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ABB ACS800-37-0060-3, Hardware Manual

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ABB ACS800-37-0060-3 Hardware Manual Download Page 225

Resistor braking

225

Custom resistor installation and wiring

Effective cooling of the resistors must be ensured.

WARNING! 

All materials near the brake resistors must be non-flammable. The 

surface temperature of the resistors is high. The temperature of the air rising from 
the resistors is hundreds of degrees Celsius. Protect the resistors against contact.

For resistor cable, use the type specified for drive input cabling (specified under 
chapter 

Technical Data) 

so the input fuses will protect the resistor cable also. Two-

conductor shielded cable with the same cross-sectional area can alternatively be 
used. The maximum length of the resistor cable is 10 m.

For protection against 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 ACS800-37 is running. This voltage is 
extremely dangerous and may cause serious damage or injuries if the isolation level 
and protection conditions for the thermal circuit breakers are not sufficient. The 
normally-closed breakers should always be properly isolated (over 2.5 kV) and 
shrouded against contact.

Note:

For the ENABLE input wiring, use cable rated as follows:

• twisted pair (screened type recommended)
• rated operating voltage between a core and earth (

U

0

): 

≥

 750 V

• insulation test voltage > 2.5 kV

Summary of Contents for ACS800-37-0060-3

Page 1: ...ACS800 Hardware Manual ACS800 37 Drives 55 to 2700 kW 75 to 3000 HP ...

Page 2: ......

Page 3: ...ACS800 37 Drives 55 to 2700 kW 75 to 3000 HP Hardware Manual 3AFE68557925 REV B EN EFFECTIVE 01 11 2005 2005 ABB Oy All Rights Reserved ...

Page 4: ......

Page 5: ...ngs and notes Warnings caution you about 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 equip...

Page 6: ...t work on the control cables when power 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...

Page 7: ... when installing Fastening the cabinet by riveting or welding is not 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 supp...

Page 8: ... connect each drive separately to protective 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 ...

Page 9: ... 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 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 Prevention of Unexpected Start feature for stopping the drive when the inv...

Page 10: ...and maintenance work Disconnect the motor from the drive with a safety switch and additionally if possible lock the motor shaft and ground the motor connection terminals temporarily by connecting them together as well as to the PE Operation Do not run the motor above the rated speed Motor overspeed leads to overvoltage which may result in explosion of the capacitors in the intermediate circuit of ...

Page 11: ...t audience 19 Common chapters for multiple products 19 Categorization according to the frame size 19 Contents 19 Installation and commissioning flowchart 20 Inquiries 21 Terms and abbreviations 22 The ACS800 37 What this chapter contains 23 The ACS800 37 23 Cabinet line up 23 Frame R6 24 Frame R7i 25 Frame R8i 26 Swing out frame 27 Cabling direction 29 Single line circuit diagram of the drive 31 O...

Page 12: ...Moving the unit 44 by crane 44 by fork lift or pallet truck 45 on rollers 45 Laying the unit on its back 45 Final placement of the unit 46 Before installation 47 Delivery check 47 Installation procedure 48 Fastening the cabinet to the floor Non marine units 49 Clamping 49 Holes inside the cabinet 50 Fastening the unit to the floor and wall Marine units 51 Joining the shipping splits 52 Procedure 5...

Page 13: ...l mode 71 Relay output contacts and inductive loads 71 Selecting the control cables 72 Relay cable 72 Control panel cable 72 Coaxial cable for use with Advant Controllers AC 80 AC 800 72 Connection of a motor temperature sensor to the drive I O 73 Installation sites above 2000 metres 6562 feet 73 Routing the cables 73 Control cable ducts 74 Electrical installation What this chapter contains 75 Opt...

Page 14: ... connections 91 Supply unit control connections 91 Connection procedure 91 Installation of optional modules and PC 93 Cabling of I O and fieldbus modules 93 Cabling of pulse encoder interface module 93 Fibre optic links 93 Tap settings of the auxiliary voltage transformer Frame R8i and up 94 Installation of brake resistors 94 Motor control and I O board RMIO What this chapter contains 95 To which ...

Page 15: ...ility 110 Checking and replacing the air filters 110 Quick connectors Frame R8i and up 111 Cooling fans 112 Supply Inverter module cooling fan replacement Frame R6 112 Supply Inverter module cooling fan replacement Frame R7i 113 LCL filter module cooling fan replacement Frame R7i 114 Supply and inverter module cooling fan replacement Frame R8i and up 115 Module fan replacement procedure 115 LCL fi...

Page 16: ...iance with the EMC Directive 139 Compliance with the EN 61800 3 2004 139 First environment drive of category C2 139 Second environment drive of category C3 140 Second environment drive of category C4 140 Machinery Directive 140 C tick marking 141 Definitions 141 Compliance with the EN 61800 3 2004 141 First environment drive of category C2 141 Second environment drive of category C3 142 Second env...

Page 17: ...combinations Technical data 220 Brake choppers Technical data 221 Brake resistors Technical data 221 Verifying the capacity of the braking equipment 222 Custom resistors 222 Calculating the maximum braking power Pbr 223 Example 1 223 Example 2 223 Example 3 224 Custom resistor installation and wiring 225 Brake circuit commissioning 226 ...

Page 18: ...Table of contents 18 ...

Page 19: ...s for multiple products Some chapters in this manual apply to several products including the ACS800 37 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 2 R8i etc The frame size is not marked on t...

Page 20: ...ection and other technical data Select the 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 th...

Page 21: ... ABB Oy AC Drives PO Box 184 00381 Helsinki Finland Connect the power cables Connect the control and the auxiliary control cables Mechanical installation Planning the electrical installation Electrical installation Check the installation Installation checklist and start up Commission the drive Installation checklist and start up and appropriate firmware manual Commission the brake chopper if prese...

Page 22: ... Gate Bipolar Transistor a voltage controlled semiconductor type widely used in inverters because of their easy controllability and high switching frequency IGBT supply unit ISU See Line side converter Inverter unit INU See Motor side converter Line side converter A converter that is connected to the supply network and is capable of transferring energy from the network to the DC link of the drive ...

Page 23: ...ve consists of one or more cubicles that contain the supply and motor terminals 1 to 6 IGBT supply module s forming the line side converter 1 to 6 inverter modules forming the motor side converter and optional equipment Frame R6 drives employ an integrated supply inverter module The actual arrangement of the cubicles varies from type to type and the selected options See also the chapter Dimensions...

Page 24: ...models 3 Cable entries for power and control cables top cable entry exit models 4 Switch fuse 5 Auxiliary voltage transformer 6 Integrated line side motor side converter module 7 Input terminals bottom cable entry exit models 8 Input terminals top cable entry exit models 9 Output terminals bottom cable entry exit models 10 Output terminals top cable entry exit models 11 Control unit RDCU for motor...

Page 25: ...ter modules are installed on the swing out frame 2 Cable entries for power and control cables bottom cable entry exit models 3 Cable entries for power and control cables top cable entry exit models 4 Switch fuse 5 Auxiliary voltage transformer 6 Line side converter module 7 LCL filter 8 Motor side converter module 9 Input terminals 10 Output terminals units without du dt filtering E205 11 Output t...

Page 26: ...nector 5 Input contactor 6 LCL filter 7 IGBT supply module 8 Intermediate DC link 9 Inverter module 10 Cooling fan for LCL filter 11 Cooling fan for IGBT supply module 12 Cooling fan for inverter module 13 Auxiliary voltage transformer accessible by opening the swing out frame 14 Auxiliary voltage circuitry relays etc In larger drives an air circuit breaker is used instead of the switch disconnect...

Page 27: ... in the picture below and moving the swing out frame aside Depending on the frame size of the drive the actual equipment of the drive may differ from what is depicted Mounting rails for additional equipment Remove screws arrowed to open swing out frame Drive control unit RDCU with I O terminal blocks Space for optional terminal block X2 Terminal block X1 I O cable entries into swing out frame Swin...

Page 28: ...ric device layout diagram for the swing out frame drive frame size R8i The diagram is also attached to the inside of the cubicle door with installed devices marked Refer to the circuit diagrams delivered with the drive for device designations ...

Page 29: ...1 42 3 Input Motor output Top entry IP54 4 Signal cable input output Bottom entry 5 Signal cable input output Top entry IP21 42 6 Signal cable input output Top entry IP54 1 6 Frame size R6 4 2 5 3 1 4 IP54 IP21 42 Description 1 Input Motor output Bottom entry 2 Input Motor output Top entry 3 Signal cable input output Bottom entry 4 Signal cable input output Top entry Frame size R7i 1 3 2 4 ...

Page 30: ...entry 10 Signal cable input output Top entry IP54 11 Signal cable input output Top entry IP21 42 With EMC RFI filtering for 1st Environment E202 only 5 6 7 8 3 2 4 11 Frame size R8i 9 B Frame size 2 R8i and up A 6 5 Description A Auxiliary control cubicle B Incoming cubicle C Inverter unit cubicle D Common motor terminal cubicle optional 1 Standard input bottom entry 2 Standard input top entry 3 S...

Page 31: ...resents a frame 2 R8i drive without a common motor terminal cubicle M Ground fault supervision Motor fan supply 400 VAC M 230 115 VAC DC bus M 3 400 VAC 400 VAC Main Supply M M 400 VAC 400 VAC Charging circuit M 230 400 VAC M M M M 230 115 VAC Supply unit Inverter unit Brake unit ...

Page 32: ...r supplying the motor side converter that runs the motor The line side converter is an active unit that together with an LCL inductor capacitor inductor filter enables low harmonic distortion at the input terminals of the drive By default the line side converter controls the DC link voltage to the peak value of the line to line voltage The DC voltage reference can be set also higher by a parameter...

Page 33: ... the Point of Common Coupling PCC The high frequency switching and high du dt slightly distort the voltage waveform at the input of the converter Typical line current iU and phase voltage uU waveforms are shown below An example spectrum and THD value of the current at the input of the drive are shown below Each harmonic is presented in percent of nominal current n denotes the ordinal number of the...

Page 34: ...d to the inverter module s by a fibre optic link distributed through an optical branching unit In the inverter modules the optic link connects to the AINT board the terminals of which are accessible through a hole on the front panel of the module Reduced run capability This functionality is available for units with parallel connected supply or inverter modules only i e frame sizes 2 R8i and up If ...

Page 35: ...ault the Control Panel of the drive is set to control the inverter unit Motor Control and I O Board RMIO Drive Control Unit RDCU 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 interface RTAC Optional module 3 DDCS communication option RDCO 01 RDCO 02 or RDCO 03 Fibre optic link...

Page 36: ...tage switch must be closed before the drive can be started Earthing switch Q9 in frame size 2 R8i and up When closed the optional earthing switch connects the supply phases L1 L2 and L3 to PE The switch is interlocked so that it cannot be closed when the drive is powered Likewise the drive will not start when the earthing switch is closed Other door switches These switches are only installed if th...

Page 37: ...en the units as follows To control the supply unit WARNING The drive does not stop by pressing the control panel Stop key in local control mode To control the inverter unit Step Action Press Display example 1 To enter the Drive Selection Mode Note In local control mode the motor side converter trips if parameter 30 02 PANEL LOSS is set to FAULT Refer to the appropriate application program firmware...

Page 38: ...CU 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 MCW Main Control Word MSW Main Status Word DC VOLT REF D...

Page 39: ...ring Standard Application Program bottom entry exit of cables coated circuit boards set of English manuals Size Refer to Technical data IEC ratings Voltage range nominal rating in bold 3 380 400 415 V AC 5 380 400 415 440 460 480 500 V AC 7 525 575 600 690 V AC options Supply frequency A013 60 Hz I O options Refer to ACS800 Ordering Information code 64556568 English Fieldbus adapter Application pr...

Page 40: ...ungrounded system Special P902 Customised specified in Technical appendix on ordering P904 Extended warranty P913 Special colour specified in Technical appendix on ordering Selection Alternatives Product series ACS800 product series Type 37 cabinet mounted Default configuration IP21 UL Type 1 main switch disconnector with aR type AC fuses or air circuit breaker 50 Hz supply 230 V AC auxiliary volt...

Page 41: ...Auxiliary voltage G304 115 V AC Cabinet options G300 Cabinet heaters external supply Not available with C129 or C134 G307 Input terminals for external UPS backed auxiliary voltage G313 Output for motor heater external supply G317 Busbar supply conductors G330 Halogen free wiring and materials Not available with C129 or C134 Language of manuals Rxxx Refer to ACS800 Ordering Information code 6455656...

Page 42: ...The ACS800 37 42 ...

Page 43: ...final position The maximum allowed 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 4200 mm are delivered as shi...

Page 44: ...opes or slings into the holes of the lifting 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 ...

Page 45: ... the upright position If using a pallet truck check its load capacity before attempting to move the unit Remove the wooden bottom frame which is 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 m...

Page 46: ... placement of the unit The cabinet can 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 ...

Page 47: ...nformation 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 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...

Page 48: ...eave some space at the left hand and right 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...

Page 49: ...he recommended maximum distance between 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...

Page 50: ...th L brackets not included and fasten the 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 ...

Page 51: ... at 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 with a rubber damper in between Fastening the cabinet at the top with brackets and rubber dampers side view Cabinet M16 bolt L bracket Rubber damper Cla...

Page 52: ...joining cubicle Special M6 screws for fastening 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 ...

Page 53: ...DC busbars and the PE busbar are connected 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 co...

Page 54: ...uously through the line up near the floor 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 ...

Page 55: ...oor must carry Viewed from above Side view This area can be used for a cable conduit With heavy cabinets support the structural C sections from below Prevent the cooling air flow from the cable conduit 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 p...

Page 56: ...h of adjacent cubicles with air inlets 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 a...

Page 57: ...eld only the flat bar under the cabinet 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 o...

Page 58: ...Mechanical installation 58 ...

Page 59: ...ion which breaches the local laws and or other regulations Furthermore if the recommendations given by ABB are not followed the drive may experience problems that the warranty does not cover Motor selection and compatibility 1 Select the motor according to the rating tables in chapter Technical Data Use DriveSize PC tool if the default load cycles are not applicable 2 Check that the motor ratings ...

Page 60: ...ns network voltage with a very short rise time This is the case with all drives employing modern IGBT inverter technology The voltage of the pulses can be almost double at the motor terminals depending on the attenuation and reflection properties of the motor cable and the terminals This in turn can cause additional stress on the motor and motor cable insulation Modern variable speed drives with t...

Page 61: ...of the motor insulation and additional requirements for explosion safe EX motors Failure of the motor to fulfil the following requirements or improper installation may shorten motor life or damage the motor bearings Manufacturer Motor type Nominal mains voltage AC line voltage Requirement for Motor insulation system ABB du dt filter insulated N end bearing and ABB common mode filter PN 100 kW and ...

Page 62: ... V Standard ÛLL 1300 V N or CMF N CMF 420 V UN 500 V Standard ÛLL 1300 V du dt du dt N du dt N CMF or du dt CMF or Reinforced ÛLL 1600 V 0 2 µs rise time N or CMF N CMF 500 V UN 600 V Reinforced ÛLL 1600 V du dt du dt N du dt N CMF or du dt CMF or Reinforced ÛLL 1800 V N or CMF N CMF 600 V UN 690 V Reinforced ÛLL 1800 V du dt du dt N du dt N CMF Reinforced ÛLL 2000 V 0 3 µs rise time N CMF N CMF A...

Page 63: ...BT supply unit If voltage is raised by the drive this is a parameter selectable function for special applications only select the motor insulation system according to the increased intermediate circuit DC voltage level especially in the 500 V supply voltage range Note 8 Calculating the rise time and the peak line to line voltage The peak line to line voltage at the motor terminals generated by the...

Page 64: ...protects itself and the input and motor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive No additional thermal protection devices are needed WARNING If the drive is connected to multiple motors a separate thermal overload switch or a circuit breaker must be used for protecting each cable and motor These devices may require a separate fus...

Page 65: ...motor and motor cable This is not a personal safety or a fire protection feature Both earth fault protective functions can be disabled See the ACS800 Ordering Information code 64556568 English available on request for other available earth fault protection options The EMC filter if present includes capacitors connected between the main circuit and the frame These capacitors and long motor cables i...

Page 66: ... to the motor but an AC motor cannot rotate without the field generated by an AC voltage The operator activates the prevention of unexpected start function using a switch mounted on a control desk When the function is activated the switch is opened and an indicator lamp will light WARNING The prevention of unexpected start function does not disconnect the voltage of the main and auxiliary circuits...

Page 67: ...re below A four conductor system can be used up to frame size R4 with up to 30 kW motors but shielded 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...

Page 68: ...pen helix of copper tape The better and tighter the shield the lower the emission level and the bearing currents Symmetrical shielded cable three phase conductors and a concentric or otherwise symmetrically constructed PE conductor and a shield Recommended PE conductor and shield Shield Shield A separate PE conductor is required if the conductivity of the cable shield is 50 of the conductivity of ...

Page 69: ...de of the joint Bond the conduits also to the drive enclosure Use separate conduits for input power motor brake resistors and control wiring When conduit is employed type MC continuous corrugated aluminum armor cable or shielded cable is not required A dedicated ground cable is always required Note Do not run motor wiring from more than one drive in the same conduit Armored cable shielded power ca...

Page 70: ...rip the drive 3 Check that the power factor compensation unit is suitable for use in systems with AC drives i e harmonic generating loads In such systems 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 switch...

Page 71: ...e transients when switched off The relay contacts of the RMIO board are protected with varistors 250 V against overvoltage peaks In spite of this it is 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...

Page 72: ...ed 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 LAPPKABEL Germany has been tested and approved by ABB Control panel cable In remote use...

Page 73: ...cuit of the drive For connection see the Firmware Manual Installation sites above 2000 metres 6562 feet WARNING Wear appropriate protection when installing operating or 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...

Page 74: ...Input power cable Control cables 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 into the inside of the cabinet Not allowed unless the 24 V cable is insulated for 230 V 120 V or insulated with an insulation sleeving for 230 V 120 V ...

Page 75: ...During the installation procedure inverter modules may have to be temporarily extracted from the cabinet The modules have a high centre of gravity In order to minimise the danger of toppling over keep the support legs if provided of the modules extended whenever manoeuvring the modules outside the cabinet Option coding Some instructions contained within this chapter are intended for drives equippe...

Page 76: ... output terminals 2 Measure the insulation resistances of the motor cable and the motor between each phase and the Protective Earth by using a measuring voltage of 1 kV DC The insulation resistance must be higher than 1 Mohm IT ungrounded systems EMC filter E202 is not suitable for use in an IT ungrounded system If the drive is equipped with EMC filter E202 disconnect the filter before connecting ...

Page 77: ...e cables into the inside of the cubicle It is recommended to apply 360 grounding of the cable shields at the entry as shown below 4 Connect the cables as follows Twist the cable shields into bundles and connect to cabinet PE ground busbar Connect any separate ground conductors or cables to cabinet PE ground busbar Connect the phase conductors to the input power terminals L1 L2 L3 For the tightenin...

Page 78: ... cables into the inside of the cubicle It is recommended to apply 360 grounding of the cable shields at the entry as shown below 4 Connect the cables as follows Twist the cable shields into bundles and connect to cabinet PE ground busbar Connect any separate ground conductors or cables to cabinet PE ground busbar Connect the phase conductors to the input power terminals L1 L2 L3 For the tightening...

Page 79: ...ouds that protect the input busbars and cable entries 3 Lead the cables into the inside of the cubicle It is recommended to apply 360 grounding of the cable shields at the entry as shown below 4 Connect the cables as follows Twist the cable shields into bundles and connect to cabinet PE ground busbar Connect any separate ground conductors or cables to cabinet PE ground busbar Connect the phase con...

Page 80: ...It is recommended to apply 360 grounding of the cable shields at the entry as shown below 4 Connect the cables as follows Twist the cable shields into bundles and connect to cabinet PE ground busbar Connect any separate ground conductors or cables to cabinet PE ground busbar Connect the phase conductors to the input power terminals L1 L2 L3 For the tightening torques see the chapter Technical data...

Page 81: ...able shields at the entry as shown below 4 Connect the cables as follows Twist the cable shields into bundles and connect to cabinet PE ground busbar Connect any separate ground conductors or cables to cabinet PE ground busbar Connect the phase conductors to the output power terminals U2 V2 W2 For the tightening torques see the chapter Technical data 5 Provide support for the cables whenever neces...

Page 82: ...cable shields at the entry as shown below 4 Connect the cables as follows Twist the cable shields into bundles and connect to cabinet PE ground busbar Connect any separate ground conductors or cables to cabinet PE ground busbar Connect the phase conductors to the output power terminals U2 V2 W2 For the tightening torques see the chapter Technical data 5 Provide support for the cables whenever nece...

Page 83: ...d cable entries 3 Lead the cables into the inside of the cubicle It is recommended to apply 360 grounding of the cable shields at the entry as shown below 4 Connect the cables as follows Twist the cable shields into bundles and connect to cabinet PE ground busbar Connect any separate ground conductors or cables to cabinet PE ground busbar Connect the phase conductors to the output power terminals ...

Page 84: ...ng direction starting on page 29 2 Remove any shrouds that protect the busbars and cable entries 3 Open the transparent cover on the front of the inverter module the rightmost module and disconnect the fibre optic cables Move the cables aside 4 Remove the L shaped DC busbars on top of the inverter module 5 Disconnect the terminal block X50 next to the DC busbars 6 Remove the two module fastening s...

Page 85: ...Electrical installation 85 5 4 7 8 9a 9b 6a 3 6b 6c ...

Page 86: ... Use the tightening torques specified in the chapter Technical data Provide support for the cables whenever necessary Insert the inverter module into the cubicle as follows 1 Move the inverter module close to the ramp then retract the support legs of the module 2 Push the module back into the cubicle mind your fingers 3 Refasten the module fixing screws at the top reconnect the DC busbars 4 Reconn...

Page 87: ...to apply 360 grounding of the cable shields at the entry as shown below 4 Connect the cables as follows Twist the cable shields into bundles and connect to cabinet PE ground busbar Connect any separate ground conductors or cables to cabinet PE ground busbar Connect the phase conductors to the output power terminals U2 V2 W2 For the tightening torques see the chapter Technical data 5 Provide suppor...

Page 88: ...ind each inverter module For the location and dimensions of the busbars see the chapter Dimensions Connection diagram WARNING The cabling from all inverter modules to the motor must be physically identical considering cable type cross sectional area and length U2 V2 W2 PE U2 V2 W2 M 3 U1 W1 V1 PE Inverter unit cubicle s PE Inverter unit cubicle U2 V2 W2 U2 V2 W2 M 3 U1 W1 V1 PE ...

Page 89: ...parent cover on the front of the inverter module the rightmost module and disconnect the fibre optic cables Move the cables aside 4 Remove the L shaped DC busbars on top of the inverter 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...

Page 90: ... the tightening torques specified in the chapter Technical data Provide support for the cables whenever necessary Insert the inverter module into the cubicle as follows 1 Move the inverter module close to the ramp then retract the support legs of the module 2 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 ...

Page 91: ...rnal emergency stop button if the unit is equipped with a local emergency stop button external buttons can be connected in series read a fault indication through a relay output communicate with the unit through a serial communication interface Refer to the circuit diagrams delivered with the drive for the connection terminals for the external control devices Connection procedure Open the cabinet d...

Page 92: ...arp edges When running cables to the swing out frame leave some slack in the cable at the hinge to allow the frame to open fully Tie the cables to the cable supports wherever necessary Cut the cables 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 ...

Page 93: ...es of type Nxxx See the RDCO User s Manual 3AFE 64492209 English for the connections Observe colour 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...

Page 94: ...1 b1 c1 a2 b2 c2 600 V A1 B1 C1 C3 A3 B3 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 ...

Page 95: ...n cabinet installed ACS800 drives The terminals of the RMIO board are optionally 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...

Page 96: ...ot in use 4 DI4 Acceleration deceleration select 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 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 out...

Page 97: ...verse 1 4 DI4 Acceleration deceleration select 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 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 outpu...

Page 98: ...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 99: ...rives Communication System 24 VDC power input Voltage 24 VDC 10 Typical current consumption without optional modules 250 mA Maximum current consumption 1200 mA with optional modules inserted The terminals on the RMIO board as well as on the optional modules attachable to the board fulfil the Protective Extra Low Voltage PELV requirements stated in EN 50178 provided that the external circuits conne...

Page 100: ...GND1 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 A...

Page 101: ...loor See Mechanical installation The cooling air will flow freely ELECTRICAL INSTALLATION See Planning the electrical installation Electrical installation The motor and the driven equipment are ready for start The EMC filter option E202 is disconnected if the drive is connected to an IT ungrounded system The drive is grounded properly The supply input power voltage matches the nominal input voltag...

Page 102: ...pecific circuit diagrams Check the settings of the relays and breakers switches of the auxiliary circuits Optional devices See delivery specific circuit diagrams Disconnect any unfinished or unchecked 230 115 VAC cables that lead from the terminal blocks to the outside of the equipment For drive types ACS800 37 0640 3 0780 5 0790 7 and up Locate the APBU xx PPCS branching units Enable memory backu...

Page 103: ...equipped with the emergency stop option when it is required to start the motor without delay after the start command or if the drive is connected to a common DC bus Otherwise the charging resistors may be damaged Note The output voltage of the drive can be raised using a parameter setting for example it is possible to run a 500 V motor off a 400 V supply Contact your local ABB representative for m...

Page 104: ...onverter by the level of digital input DI2 The line converter starts 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 37 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 Autom...

Page 105: ...tomatic reset for the intermediate link 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 COMMAN...

Page 106: ... ACS800 Standard 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 107: ...quals to 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 t...

Page 108: ...Installation checklist and start up 108 ...

Page 109: ...n appropriate environment the drive requires very little maintenance This table lists the routine maintenance intervals recommended by ABB Interval Maintenance action Instruction Every year of storage Capacitor reforming See document ACS 600 800 Capacitor Reforming Guide Code 3BFE 64059629 English and Capacitors Every 6 to 12 months depending on dustiness of environment Heatsink temperature check ...

Page 110: ...op module guide to block airflow through the empty module bay 4 Make the necessary parameter adjustments in the drive firmware Refer to the appropriate Firmware Manual Reconnect the module after service in reverse order Checking and replacing the air filters 1 Read and repeat the steps in Safety instructions above 2 Open the cabinet doors 3 Check the air filters and replace if necessary see Techni...

Page 111: ...on 4 Check the tightness of the cable connections at the quick connector Use the tightening torque table in Technical data 5 Clean all contact surfaces of the quick connector and apply a layer of suitable joint compound e g Isoflex Topas NB 52 from Klüber Lubrication onto them 6 Re insert the supply inverter module 7 Repeat steps 3 to 6 for all remaining supply and inverter modules 8 On frame R8i ...

Page 112: ... R6 1 Read and repeat the steps in section Safety instructions above 2 Loosen the fastening screws of the top plate 3 Lift the top plate upwards and pull it out 4 Disconnect the fan supply wires detachable connector 5 Lift the fan up 6 Install the new fan in reverse order 3 4 2 2 5 ...

Page 113: ...le cooling fan replacement Frame R7i 1 Disconnect the wire plug 2 Remove the two screws holding the fan unit 3 Pull the fan unit slightly towards the front of the cubicle then downwards to free it 4 Install new fan in reverse order 3 2 1 ...

Page 114: ...enance 114 LCL filter module cooling fan replacement Frame R7i 1 Disconnect the wire plug 1 2 Remove the two screws holding the fan unit 2 3 Pull the fan unit out 3 4 Install new fan in reverse order 2 2 3 1 ...

Page 115: ...e from ABB Do not use other than ABB specified spare parts The supply and inverter application programs keep track of the running times of the cooling fans of the supply and inverter modules respectively See the Firmware Manuals delivered with the drive for the actual signals which indicate the running time Module fan replacement procedure 1 Read and repeat the steps in section Safety instructions...

Page 116: ...an ambient temperature and dust concentration Replacements are available from ABB Do not use other than ABB specified spare parts LCL filter fan replacement procedure 1 Read and repeat the steps in section Safety instructions above 2 Disconnect the fan wiring plug 1 3 Remove the screws of the fan fastening rail clip 2 4 Pull the fan out 3 5 Install a new fan in reverse order 2 1 ALCL 1x ALCL 2x 3 ...

Page 117: ...he fan to the holder 8 Install new fan in reverse order Cabinet fan replacement Frame R8i and up with IP21 42 The fan is located within the roof structure above the input cubicle as shown in the picture below 1 Remove the eight screws attaching the fan holder to the cabinet roof 2 Lift the fan holder until the fan cable can be disconnected 3 Disconnect the fan cable 4 Remove the fan from the fan h...

Page 118: ... 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 fan 10 Remove the fan capacitor by undoing the fastening screw of the clamp 11 Undo the fastening screws of the fan 12 Pull the fan out 13 Install the new fan a...

Page 119: ...ntering adjoining equipment 3 Refit the cooling fan Capacitors The inverter modules employ several electrolytic capacitors Their lifespan is at least 90 000 hours depending on the operating time of the drive loading and ambient temperature Capacitor life can be prolonged by lowering the ambient temperature It is not possible to predict capacitor failure Capacitor failure is usually followed by dam...

Page 120: ...r maintenance actions Power module replacement Frame R8i and up To replace power modules i e supply and inverter modules follow the instructions on module removal and refitting given in the chapter Electrical installation ...

Page 121: ...de converter when the panel is controlling the motor side converter To display the warning or fault identification text switch the control panel to view the line side converter as described in section Control panel on page 37 Conflicting ID numbers If the ID numbers of the line side and the motor side converters are set equal the control panel stops functioning To clear the situation Disconnect th...

Page 122: ...e control panel removed Red 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 cover on the front of the supply and inverter modules V204 green 5 V voltage of the board is OK V309 red Prevention of unexpected start is ON V310 green IGBT control signal transmission to the gate driver control boards is enabled ...

Page 123: ...10 3 730 1000 400 701 355 546 250 23 3160 75 ACS800 37 0640 3 919 1258 500 882 500 688 355 24 6400 77 ACS800 37 0770 3 1111 1521 630 1067 630 831 450 31 6400 77 ACS800 37 0960 3 1379 1888 800 1324 710 1031 560 43 6400 77 ACS800 37 1070 3 1535 2102 900 1474 800 1149 630 46 10240 78 ACS800 37 1430 3 2056 2814 1200 1973 1100 1538 800 63 10240 78 ACS800 37 1810 3 2610 3573 1600 2506 1400 1953 1100 83 ...

Page 124: ...600 106 17920 79 ACS800 37 3310 7 2665 3987 2700 2559 2600 1999 2000 121 19200 79 1 156 A allowed at 460 V 2 240 A allowed at 460 V 3 302 A allowed at 460 V 4 361 A allowed at 460 V PDM 184674 G5 Nominal ratings Icont max Continuous RMS output current No overloadability at 40 C 104 F Imax Maximum output current Allowable for 10 seconds at start otherwise as long as allowed by drive temperature Typ...

Page 125: ...lated by multiplying the current given in the rating table by the derating factor Example If the ambient temperature is 50 C 122 F the derating factor is 100 1 10 C 90 or 0 90 The output current is then 0 90 I2N or 0 90 Icont max Altitude derating At altitudes from 1000 to 4000 m 3281 to 13123 ft above sea level the derating is 1 for every 100 m 328 ft For a more accurate derating use the DriveSiz...

Page 126: ... 37 0870 5 1458 900 965 800 752 650 109000 3770 77 ACS800 37 1160 5 1941 1150 1284 1050 1001 850 150000 3770 77 ACS800 37 1330 5 2217 1300 1467 1250 1143 1000 157000 6030 78 ACS800 37 1820 5 2956 1650 1956 1650 1524 1250 229000 6030 78 ACS800 37 2200 5 3670 2150 2428 2050 1892 1600 277000 7530 79 Three phase supply voltage 525 V 575 V or 600 V ACS800 37 0170 7 202 125 133 125 104 100 27300 765 74 ...

Page 127: ...ly to most 4 pole NEMA rated motors at nominal voltage 460 or 575 V Normal use 10 overloadability I2N Continuous rms current 10 overload is allowed for 1 minute every 5 minutes PN Typical motor power The power ratings apply to most 4 pole NEMA rated motors at nominal voltage 460 or 575 V Heavy duty use 50 overloadability I2hd Continuous rms current 50 overload is allowed for 1 minute every 5 minut...

Page 128: ... 5 1 ACS800 104 0320 5 ACS800 37 0400 5 R8i 1 ACS800 104 0460 5 1 ALCL 14 5 1 ACS800 104 0400 5 ACS800 37 0460 5 R8i 1 ACS800 104 0610 5 1 ALCL 15 5 1 ACS800 104 0460 5 ACS800 37 0510 5 R8i 1 ACS800 104 0610 5 1 ALCL 15 5 1 ACS800 104 0610 5 ACS800 37 0610 5 R8i 1 ACS800 104 0610 5 1 ALCL 15 5 1 ACS800 104 0610 5 ACS800 37 0780 5 2 R8i 2 ACS800 104 0460 5 1 ALCL 24 5 2 ACS800 104 0400 5 ACS800 37 ...

Page 129: ...M3017 ACS800 37 0210 5 3 400 170M5808 170M5008 ACS800 37 0260 5 3 450 170M5809 6 9URD2PV0450 170M5059 ACS800 37 0320 5 3 630 170M6810 6 9URD3PV0630 170M6210 ACS800 37 0400 5 3 800 170M8545 6 9URD3PV0800 170M6212 ACS800 37 0460 5 3 1000 170M6814 6 9URD3PV1000 170M6214 ACS800 37 0510 5 3 1000 170M6814 6 9URD3PV1000 170M6214 ACS800 37 0610 5 3 1000 170M6814 6 9URD3PV1000 170M6214 ACS800 37 0780 5 3 1...

Page 130: ...ACS800 37 0070 5 ACS800 37 0610 5 ACS800 37 0780 5 8 170M8552 6 9URD3PV1000 1000 170M6215 1000 ACS800 37 0870 5 8 170M8552 6 9URD3PV1000 1000 170M6215 1000 ACS800 37 1160 5 8 170M8547 6 9URD33PA1250 1250 170M6216 1250 ACS800 37 1330 5 12 170M8547 6 9URD33PA1250 1250 170M6216 1250 ACS800 37 1820 5 12 170M8547 6 9URD33PA1250 1250 170M6216 1250 ACS800 37 2200 5 16 170M8547 6 9URD33PA1250 1250 170M621...

Page 131: ...R fuses Frequency 50 2 Hz or 60 2 Hz Maximum rate of change 17 s Imbalance Max 3 of nominal phase to phase input voltage Voltage dips Max 25 Power factor Harmonic distortion Harmonics are below the limits defined in IEEE519 for all Isc IL Each individual harmonic current fulfils IEEE519 table 10 3 for Isc IL 20 Current THD and each individual current harmonic fulfil IEC 61000 3 4 table 5 2 for Rsc...

Page 132: ...t terminals L1 L2 L3 Frame R7i Bottom cable entry exit Front view Bolt size M10 Tightening torque 40 Nm 29 5 lbf ft Top cable entry exit Front view Bolt size M10 Tightening torque 40 Nm 29 5 lbf ft Side view Bolt size M12 or Tightening torque 70 Nm 52 lbf ft ...

Page 133: ...otor rated motor frequency Frequency resolution 0 01 Hz Current See section IEC 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 3 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 cha...

Page 134: ...ut terminals U2 V2 W2 Frame R7i Bottom cable entry exit Front view Bolt size M10 Tightening torque 40 Nm 29 5 lbf ft Top cable entry exit Front view Bolt size M10 Tightening torque 40 Nm 29 5 lbf ft Front view Bolt size M12 or Tightening torque 70 Nm 52 lbf ft ...

Page 135: ...mon motor terminal cubicle Frame 2 R8i and larger units without option H359 Output terminals Units with option H359 common motor terminal cubicle 8 Ø13 mm per phase Tightening torque 70 Nm 52 lbf ft See the chapter Dimensions Bottom or top exit Front view Bolt size M12 or Tightening torque 70 Nm 52 lbf ft Bottom exit Side view Bolt size M12 or Tightening torque 70 Nm 52 lbf ft Cabling direction To...

Page 136: ... Derating Air temperature 15 to 50 C 5 to 122 F See section Derating 40 to 70 C 40 to 158 F 40 to 70 C 40 to 158 F Relative humidity 5 to 95 Max 95 Max 95 No condensation allowed Maximum allowed relative humidity is 60 in the presence of corrosive gases Contamination levels IEC 60721 3 3 IEC 60721 3 2 IEC 60721 3 1 No conductive dust allowed Boards without coating Chemical gases Class 3C1 Solid pa...

Page 137: ...apacitors and printed circuit boards can be landfilled The DC capacitors C1 1 to C1 x contain electrolyte and the printed circuit boards contain lead both of which are classified as hazardous waste within the EU They must be removed and handled according to local regulations For further information on environmental aspects and more detailed recycling instructions please contact your local ABB dist...

Page 138: ...0 3 2004 Adjustable speed electrical power drive systems Part 3 EMC requirements and specific test methods UL 508C UL Standard for Safety Power Conversion Equipment second edition CSA C22 2 No 14 95 Industrial control equipment ...

Page 139: ...e of rated voltage less than 1000 V and intended for use in the second environment and not intended for use in the first environment Drive of category C4 drive of rated voltage equal to or above 1000 V or rated current equal to or above 400 A or intended for use in complex systems in the second environment Compliance with the EMC Directive The EMC Directive defines the requirements for immunity an...

Page 140: ...s 1 It is ensured that no excessive emission is propagated to neighbouring low voltage networks In some cases the natural suppression in transformers and cables is sufficient If in doubt the supply transformer with static screening between the primary and secondary windings can be used 2 An EMC plan for preventing disturbances is drawn up for the installation A template is available from the local...

Page 141: ... supplying domestic premises Drive of category C2 drive of rated voltage less than 1000 V and intended to be installed and commissioned only by a professional when used in the first environment Note A professional is a person or organisation having necessary skills in installing and or commissioning power drive systems including their EMC aspects Drive of category C3 drive of rated voltage less th...

Page 142: ...an IT unearthed network the requirements of the EMC Directive can be met as follows 1 It is ensured that no excessive emission is propagated to neighbouring low voltage networks In some cases the natural suppression in transformers and cables is sufficient If in doubt the supply transformer with static screening between the primary and secondary windings can be used 2 An EMC plan for preventing di...

Page 143: ... 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 suppliers or subcontractors be liable for special indirect incidental or consequential damages losses or penalties THIS IS THE SOLE AND EXCLUSIVE WARRANTY GIVEN BY THE MANUFACTURER WITH RESPECT TO THE ...

Page 144: ...Technical data 144 ...

Page 145: ...s without options ACS800 37 Weight kg lb 0060 3 0070 3 0100 3 0070 5 0100 5 0120 5 250 550 0140 3 0170 3 0170 5 0210 5 0170 7 0210 7 400 880 0210 3 0260 3 0320 3 0390 3 0510 3 0260 5 0320 5 0400 5 0460 5 0510 5 0610 5 0260 7 0320 7 0400 7 0440 7 0540 7 950 2090 0640 3 0770 3 0960 3 0780 5 0870 5 1160 5 0790 7 0870 7 1160 7 2000 4410 1070 3 1430 3 1330 5 1820 5 1330 7 1510 7 3060 6750 1810 3 2200 5...

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Page 219: ...pe D151 400 V ACS800 37 0060 3 ACS800 37 0170 3 NBRA 658 2 SAFUR210F575 ACS800 37 0210 3 ACS800 37 0510 3 NBRA 659 2 SAFUR180F460 ACS800 37 0640 3 ACS800 37 0770 3 2 NBRA 659 2 2 SAFUR180F460 ACS800 37 0960 3 3 NBRA 659 3 2 SAFUR180F460 500 V ACS800 37 0070 5 ACS800 37 0210 5 NBRA 658 2 SAFUR125F500 ACS800 37 0260 5 ACS800 37 0610 5 NBRA 659 2 SAFUR200F500 ACS800 37 0780 5 ACS800 37 0870 5 2 NBRA ...

Page 220: ... 268 36 408 192 237 111 137 2500 1 NBRA 659 2 SAFUR200F500 1 35 403 54 605 287 355 167 206 2500 2 NBRA 659 2 2 SAFUR200F500 1 35 806 108 605 575 355 333 206 5000 3 NBRA 659 3 2 SAFUR200F500 1 35 1208 162 605 862 355 500 206 7500 690 V 1 NBRA 669 2 SAFUR200F500 1 35 404 54 835 287 355 167 206 2500 2 NBRA 669 2 2 SAFUR200F500 1 35 807 108 835 287 355 333 206 5000 3 NBRA 669 3 2 SAFUR200F500 1 35 121...

Page 221: ...oltage Pbrmax Maximum short term 1 min every 10 mins braking power Pcont Maximum continuous braking power Imax Maximum peak current Irms Corresponding RMS current R Recommended resistance Pbr Braking power for the specified duty cycle Note This value may be limited by Pbrmax Ubr_on DC voltage at which chopper starts conducting Ubr_off DC voltage at which chopper stops conducting Airflow Airflow re...

Page 222: ...rd resistors are connected in parallel 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 particula...

Page 223: ...ing is considered continuous The allowed 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 ...

Page 224: ... The braking time is 10 seconds Result 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 ...

Page 225: ...esistor cable is 10 m For protection against 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 37 is running This voltage is extremely dangerous an...

Page 226: ...connection Brake circuit commissioning 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 ...

Page 227: ......

Page 228: ...es 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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