Frame size R5 without front and connection box covers U1 V1 W1 V2 W2 U2 UDC UDC PE U1 V1 W1 U2 V2 W2 UDC UDC PE I O terminals Power cable terminals ...

Page 25: ...n be viewed and changed using one control panel The control panel can be switched between the converters as described in chapter Operation Line side converter The IGBT supply module rectifies three phase AC current to direct current for the intermediate DC link of the drive The intermediate DC link is further supplying the motor side converter that runs the motor The line filter suppresses the AC ...

Page 26: ...he high frequency switching and high du dt slightly distort the voltage waveform at the input of the converter Typical line current iU and voltage uUV waveforms are shown below Note The diagrams represent a larger unit than the ACS800 11 An example spectrum of the voltage distortion at the output of the transformer is shown below Each harmonic is presented as compared to fundamental voltage refere...

Page 27: ...drive contains the following printed circuit boards as standard main circuit board GINT motor control and I O board RMIO 2 pcs EMC filter unit GRFCU when EMC equipment is selected filter boards GRFC or RRFC varistor board GVAR control panel CDP 312R current measurement board GCUR in frame size R5 only charging diode board GDIO DDCS communication modules The drive includes an RDCO 03 module in the ...

Page 28: ...nverter UDC UDC Line side converter control program External control via analogue digital inputs and outputs Optional module 1 RMBA RAIO RDIO RDNA RLON RIBA RPBA RCAN RCNA RMBP RETA or RTAC Optional module 2 RTAC RAIO or RDIO DDCS communication module RDCO 03 default RDCO 01 or RDCO 02 RMIO board of the line side converter DDCS U2 V2 W2 RDCO 03 Simplified main circuit Input power Output power UDC ...

Page 29: ...from below boards with coating one set of manuals U11 wall mounted USA When no options are selected UL type 1 Control Panel CDP312R DDCS communication option module RDCO 03 no EMC filter US version of the Standard Application Program three wire start stop as default setting US gland conduit plate boards with coating one set of English manuals Size Refer to Technical data IEC ratings Voltage range ...

Page 30: ...The ACS800 11 U11 30 ...

Page 31: ...re are no signs of damage Before attempting installation and operation check the information on the type designation label of the drive to verify that the unit is of the correct type The label includes an IEC and NEMA rating C UL CSA and CE markings a type code and a serial number which allow individual recognition of each unit The first digit of the serial number refers to the manufacturing plant...

Page 32: ...the heat sink and the serial number label to the lower part of the back plate of the unit Example labels are shown below Moving the unit Lift the unit using the lifting holes at the top and bottom Type designation label Serial number label Lifting a unit of frame size R6 ...

Page 33: ...e allowed operation conditions of the drive Wall The wall should be as close to vertical as possible of non flammable material and strong enough to carry the weight of the unit Check that there is nothing on the wall to inhibit the installation Floor The floor material below the installation should be non flammable Free space around the unit Required free space around the drive to enable cooling a...

Page 34: ...in a cabinet without the plastic front top and connection box covers and without the lead through plate The required distance between parallel units is 50 millimetres 1 97 in in installations without the front cover The cooling air entering the unit must not exceed 40 C 104 F Contact ABB if two units are to be installed side by side at a distance smaller than 50 millimetres 1 97 in i e the side ai...

Page 35: ...Mechanical installation 35 Unit above another Lead the out coming hot cooling air away from the air input of the drive above Example max 40 C 104 F ...

Page 36: ...Mechanical installation 36 ...

Page 37: ...tions given by ABB are not followed the drive may experience problems that the warranty does not cover To which products this chapter applies This chapter applies to the ACS800 01 U1 ACS800 11 U11 ACS800 02 U2 ACS800 04 U4 and ACS800 07 U7 types up to 0610 x Motor selection and compatibility 1 Select the motor according to the rating tables in chapter Technical Data Use the DriveSize PC tool if th...

Page 38: ...2 When 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 fr...

Page 39: ...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 40: ... 500 134 HP PN 469 HP or frame size NEMA 500 PN 469 HP or frame size NEMA 580 A B B Random wound M2_ and M3_ UN 500 V Standard N N CMF 500 V UN 600 V Standard du dt du dt N du dt N CMF or Reinforced N 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 ...

Page 41: ... wound windings All HXR machines manufactured in Helsinki starting 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 sim...

Page 42: ...n for installation and maintenance work ACS800 U2 with enclosure extension ACS800 07 and ACS800 U7 These units are equipped with a hand operated input disconnecting device disconnecting means which isolates the drive and the motor from the AC power as standard The disconnecting device does not however isolate the input busbars from the AC power Therefore during installation and maintenance work on...

Page 43: ...t enclosure extension and ACS800 04 U4 When placed at the distribution board standard gG fuses US CC or T for the ACS800 U1 and ACS800 U11 T or L for the ACS800 U2 and ACS800 U4 will protect the input cable in short circuit situations restrict drive damage and prevent damage to adjoining equipment in case of a short circuit inside the drive Drive AC fuses ACS800 07 U7 and ACS800 02 U2 with enclosu...

Page 44: ...personal safety or a fire protection feature The ground fault protective function can be disabled with a parameter refer to the appropriate ACS800 Firmware Manual The EMC filter of the drive includes capacitors connected between the main circuit and the frame These capacitors and long motor cables increase the ground leakage current and may cause fault current circuit breakers to function Emergenc...

Page 45: ...that the prevention is active The switch can be locked out The user must install on a control desk near the machinery switching disconnecting device for the circuitry Means shall be provided to prevent inadvertent and or mistaken closure of the disconnecting device EN 60204 1 1997 indicating lamp on starting the drive is prevented off drive is operative For connections to the drive see the circuit...

Page 46: ...cable should be at least 1 kV For drive frame size R5 and larger or motors larger than 30 kW 40 HP symmetrical shielded motor cable must be used figure below A four conductor system can be used up to frame size R4 with up to 30 kW 40 HP motors but shielded symmetrical motor cable is recommended A four conductor system is allowed for input cabling but shielded symmetrical cable is recommended To op...

Page 47: ...en helix of copper tape The better and tighter the shield the lower the emission level and bearing currents Symmetrical shielded cable three phase conductors and a concentric or otherwise symmetrically 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: ...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 trade names i...

Page 49: ...motor cable shielding runs consistently without breaks from the drive to the motor Bypass connection WARNING Never connect the supply power to the drive output terminals U2 V2 and W2 If frequent bypassing is required employ mechanically connected switches or contactors Mains line voltage applied to the output can result in permanent damage to the unit Before opening a contactor DTC control mode se...

Page 50: ...ads with noise attenuating circuits varistors RC filters AC or diodes DC in order to minimize the EMC emission at switch off If not suppressed the disturbances may connect capacitively or inductively to other conductors in the control cable and form a risk of malfunction in other parts of the system Install the protective component as close to the inductive load as possible Do not install protecti...

Page 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 VAC signals in the same cable Relay cable The cable type with braided metallic screen e g ÖLFLEX by LAP...

Page 52: ...om other low voltage circuits 3 An external thermistor relay is used The insulation of the relay must be rated for the same voltage level as the main circuit of the drive For connection see ACS800 Firmware Manual Routing the cables Route the motor cable away from other cable routes Motor cables of several drives can be run in parallel installed next to each other It is recommended that the motor c...

Page 53: ...mm 20 in Motor cable Input power cable Control cables min 200 mm 8 in min 300 mm 12 in Motor cable Power cable Drive 230 V 24 V 24 V 230 V Lead 24 V and 230 V control cables in separate ducts inside the cabinet Not allowed unless the 24 V cable is insulated for 230 V or insulated with an insulation sleeving for 230 V ...

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

Page 55: ...n of the installation Drive Every drive has been tested for insulation between the main circuit and the chassis 2500 V rms 50 Hz for 1 second at the factory Therefore do not make any voltage tolerance or insulation resistance tests e g hi pot or megger on any part of the drive Input cable Check the insulation of the input cable before connecting it to the drive according to local regulations Motor...

Page 56: ...istance 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 Disconnecting the EMC filter capacitors Remove the two screws shown below Note When the EMC filter capacitors are disconnected and the motor cable is longer than 100 m 328 ft the EMC Directive requirements may not be fulf...

Page 57: ...tivity of the input cable shield is 50 of the conductivity of the phase conductor Ground the other end of the input cable shield or PE conductor at the distribution board 3 360 degrees grounding recommended if shielded cable is used 4 360 degrees grounding required 5 Use a separate grounding cable if the conductivity of the cable shield is 50 of the conductivity of the phase conductor and there is...

Page 58: ...e bottom plate 5 Strip off the outer sheathing of the cables under the 360 degrees grounding clamps Fasten the clamps onto the stripped parts of the cables 6 Tighten the grounding clamps onto the twisted shields of the cables 7 Connect the phase conductors of the mains cable to the U1 V1 and W1 terminals and the phase conductors of the motor cable to the U2 V2 and W2 terminals 8 Cut holes to the c...

Page 59: ...Electrical installation 59 1 2 3 Views of frame size R5 U1 V1 W1 V2 W2 U2 UDC UDC 5 5 PE 6 6 8 9 9 ...

Page 60: ... tape or shrink tubing 5 5 a Connect the cable to the terminal b Connect the terminal to the drive WARNING If the wire size is less than 95 mm2 3 0 AWG a cable lug must be used A cable of wire size less than 95 mm2 3 0 AWG connected to this terminal will loosen and may damage the drive a b 5 5 6 PE 6 PE Remove the cable terminals Fasten the cable lugs with screws Shroud on the cable terminals cabl...

Page 61: ...les of the gland plate 6 Lead the cables through the glands 7 Fasten the gland plate 3 8 Connect the grounding conductors of the input and motor cables to the grounding clamps 9 Remove the clear plastic shroud as shown in section Power cable installation procedure on page 58 10 Connect the phase conductors of the input cable to the U1 V1 and W1 terminals and the phase conductors of the motor cable...

Page 62: ... Ground the twisted shields of the power cables under the PE and grounding clamps Secure the cables mechanically Protect the RMIO board terminals X25 to X27 against contact when input voltage exceeds 50 VAC Cover the power cable terminals with the clear plastic shroud as shown in section Power cable installation procedure on page 58 Wire size Compression lug Crimping tool kcmil AWG Manufacturer Ty...

Page 63: ...the RMIO board refer to chapter Motor control and I O board RMIO Tighten the screws to secure the connection Terminals Detachable connection terminals pull up Optional module 1 Optional module 2 Control panel Control cable grounding see section 360 degrees grounding DDCS communication module RDCO Channel CH1 is used for the internal communication between the line side and motor side converters Vie...

Page 64: ... route to the nearest grounding hole with a cable lug and a screw Double shielded cables Connect each pair cable shield twisted grounding wires with other pair cable shields of the same cable to the nearest grounding hole with a cable lug and a screw Do not connect shields of different cables to the same cable lug and grounding screw Leave the other end of the shield unconnected or ground it indir...

Page 65: ...C 2 3 4 1 Wrap copper tape around the stripped part of the cable under the clamp Be careful Do not cut the grounding wire 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 dr...

Page 66: ...ace is inserted in the optional module slot of the RMIO board see Connecting the control cables and fixed with two screws See the appropriate optional module manual for cable connections Note Two RDCO modules are provided for the DDCS fibre optic link between the RMIO boards of the line side and motor side converters Channel CH0 of the RDCO 03 module in the line side converter and channel CH1 of t...

Page 67: ...00 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 disconnecting wires from spring terminals use a screw driver with a blade thickness of 0 6 mm 0 024 in and width of 3 5 mm 0 138 in e g PHOENIX CONTACT SZF 1 0 6X3 5 ...

Page 68: ...on deceleration select 2 5 5 DI5 Constant speed select 3 6 6 DI6 Constant speed select 3 7 7 24VD 24 VDC max 100 mA 8 8 24VD 9 9 DGND1 Digital ground 10 10 DGND2 Digital ground 11 11 DIIL Start interlock 0 stop 4 X23 X23 1 1 24V Auxiliary voltage output non isolated 24 VDC 250 mA 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 X...

Page 69: ... deceleration select 2 5 5 DI5 Constant speed select 3 6 6 DI6 Constant speed select 3 7 7 24VD 24 VDC max 100 mA 8 8 24VD 9 9 DGND1 Digital ground 10 10 DGND2 Digital ground 11 11 DIIL Start interlock 0 stop 4 X23 X23 1 1 24V Auxiliary voltage output non isolated 24 VDC 250 mA 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 X27...

Page 70: ...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 71: ...cation adapter module RDCO Protocol DDCS ABB Distributed Drives Communication System 24 VDC power input Voltage 24 VDC 10 Typical current consumption without optional modules 250 mA Maximum current consumption 1200 mA with optional modules inserted The terminals on the RMIO board as well as on the optional modules attachable to the board fulfil the Protective Extra Low Voltage PELV requirements st...

Page 72: ...ND1 5 DI5 6 DI6 7 24VD 8 24VD 11 DIIL 10 DGND2 X23 1 24 V 2 GND X25 1 RO1 2 RO1 3 RO1 X26 1 RO2 2 RO2 3 RO2 X27 1 RO3 2 RO3 3 RO3 Common mode voltage between channels 15 V J1 Test voltage 500 V AC or Jumper J1 settings All digital inputs share a common ground This is the default setting Grounds of input groups DI1 DI4 and DI5 DI6 DIIL are separate isolation voltage 50 V Ground Test voltage 4 kV AC...

Page 73: ...llation Electrical installation The E202 and E200 EMC filter capacitors are disconnected if the drive is connected to an IT ungrounded system The capacitors are reformed if stored over one year refer to ACS 600 800 Capacitor Reforming Guide 64059629 English The drive is grounded properly The mains input power voltage matches the drive nominal input voltage The mains input power connections at U1 V...

Page 74: ...Installation checklist 74 ...

Page 75: ... procedure or in normal use However it is recommended to set parameter 16 15 I O START MODE to DI2 LEVEL if the motor is started and stopped frequently This prolongs the lifespan of the charging contactor when starting the motor without delay after the start command is required If the drive is connected to a common DC bus Otherwise the charging resistor may be damaged Note By default the control p...

Page 76: ...rts to modulate and the charging resistors will be by passed when the line converter RMIO board is powered its digital input DI2 is ON and there are no faults Note With the ACS800 11 ACS800 U11 and ACS800 17 this selection changes the value of par 98 01 COMMAND SEL from the default setting MCW to I O on the next RMIO board power up 1 31 AUTOMATIC RESET Automatic fault reset Automatic resets are po...

Page 77: ...ink overvoltage fault B NO NO Inactive 0 YES Active 65535 31 06 UNDERVOLTAGE Activates deactivates the automatic reset for the intermediate link undervoltage fault B NO NO Inactive 0 YES Active 65535 Parameter Default value If changed 11 01 DC REF SELECT FIELDBUS the default values will be restored on the next power up 11 02 Q REF SELECT PARAM 24 02 98 01 COMMAND SEL MCW Note If par 16 15 I O STAR...

Page 78: ...ndard Application Program Terms and abbreviations Term Definition Actual signal Signal measured or calculated by the drive Can be monitored by the user No user setting possible FbEq Fieldbus equivalent The scaling between the value shown on the control panel and the integer used in serial communication Parameter A user adjustable operation instruction of the drive ...

Page 79: ... 1000 kVAr of par 24 02 Q POWER REF2 Value of par 24 01 Q POWER REF is then 100 1000 kVAr divided by converter nominal power in kVAr Scaling example 3 Par 24 03 Q POWER REF2 SEL is set to PHI A value of 10000 of par 95 06 equals to a value of 100 deg of parameter 24 02 Q POWER REF2 which is limited to 30 deg The value of par 24 01 Q POWER REF will be determined approximately according to the follo...

Page 80: ...onverter Dataset 123 CH1 95 08 LCU PAR1 SEL 95 09 LCU PAR2 SEL 24 04 Dataset 122 CH0 MSW fixed 106 value 110 value PARAM 23 01 AI1 AI2 AI3 FIELD BUS 11 01 DC REF SELECT 23 01 Dataset 121 CH0 MCW fixed Q REF fixed DC REF fixed Dataset 121 CH1 MCW 95 06 LCU Q POW REF 95 07 LCU DC REF V Dataset 122 CH1 MSW 9 12 LCU ACT SIGNAL 1 9 13 LCU ACT SIGNAL 2 98 02 COMM MODULE INVERTER 112 04 SUPPLY CTRL MODE ...

Page 81: ...ohm 8 AI3 9 AO1 By default not in use 0 4 20 mA Rin 100 ohm 10 AO1 11 AO2 By default not in use 0 4 20 mA Rin 100 ohm 12 AO2 X22 1 DI1 Acknowledgement of converter fan 1 2 DI2 Stop Start 3 DI3 Acknowledgement from main contactor 1 4 DI4 By default not in use 5 DI5 By default not in use 6 DI6 Reset 1 7 24V 24 VDC max 100 mA 8 24V 9 DGND Digital ground 10 DGND Digital ground 11 DI7 DIIL By default n...

Page 82: ... RMIO board to 2 For the setting procedure see the application program firmware manual Connect the disconnected cable to the RMIO board of the motor side converter again and set the ID number to 1 Changing the control panel to the line side converter WARNING The drive does not stop by pressing the control panel Stop key in local control mode Step Action Press key Display example 1 To enter the Dri...

Page 83: ...on Press key Display example 1 To enter the Drive Section Mode 2 To scroll to ID number 1 3 To verify the change to the motor side converter DRIVE ACS 800 0050_5LR IXXR7xxx ID NUMBER 2 ACS 800 0050_5MR ACXR7xxx ID NUMBER 1 ACT FREQ 0 00 Hz CURRENT 0 00 A POWER 0 00 1 L 0 0 rpm I ...

Page 84: ...Operation 84 ...

Page 85: ...led in an appropriate environment the drive requires very little maintenance This table lists the routine maintenance intervals recommended by ABB Maintenance Interval Instruction Capacitor reforming Every year when stored See Reforming Heatsink temperature check and cleaning Depends on the dustiness of the environment every 6 to 12 months See Heatsink Change of additional cooling fan Every three ...

Page 86: ... of the dust entering adjoining equipment perform the cleaning in another room 3 Replace the cooling fan Main cooling fan The cooling fan lifespan of the drive is about 50 000 operating hours The actual lifespan depends on the drive usage and ambient temperature See the appropriate ACS800 firmware manual for an actual signal which indicates the hours of usage of the fan Fan failure can be predicte...

Page 87: ...p plate up 4 Disconnect the fan supply wires detachable connector 5 Lift the fan up 6 Install the new fan in reverse order Additional fan Replacement R5 Remove the front cover The fan is located on the right hand side of the control panel R5 Lift the fan out and disconnect the cable Install the new fan in reverse order 3 4 1 1 5 ...

Page 88: ...to predict a capacitor failure Capacitor failure is usually followed by a mains 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 LEDs This table describes LEDs of the ...

Page 89: ...315 0040 2 120 168 37 114 30 84 22 R6 405 1585 0050 2 150 234 45 143 45 117 30 R6 405 2125 0060 2 169 264 45 157 45 132 37 R6 405 2530 Three phase supply voltage 380 V 400 V or 415 V 0016 3 34 52 15 32 15 26 11 R5 350 550 0020 3 38 61 18 5 36 18 5 34 15 R5 350 655 0025 3 47 68 22 45 22 38 18 5 R5 350 760 0030 3 59 90 30 56 30 45 22 R5 350 1000 0040 3 72 118 37 69 37 59 30 R5 350 1210 0050 3 86 144...

Page 90: ... 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 or 0 90 I2hd Altitude derating In altitudes from 1000 to 4000 m 3300 to 13123 ft above sea level the derating is 1 for every 100 m 328 ft For a more accurate derating use the DriveSize PC tool If the installa...

Page 91: ...0H80 000 0030 2 82 100 63600 500 ABB Control OFAF000H100 000 0040 2 112 125 103000 500 ABB Control OFAF00H125 00 0050 2 140 160 200000 500 ABB Control OFAF00H160 00 0060 2 157 200 350000 500 ABB Control OFAF1H200 1 Three phase supply voltage 380 V 400 V or 415 V 0016 3 32 40 9140 500 ABB Control OFAF000H40 000 0020 3 35 40 9140 500 ABB Control OFAF000H40 000 0025 3 44 50 15400 500 ABB Control OFAF...

Page 92: ...ques are given below with cable lugs 16 70 mm2 tightening torque 20 40 Nm Dimensions weights and noise Copper cables with concentric copper shield Aluminium cables with concentric copper shield Max load current A Cable type mm2 Max load current A Cable type mm2 34 3x6 61 3x25 47 3x10 75 3x35 62 3x16 91 3x50 79 3x25 117 3x70 98 3x35 143 3x95 119 3x50 165 3x120 153 3x70 191 3x150 186 3x95 215 3x120 ...

Page 93: ...f change 17 s Imbalance Max 3 of nominal phase to phase input voltage Voltage dips Max 25 Fundamental power factor cos phi1 1 00 fundamental at nominal load Harmonic distortion THD current 0 05 I1cont max if supply network voltage is not distorted by other loads Motor connection Voltage U2 0 to U1 3 phase symmetrical Umax at the field weakening point Frequency DTC mode 0 to 3 2 fFWP Maximum freque...

Page 94: ...x 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 with coating Chemical gases Class 3C2 Solid particles Class 3S2 Boards with coating Chemical gases Class 1C2 Solid particles Class 1S3 Boards with coating Chemical gases Class 2C2 Solid particles Cla...

Page 95: ...ng to local regulations For further information on environmental aspects and more detailed recycling instructions please contact your local ABB distributor Applicable standards The drive complies with the following standards The compliance with the European Low Voltage Directive is verified according to standards EN 50178 and EN 60204 1 EN 50178 1997 Electronic equipment for use in power installat...

Page 96: ...ribution in which the supply of equipment is not dependent on the EMC competence of the customer or user for the application of drives Compliance with the 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 wi...

Page 97: ...sion is propagated to neighbouring low voltage networks In some cases the natural suppression in transformers and cables is sufficient If in doubt a 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 contro...

Page 98: ...t environment includes establishments connected to a low voltage network which supplies buildings used for domestic purposes Second environment includes establishments connected to a network not supplying domestic premises Restricted distribution mode of sales distribution in which the manufacturer restricts the supply of equipment to suppliers customers or users who separately or jointly have tec...

Page 99: ... resulting from a failure if the installation commissioning repair alternation or ambient conditions of the drive do not fulfil the requirements specified in the documentation delivered with the unit and other relevant documentation units subjected to misuse negligence or accident units comprised of materials provided or designs stipulated by the purchaser In no event shall the manufacturer its su...

Page 100: ...14 40 84 25 R6 238 5420 0050 2 234 143 50 117 30 R6 238 7260 0060 2 264 157 60 132 40 R6 238 8650 Three phase supply voltage 380 V 400 V 415 V 440 V 460 V or 480 V 0020 5 52 29 20 25 15 R5 206 2240 0025 5 61 34 25 30 20 R5 206 2600 0030 5 68 45 30 37 25 R5 206 3420 0040 5 90 55 40 47 30 R5 206 4140 0050 5 118 67 50 57 40 R5 206 4960 0060 5 144 78 60 65 50 R5 206 5980 0070 5 168 114 75 88 60 R6 238...

Page 101: ...her manufacturers can be used if they meet the ratings ACS800 U11 type ACS800 11 type Input current Fuse A A V Manufacturer Type UL class Three phase supply voltage 208 V 220 V 230 V or 240 V 0011 2 32 40 600 Bussmann JJS 40 T 0016 2 44 70 600 Bussmann JJS 70 T 0020 2 55 80 600 Bussmann JJS 80 T 0025 2 70 90 600 Bussmann JJS 90 T 0030 2 82 100 600 Bussmann JJS 100 T 0040 2 112 150 600 Bussmann JJS...

Page 102: ...nd tightening torques are given below with cable lugs 6 2 0 AWG tightening torque 14 8 29 5 lbf ft Dimensions and weights Copper cables with concentric copper shield Max load current A Cable type AWG kcmil 31 10 44 8 57 6 75 4 88 3 101 2 114 1 132 1 0 154 2 0 176 3 0 202 4 0 224 250 MCM or 2 x 1 251 300 MCM or 2 x 1 0 273 350 MCM or 2 x 2 0 PDM code 00096931 C Frame size U1 V1 W1 U2 V2 W2 UDC UDC ...

Page 103: ...kA rms symmetrical amperes at the drive nominal voltage 600 V maximum for 690 V units when protected by T class fuses The drive provides overload protection in accordance with the National Electrical Code US See ACS800 Firmware Manual for setting Default setting is off must be activated at start up The drives are to be used in a heated indoor controlled environment See section Ambient conditions f...

Page 104: ...Technical data 102 ...

Page 105: ...Dimensional drawings 103 Dimensional drawings The dimensions are given in millimetres and inches ...

Page 106: ...ensional drawings 104 Frame size R5 IP 21 UL type open 68406200 A US gland conduit plate Diameters of knock out holes 50 mm 1 97 in 22 7 mm 89 in The unit is UL type 1 when equipped with the US gland plate ...

Page 107: ...nsional drawings 105 Frame size R6 IP 21 UL type open 68405726 A US gland conduit plate Diameters of knock out holes 63 5 mm 2 50 in 22 7 mm 89 in The unit is UL type 1 when equipped with the US gland plate ...

Page 108: ...Dimensional drawings 106 ...

Page 109: ...ne side converter please contact ABB When to use External 24 V power supply for the RMIO board is recommended if the application requires fast start after connecting the input power supply fieldbus communication is required when the input power supply is disconnected For current consumption of the RMIO board see chapter Motor control and I O board RMIO Parameter settings In Standard Application Pr...

Page 110: ...e wires from the connector keep the connector for later use 4 Isolate the ends of the wires individually with insulating tape 5 Cover the isolated ends of the wires with insulating tape 6 Push the wires inside the skeleton 7 Connect the wires of the 24 V external power supply to the disconnected connector wire to terminal 1 and wire to terminal 2 8 Plug the connector in Frame sizes R5 and R6 1 3 4...

Page 111: ...External 24 V power supply for the RMIO board 109 5 6 7 8 ...

Page 112: ...External 24 V power supply for the RMIO board 110 ...

Page 113: ......

Page 114: ...ABB Oy AC Drives P O Box 184 FI 00381 HELSINKI FINLAND Telephone 358 10 22 11 Fax 358 10 22 22681 Internet http www abb com ABB Inc Automation Technologies Drives Motors 16250 West Glendale Drive New Berlin WI 53151 USA Telephone 262 785 3200 800 HELP 365 Fax 262 780 5135 ...

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