ABB ACS850-04 series Hardware Manual Download

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Table of contents

Mounting procedure   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Assembly drawing of installing the drive module to the cabinet (frame G1)  . . . . . . . . . . . . . .93
Assembly drawing of installing the drive module to the cabinet (frame G2)  . . . . . . . . . . . . . .94
Removing the protective covering from the module air outlet  . . . . . . . . . . . . . . . . . . . . . . . . .95

Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Mounting the external control unit to wall   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Mounting the external control unit vertically on a DIN rail  . . . . . . . . . . . . . . . . . . . . . .100
Mounting the control unit horizontally on a DIN rail  . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Installing optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Wiring the modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Connecting the control cables to the terminals of the control unit . . . . . . . . . . . . . . . . . . . . .102
Default I/O connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

Control cable connection procedure of units with internal control unit (P905) . . . . . . . . . .108
Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

Installation checklist

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

Start-up

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

Fault tracing

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Warning and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

Maintenance

Summary of Contents for ACS850-04 series

Page 1: ...ABB machinery drives Hardware manual ACS850 04 drive modules 160 to 560 kW 200 to 700 hp ...

Page 2: ...rd control program quick start up guide 3AUA0000045498 ACS850 standard control program firmware manual 3AUA0000045497 ACS850 crane control program supplement to std ctrl prg 3AUA0000081708 ACS850 04 drives with SynRM motors option N7502 supplement 3AUA0000123521 Option manuals and guides ACS CP U Control Panel IP54 Mounting Platform Kit J410 Installation Guide 3AUA0000049072 ACS850 Common DC confi...

Page 4: ......

Page 5: ...e manual What this chapter contains 21 Target audience 21 Contents of the manual 21 Categorization by frame size and option code 22 Quick installation commissioning and operating flowchart 22 Terms and abbreviations 24 Operation principle and hardware description What this chapter contains 27 Product overview 27 Layout 28 Power connections and control interfaces 32 External control unit connection...

Page 6: ... 49 Other regions 49 Selecting and dimensioning the main contactor 49 Protecting the motor insulation and bearings 50 Checking the compatibility of the motor and drive 50 Requirements table 51 Additional requirements for explosion safe EX motors 53 Additional requirements for HXR and AMA motors 53 Additional requirements for ABB motors of types other than M2_ M3_ M4_ HX_ and AM_ 53 Additional requ...

Page 7: ...the drive 64 Implementing a safety switch between the drive and motor 65 Using a contactor between the drive and the motor 65 Implementing a bypass connection 66 Example bypass connection 66 Switching the motor power supply from drive to direct on line 67 Switching the motor power supply from direct on line to drive 67 Protecting the contacts of relay outputs 67 Connecting a motor temperature sens...

Page 8: ...Mounting the external control unit vertically on a DIN rail 100 Mounting the control unit horizontally on a DIN rail 100 Installing optional modules 101 Mechanical installation 101 Wiring the modules 101 Connecting the control cables to the terminals of the control unit 102 Default I O connection diagram 104 Jumpers 105 External power supply for the JCU control unit XPOW 106 DI6 XDI 6 as a thermis...

Page 9: ...data and noise 129 Terminal and lead through data for the power cables 129 Units with optional common mode filter E208 129 Units with optional cabling panels H381 or H383 129 Units without optional cabling panels no H381 or H383 130 Terminal data for the control cables 130 Electrical power network specification 130 Motor connection data 130 Brake resistor connection data 130 DC connection data 131...

Page 10: ...e circuit diagram 154 Resistor braking What this chapter contains 155 Availability of brake choppers and resistors 155 When is resistor braking needed 155 Operation principle 155 Planning the braking system 155 Selecting the brake circuit components 155 Placing the brake resistors 156 Protecting the system in fault situations 157 Thermal overload protection 157 Short circuit protection 157 Selecti...

Page 11: ... 161 When is du dt filter needed 161 Selection table 161 Description installation and technical data of the FOCH filters 161 Further information Product and service inquiries 163 Product training 163 Providing feedback on ABB Drives manuals 163 Document library on the Internet 163 ...

Page 12: ...Table of contents 12 ...

Page 13: ...ult in serious injury or death and or damage to the equipment and advise on how to avoid the danger The following warning symbols are used in this manual Electricity warning warns of hazards from electricity which can cause physical injury and or damage to the equipment General warning warns about conditions other than those caused by electricity which can result in physical injury and or damage t...

Page 14: ... the frame is close to 0 V 2 voltage between terminals UDC and UDC and the frame is close to 0 V Do not 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 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 ...

Page 15: ...zed as required by safety regulations In a multiple drive installation connect each drive separately to protective earth PE Where EMC emissions must be minimized make a 360 high frequency grounding of cable entries at the cabinet lead through in order to suppress electromagnetic disturbances In addition connect the cable shields to protective earth PE in order to meet safety regulations Note Power...

Page 16: ...op the motor Ensure that there is no voltage on the drive power terminals according to step 1 or 2 or if possible according to the both steps 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 output or DC terminals U1 V1 W1 U2 V2 W2 UDC UDC 2 Ensure that the motor cannot rotate during work Make sure that no othe...

Page 17: ...the drive module carefully Make sure that the module does not fall down when moving it on the floor and during installation and maintenance work Open the support legs by pressing each leg a little down 1 2 and turning it aside When ever possible secure the module also with chains Do not tilt the drive module A It is heavy over 160 kg 350 lb and its center of gravity is high The module will overtur...

Page 18: ...bolts of the ramp carefully 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 dust from borings and grindings does not enter the drive when installing Electrically conductive dust inside the unit may cause damage or malfunctioning Ensure sufficient cooling Do not fasten the drive by rivetin...

Page 19: ...or and all driven equipment are suitable for operation throughout the speed range provided by the drive The drive can be adjusted to operate the motor at speeds above and below the speed provided by connecting the motor directly to the power line Do not activate any automatic fault reset functions of the drive control program if dangerous situations can occur When activated these functions will re...

Page 20: ...Safety instructions 20 ...

Page 21: ...lectrical schematic symbols The manual is written for readers worldwide Both SI and imperial units are shown Contents of the manual This manual contains the instructions and information for the basic drive module configuration The chapters of the manual are briefly described below Safety instructions give safety instructions for the installation commissioning operation and maintenance of the drive...

Page 22: ... G1 or G2 The frame size is marked on the type designation label The instructions and technical data which concern only certain optional selections are marked with option codes eg H381 The options included in the drive can be identified from the option codes visible on the type designation label The option selections are listed in section Type designation key on page 35 Quick installation commissi...

Page 23: ... to the drive module busbars If external drive control unit connect the power supply and fiber optic cables from the drive module to the control unit and install the control unit into the cabinet Units without optional cabling panels no H381 or H383 Install the additional components into the cabinet composition varies for example main PE busbar main disconnector main contactor main AC fuses etc In...

Page 24: ...on board APOW Power supply board BFPS Power supply board EMC Electromagnetic compatibility EMI Electromagnetic interference FCAN 01 Optional CANopen adapter module FDNA 01 Optional DeviceNet adapter module FECA 01 Optional EtherCAT adapter module FEN 01 Optional TTL encoder interface module FEN 11 Optional absolute encoder interface module FEN 21 Optional resolver interface module FEN 31 Optional ...

Page 25: ...easy controllability and high switching frequency I O Input Output JCU The control unit of the drive module The external I O control signals are connected to the JCU or to optional I O extension modules mounted on it JGDR Gate driver board JINT Main circuit board JMU xx The memory unit attached to the control unit JCU JRIB Adapter board connected to the control board in the control unit JCU STO Sa...

Page 26: ...Introduction to the manual 26 ...

Page 27: ...he drive module is shown below 1 AC choke 2 Rectifier Converts alternating current and voltage to direct current and voltage 3 DC link DC circuit between rectifier and inverter 4 Inverter Converts direct current and voltage to alternating current and voltage 5 Brake chopper option D150 Conducts the surplus energy from the intermediate circuit of the drive to the brake resistor when necessary The c...

Page 28: ...rs and optional DC and DC busbars H356 4 Circuit board compartment 5 Power supply and fiber optic cables to be connected to the external control unit 6 Output cable connection busbars and optional brake resistor connection busbars D150 7 PE terminal 8 Control cable duct 9 Main cooling fans 10 Pedestal 11 Retractable support legs 9 6 3 2 1 8 4 A 5 7 B 1 2 3 8 W1 V1 U1 W2 V2 U2 11 12 13 14 15 10 17 ...

Page 29: ... module out of the cabinet 14 Pedestal guide plate 15 Telescopic extraction and insertion ramp 16 Top guide plate 17 Optional common mode filter E208 18 Grounding busbar B Control unit JCU 1 Control unit with front cover 2 Control unit with front cover removed 3 Control cable clamp plate Item Description ...

Page 30: ...l to be fastened to the cabinet H381 or H383 3 Front cover With option P905 the control panel is placed on this cover 4 Input power cabling panel H381 or H383 5 Side guides H381 or H383 6 Output power cabling panel H381 or H383 7 Rubber grommet H381 B Control unit variants 1 Control unit with control panel holder J414 2 Control unit with control panel holder J414 when cover a is removed 3 Control ...

Page 31: ...emoved Slots 1 and 2 for optional I O extension and encoder resolver interface modules Slot 3 for optional fieldbus adapter module Relay outputs 24VD Digital inputs Digital input outputs Analog inputs Analog outputs Drive to drive link Control panel PC connection Memory unit JMU connection External 24 V power input Safe torque off connection ...

Page 32: ...cifications see page 131 programmable 2 Memory unit see page 124 3 Brake resistor optional 4 du dt or sine filter optional see page 161 Slot 3 Fieldbus adapter modules FCAN 01 FDNA 01 FENA 11 FECA 01 FLON 01 FSCA 01 FPBA 01 XPOW External power input XRO1 3 Relay outputs 3 pcs XD24 24 V DC output XDI Digital inputs 6 pcs XDIO Digital input outputs 2 pcs XAI Analog inputs XAO Analog outputs XD2D Dri...

Page 33: ...cting the drive module and control panel to the control unit are shown below See sections Connecting the external control unit to the drive module page 97 and Connecting a PC page 108 for the actual connections 3 m 9 8 ft JINT APOW 3 m 9 8 ft 2560 mm 8 4 ft Category 5e cable JRIB 8 0 3 1 5 JCU ACS850 04 JGDR ...

Page 34: ...on label is located on the front cover An example label is shown below No Description 1 Type designation see section Type designation key on page 35 2 Frame size 3 Ratings 4 Valid markings 5 Serial number The first digit of the serial number refers to the manufacturing plant The next four digits refer to the unit s manufacturing year and week respectively The remaining digits complete the serial n...

Page 35: ...nge 5 380 500 V AC Option codes plus codes Resistor braking D150 Brake chopper and brake resistor connection busbars and R and R terminals in the power cabling panel H381 or H383 if the power cabling panels are ordered Filters E208 Common mode filter Includes three extension busbars to the drive module output busbars with units without option H381 or H383 Cabling panels H381 Power cabling panels U...

Page 36: ...te encoder interface module L519 FIO 21 analog and digital I O extension module Control programs N2007 Standard control program version UIFI2110 frame G2 only N2008 Standard control program version UIFI2200 frame G2 only N2009 Standard control program version UIFI2210 frame G2 only N2010 Standard control program version UIFI2300 frame G2 only N3050 Crane technology library N5050 Crane control prog...

Page 37: ...breaches the local laws and or other regulations Basic requirements for the cabinet Use a cabinet which has a frame sturdy enough to carry the weight of the drive components control circuitry and other equipment installed in it protects the user and drive module against contact and meets the requirements for dust and humidity has sufficient air inlet and outlet gratings that allow free flow of coo...

Page 38: ...ith an extra exhaust fan for the drive module 2b Air outlet for the other equipment 2c Air outlet for the drive module and other equipment on the cabinet roof An exhaust fan if needed We recommend this alternative instead of 2a 3 Drive control panel with DPMP 01 mounting platform option J410 The control panel is connected to the JCU control unit inside the cabinet 4 Contactor control switch and em...

Page 39: ...he lower part of the 11 Grounding screws cabinet door see 1b on page 38 12 Alternative to grounding screws 11 3 Cabinet grounding busbar PE 13 Air flow to the roof 4 Input power cable including the protective 14 Air flow through the drive module side view ground conductor PE of the drive 15 Air inlet gratings in the cabinet door 5 Disconnector and fuses 16 Air inlet for the brake option 6 Contacto...

Page 40: ...s note the following Tin plated copper is recommended but aluminium can also be used The oxide layer from aluminium busbar joints must be removed and suitable anti oxidant joint compound applied Tightening torques Apply the following torques to grade 8 8 screws with or without joint compound that tighten electric contacts Planning the fastening of the cabinet Note the following when planning the f...

Page 41: ...mm Pay special attention to the cooling air inlet and outlet gratings The best galvanic connection between the steel panels is achieved by welding them together as no holes are necessary If welding is not possible the seams between the panels are recommended to be left unpainted and equipped with special conductive EMC strips to provide adequate galvanic connection Usually reliable strips are made...

Page 42: ...an be implemented by a knitted wire mesh screening as shown below 360 high frequency grounding of the control cable shields is recommended at their entries The shields can be grounded by means of conductive shielding cushions pressed against the cable shield from both directions Cable ties Knitted wire mesh Bare cable shield Cabinet bottom plate Lead through plate Cable Shielding cushion conductiv...

Page 43: ...ure requirements of the drive module are met see pages 129 and 134 The internal cooling fan of the drive module rotates at a constant speed thus blowing constant air flow through the module Whether the same amount of air must be replaced all the time in the facility depends on how much heat must be removed Example cable lead through 1 To power cable terminals 2 Cable shield 3 PE ground terminal of...

Page 44: ...r splashes from entering the cabinet The drawing below shows two typical cabinet cooling solutions The air inlet is at the bottom of the cabinet while the outlet is at the top either on the upper part of the door or on the roof We recommend that the air outlet is on the cabinet roof Use an extra exhaust fan if the air outlet is on the cabinet door The internal cooling fans of the drive modules and...

Page 45: ...of of the cabinet Prevent hot air circulation inside the cabinet with for example leak proof air baffles at the positions shown in the diagram below No gaskets are usually required 1a Air flow to the drive module max 40 C 104 F 3 Drive module 1b Air inlet to the drive circuit boards and DC and output busbars 4 Disconnector and fuses 2a Vertical air baffle that separates the cool and hot areas in t...

Page 46: ...Planning the cabinet installation 46 1a 7 PE U1 V1 W1 W2 V2 U2 3 2a 2c 2b 3 C C C C B B A A 2a 2c B B A A 2c 3 2a 2a 2b 2c 3 2d 2a 2d 4 5 6 X Y X Y 2e 2e 1b 2d 2e 2d 3 2b 2b ...

Page 47: ...inlets on the cabinet door are also shown Free space around the drive module 20 mm 0 79 in free space around the drive module is required from the cabinet back panel and front door No free space for cooling is required on the left and right hand sides of the module The module is designed to be installed in a cabinet with the following measurements width 400 mm 15 75 in depth 600 mm 23 62 in and he...

Page 48: ...nel can be mounted onto the cabinet door using the control panel mounting kit J410 For the installation instructions refer to ACS CP U Control Panel IP54 Mounting Platform Kit J410 Installation Guide 3AUA0000049072 English Planning the use of the cubicle heaters Use a cubicle heater if there is a risk of condensation in the cabinet Although the primary function of the heater is to keep the air dry...

Page 49: ...cting device must be of a type that can be locked to the open position for installation and maintenance work European Union To meet the European Union Directives according to standard EN 60204 1 Safety of Machinery the disconnecting device must be one of the following types switch disconnector of utilization category AC 23B EN 60947 3 disconnector that has an auxiliary contact that in all cases ca...

Page 50: ...the compatibility of the motor and drive Use an asynchronous AC induction motor a permanent magnet motor or an ABB synchronous reluctance motor SynRM with the drive Several induction motors can be connected at a time but only one permanent magnet motor Select the motor and drive according to the rating tables in chapter Technical data Use the DriveSize PC tool if the default load cycles are not ap...

Page 51: ...uirement for Motor insulation system ABB du dt filter insulated N end bearing and ABB common mode filter PN 100 kW and frame size IEC 315 100 kW PN 350 kW or frame size IEC 315 PN 350 kW or frame size IEC 400 PN 134 hp and frame size NEMA 500 134 hp PN 469 hp or frame size NEMA 500 PN 469 hp or frame size NEMA 580 A B B Random wound M2_ M3_ and M4_ UN 500 V Standard N N CMF 500 V UN 600 V Standard...

Page 52: ...rced ÛLL 1800 V N or CMF N CMF 600 V UN 690 V Reinforced ÛLL 1800 V du dt du dt N du dt N CMF Reinforced ÛLL 2000 V 0 3 microsecond rise time N CMF N CMF Abbreviation Definition UN Nominal voltage of the supply network ÛLL Peak line to line voltage at motor terminals which the motor insulation must withstand PN Motor nominal power du dt du dt filter at the output of the drive CMF Common mode filte...

Page 53: ...ing similar to increasing the motor supply voltage by up to 20 percent Consider this voltage increase when specifying the motor insulation requirements if the motor will be braking a large part of its operation time Example Motor insulation requirement for a 400 V drive must be selected as if the motor were supplied with 480 V Additional requirements for ABB high output motors and IP23 motors The ...

Page 54: ... size IEC 315 100 kW PN 350 kW or IEC 315 frame size IEC 400 PN 134 hp or frame size NEMA 500 134 hp PN 469 hp or NEMA 500 frame size NEMA 580 UN 420 V Standard ÛLL 1300 V N or CMF N CMF 420 V UN 500 V Standard ÛLL 1300 V du dt N or CMF N du dt CMF or Reinforced ÛLL 1600 V 0 2 microsecond rise time N or CMF N CMF 500 V UN 600 V Reinforced ÛLL 1600 V du dt N or CMF du dt N CMF or Reinforced ÛLL 180...

Page 55: ...nominal supply voltage UN Voltage rise time Read the relative values ÛLL UN and du dt UN from the appropriate diagram below Multiply the values by the nominal supply voltage UN and substitute into equation t 0 8 ÛLL du dt Additional note for sine filters Sine filters protect the motor insulation system A factory installed sine filter is available for the cabinet installed units The peak phase to p...

Page 56: ...le see page 58 Note When continuous metal conduit is employed shielded cable is not required The conduit must have bonding at both ends as with cable shield A four conductor system is allowed for input cabling but shielded symmetrical cable is recommended To operate as a protective conductor the shield conductivity requirements according to IEC 60439 1 are shown below when the protective conductor...

Page 57: ...per wires 75 C 167 F wire insulation at 40 C 104 F ambient temperature Not more than three current carrying conductors in raceway or cable or earth directly buried For other conditions dimension the cables according to local safety regulations appropriate input voltage and the load current of the drive Drive type ACS850 04 IEC 1 US 2 Cu cable type Al cable type Cu cable type Al cable type mm2 mm2 ...

Page 58: ...quirement of the motor cable shield of the drive is shown below It consists of a concentric layer of copper wires with an open helix of copper tape or copper wire The better and tighter the shield the lower the emission level and bearing currents Recommended Symmetrical shielded cable three phase conductors and a concentric or otherwise symmetrically constructed PE conductor and a shield PE conduc...

Page 59: ...hielded cable is not required A dedicated ground cable is always required Note Do not run motor wiring from more than one drive in the same conduit Armored cable shielded power cable Six conductor 3 phases and 3 ground type MC continuous corrugated aluminum armor cable with symmetrical grounds is available from the following suppliers trade names in parentheses Anixter Wire Cable Philsheath BICC G...

Page 60: ...ng the control panel to the drive must not exceed 3 meters 10 ft The cable type tested and approved by ABB is used in control panel option kits 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 cable input power cable and control cables be installed on separate tr...

Page 61: ...ke cable Input power cable Control cables min 200 mm 8 in min 300 mm 12 in Motor cable Power cable Drive Control cables 24 V Lead 24 V and 230 V 120 V control cables in separate ducts inside the cabinet 230 V 120 V 24 V 230 V Not allowed unless the 24 V cable is insulated for 230 V 120 V or insulated with an insulation sleeving for 230 V 120 V 120 V ...

Page 62: ...ng to local regulations for the input cable protection Select the fuses for the drive according to the instructions given in chapter Technical data The fuses for the drive protection will restrict drive damage and prevent damage to adjoining equipment in case of a short circuit inside the drive Note 1 If the fuses for the drive protection are placed at the distribution board and the input cable is...

Page 63: ... given by motor temperature sensors The user can tune the thermal model further by feeding in additional motor and load data The most common temperature sensors are motor sizes IEC180 225 thermal switch eg Klixon motor sizes IEC200 250 and larger PTC or Pt100 See the firmware manual for more information on the motor thermal protection and the connection and use of the temperature sensors Protectin...

Page 64: ... ACS850 drives Q971 application guide 3AUA0000074343 English Implementing the Power loss ride through function Implement the power loss ride through function as follows 1 Activate the power loss ride through function of the drive parameter 47 02 Undervolt ctrl in the Standard Control Program 2 If the installation is equipped with a main contactor prevent its tripping at the input power break For e...

Page 65: ... the drive and the motor Arrange the control of the output contactor by applying one of the alternatives described below Alternative 1 When you have selected to use the default motor control mode DTC and motor coast stop in the drive open the contactor as follows 1 Give a stop command to the drive 2 Open the contactor Alternative 2 When you have selected to use the default motor control mode DTC a...

Page 66: ...wer to the drive output terminals U2 V2 and W2 Line voltage applied to the output can result in permanent damage to the unit Example bypass connection An example bypass connection is shown below Switch Description Switch Description Q1 Drive main switch S11 Drive main contactor on off control Q4 Bypass circuit breaker S40 Motor power supply selection drive or direct on line K1 Drive main contactor...

Page 67: ...wo seconds and leave to position 1 4 Start the drive and the motor with the drive control panel drive in the local control mode or the external start signal drive in the remote control mode Protecting the contacts of relay outputs Inductive loads relays contactors motors cause voltage transients when switched off The relay contacts on the JCU control unit are protected with varistors 250 V against...

Page 68: ...n be implemented in three alternate ways 1 There is double or reinforced insulation between the thermistor and live parts of the motor 2 Circuits connected to all digital and analog inputs of the drive are protected against contact and insulated with basic insulation the same voltage level as the drive main circuit from other low voltage circuits 3 An external thermistor relay is used The insulati...

Page 69: ...amp Fastening screws in a plastic bag External control unit Drive module options Option code Qty pcs Description H381 1 Power cabling panels and a rubber grommet H383 Power cabling panels P905 1 Internal control unit Rittal parts Rittal part code Qty pcs Description TS 8406 510 1 Enclosure without mounting plate Includes frame door side and back panels TS 8612 160 5 Punched section with mounting f...

Page 70: ...stor cables are to be connected the lower side plate of the output cabling panel must be removed and the resistor cables lead from side to the terminals of the output cabling panel Note 3 Installations without the optional cabling panels no H381 or H383 Install the PE terminal as shown below M8 16 Hex ...

Page 71: ...Installation 71 Note 4 Mounting the drive module to an assembly panel Mount the assembly support as shown below M4 12 Torx ...

Page 72: ...ugh the rubber grommet of the optional cabling panels provides the degree of protection of IP20 for the unit Mount the grommet as follows 1 Cut adequate holes into the grommet for the input power cables 2 Lead the cables through the grommet 3 Mount the grommet to the input cabling panel with five M4x8 Torx T20 screws as shown below ...

Page 73: ...llow the Safety instructions on the first pages of this manual Ignoring the safety instructions can cause injury or death Checking the installation site The material below the drive must be non flammable and strong enough to carry the weight of the drive See section Ambient conditions on page 134 for the allowed ambient conditions and section Losses cooling data and noise on page 129 for the requi...

Page 74: ...ation place Description of the package contents 1 Input cabling panel option H381 or H383 see contents below 2 Output cabling panel option H381 or H383 see contents below 3 Plywood support 4 Drive module with factory installed options and multilingual residual voltage warning sticker top guide plate pedestal guide plate telescopic ramp package fastening screws in a plastic bag external control uni...

Page 75: ...e plate 6 Telescopic extraction and insertion ramp 7 Fastening bracket 8 Top guide plate 9 Support 7 1 2 3 4 5 6 8 Output power cabling panel option H381 or H383 package contents 1 Paper fill 2 Cardboard tray 3 Top cardboard cover 4 Support 5 Bands 6 Plastic bag 7 Output power cabling panel 8 Side guides for Rittal cabinet assembly ...

Page 76: ...r insulation between the main circuit and the chassis at the factory Also there are voltage limiting circuits inside the drive which cut down the testing voltage automatically Input cable Check the insulation of the input cable according to local regulations before connecting it to the drive 2 1 3 4 5 6 7 8 9 10 Input power cabling panel option H381 or H383 package contents 1 Screw package 2 Paper...

Page 77: ...t the manufacturer s instructions Note Moisture inside the motor casing will reduce the insulation resistance If moisture is suspected dry the motor and repeat the measurement Brake resistor and resistor cable Check the insulation of the brake resistor assembly if present as follows 1 Check that the resistor cable is connected to the resistor and disconnected from the drive output terminals R and ...

Page 78: ... 2 Install the auxiliary components such as mounting plates air baffles switches busbars etc The component manufacturer s instructions Layout example door open page 38 3 Connect the power cables to the cabling panels Connecting the power cables page 84 4 Mount the drive module into the cabinet Mounting the drive module into the cabinet page 89 5 Drive modules with an external control unit Mount th...

Page 79: ...s accordingly 2 If you use Rittal support rails TS 4396 500 install three support rails on the bottom of the cabinet see also the dimension drawing on page 145 frame G1 or page 149 frame G2 3 Install the pedestal guide onto the bottom plate or support rails 4 Install the Rittal punched sections TS 8612 610 5 pcs and TS8612 140 3 pcs 5 Install the air baffles see page 83 6 Install the top guide pla...

Page 80: ... input cabling panel option H381 or H383 Back view is shown below 10 Mount the side guides to the input cabling panel 2 screws for each side guide and mount the input cabling panel to the punched section M8 16 Torx M8 16 Torx Frame size G1 Frame size G2 ...

Page 81: ...Installation 81 Assembly drawing frame G1 3AUA0000132078 ...

Page 82: ...Installation 82 Assembly drawing frame G2 3AUA0000132062 ...

Page 83: ...Installation 83 Assembly drawing air baffles 3AUA0000132062 ...

Page 84: ...tions page 14 Ignoring the instructions can cause physical injury or death or damage to the equipment Connection diagram 7 5 INPUT OUTPUT U1 V1 W1 U2 V2 W2 R ACS850 04 U1 V1 W1 3 Motor R UDC UDC U2 V2 W2 R R U1 V1 W1 UDC UDC PE PE PE L1 L2 L3 L1 L2 L3 1 2a 3 4 5 6 8 9 2b 10 4 PE ...

Page 85: ...grounding at the cabinet entry is recommended see page 41 6 Use a separate grounding cable if the conductivity of the cable shield is 50 of the conductivity of the phase conductor and there is no symmetrically constructed grounding conductor in the cable see page 58 7 External brake resistor see page 155 8 Common mode filter option E208 see page 51 9 du dt filter optional see page 161 10 The drive...

Page 86: ...o the PE ground terminal of the input power cabling panel 3 Connect the phase conductors of the input cables to terminals U1 V1 and W1 of the input cabling panel For the tightening torques see page 129 4 Lead the motor cables into the inside of the cabinet Ground the cable shield 360 at the lead through plate 5 Twist the cable shields of the motor cables into bundles and connect them and any separ...

Page 87: ...nto the cabinet C A View without cabinet side plate in place A 360 degree grounding at the lead through plate for the input power cables B Grounding busbar of the input power cabling panel C 360 degree grounding at the lead through plate for the output power cables D Grounding busbar of the output power cabling panel E Allowed space for power cables A U1 V1 W1 B U2 V2 W2 C D 102 mm 4 in E E ...

Page 88: ...lows flattened width 1 5 length DC connection The UDC and UDC terminals are intended for common DC configurations of a number of drives allowing regenerative energy from one drive to be utilised by the other drives in the motoring mode For more information see Common DC configuration application guide for ACS850 04 drive modules 3AUA0000073108 English 1 a b b 1 5 a ...

Page 89: ... does not fall down when moving it on the floor and during installation and maintenance work Open the support legs by pressing each leg a little down and turning it aside 1 2 When ever possible secure the module also with chains from top Do not tilt the drive module A It is heavy over 160 kg 350 lb and its center of gravity is high The module will overturn from a sideways tilt of 5 degrees Do not ...

Page 90: ...tening bracket to the drive module 2 Mount the grounding busbar that has been previously mounted to the input cabling panel to the drive module Note The design of the grounding busbar can differ from what is shown in the figure 1 M8 20 Hex M8 20 Hex 2 ...

Page 91: ... cabling panels combi screw M12 70 N m 52 lbf ft 7 Mount the drive module to the cabinet from top and bottom as shown below and in the assembly drawing on page 93 frame G1 or page 94 frame G2 Note The screws ground the module to the cabinet frame 8 Units with an external control unit Put back the removed front covers of the drive module on the power cable sections Units with an internal control un...

Page 92: ...Installation 92 3 6a 6b 5 4 8 4 8 6a 6b 7a 7b 7b ...

Page 93: ...Installation 93 Assembly drawing of installing the drive module to the cabinet frame G1 3AUA0000132078 ...

Page 94: ...Installation 94 Assembly drawing of installing the drive module to the cabinet frame G2 3AUA0000132062 ...

Page 95: ... the control unit Fastening the control cable clamp plate page 97 3 Install the optional modules to the control unit if not mounted yet Installing optional modules page 101 4 Connect the power supply and fiber optic cables between the control unit and the drive module Connecting the external control unit to the drive module page 97 5 Mount the control unit to the wall or DIN rail Mounting the exte...

Page 96: ... assembly The numbers refer to the illustrations below 1 Press the tab slightly with a screwdriver 2 Slide the lower cover plate slightly downwards and pull it out 3 Disconnect the panel cable if present 4 Remove the fastening screw at the top of the cover assembly 5 Carefully pull the lower part of the base outwards by the two tabs 6 Refit the cover in reverse order to the above when the control ...

Page 97: ...e JRIB board that is inside the JCU control unit Do not interchange JCU control units between drives with different power ratings This can cause damage to the equipment Connect the fiber optic cables and power supply cable coming from the drive module through the U hole in the circuit board compartment cover to the external control unit as follows 1 Thread the cables inside the back frame of the c...

Page 98: ...Installation 98 3AUA0000038989 TXD transmitter RXD receiver JRIB V2 V1 V7 V6 1 2 APOW JINT 2 JRIB 1 4 3 JGDR ...

Page 99: ...ol unit can be fastened on a mounting plate through the fastening holes in its back or by using a DIN rail Mounting the external control unit to wall 1 Fasten the fastening screws in the wall 2 Lift the unit onto the screws and tighten the screws 3aua0000038989 1 2 2 ...

Page 100: ...the control unit with three screws 2 Click the control unit to the rail as shown below B Mounting the control unit horizontally on a DIN rail 1 Fasten the latches A to the back of the control unit with three screws 2 Click the control unit to the rail as shown below B 3aua0000038989 A A B B 3aua0000038989 A A B B ...

Page 101: ...emove the control unit cover 2 Remove the protective cover if present from the connector of the slot 3 Insert the module carefully into its position on the control unit 4 Fasten the screw Note Correct installation of the screw is essential for fulfilling the EMC requirements and for proper operation of the module Wiring the modules See the appropriate optional module manual for specific installati...

Page 102: ...se to the terminals of the control unit as possible Only remove the outer jacket of the cable at the cable clamp so that the clamp presses on the bare shield The shield especially in case of multiple shields can also be terminated with a lug and fastened with a screw at the clamp plate Leave the other end of the shield unconnected or ground it indirectly via a few nanofarads high frequency capacit...

Page 103: ...cure the connection 3 Connect the conductors to the appropriate detachable terminals of the control unit See section Default I O connection diagram page 104 Use shrink tubing or insulating tape to contain any stray strands Note Keep any signal wire pairs twisted as close to the terminals as possible Twisting the wire with its return wire reduces disturbances caused by inductive coupling ...

Page 104: ...ut DI2 DI2 2 Digital input DI3 Reset DI3 3 Digital input DI4 DI4 4 Digital input DI5 DI5 5 Digital input DI6 or thermistor input DI6 6 Start interlock 0 Stop DIIL A XDIO Digital input output DIO1 Output Ready DIO1 1 Digital input output DIO2 Output Running DIO2 2 XAI Reference voltage VREF 1 Reference voltage VREF 2 Ground AGND 3 Analog input AI1 Current or voltage selectable by jumper AI1 Speed r...

Page 105: ...onnected to XD24 2 The common can be either GND or Vcc as DI1 DI5 are of the NPN PNP type AI1 Determines whether analog input AI1 is used as a current or voltage input AI2 Determines whether analog input AI2 is used as a current or voltage input T Drive to drive link termination Must be set to the ON position when the drive is the last unit on the link 1 DIGND floats DIGND tied to DIOGND XD24 2 4 ...

Page 106: ...t one end leave that end of the shield unconnected The connection of temperature sensors involves parameter adjustment See the firmware manual of the drive PTC as well as KTY84 sensors can alternatively be connected to a FEN xx encoder interface See the user s manual of the interface for wiring information Pt100 and KTY84 sensors are not to be connected to the thermistor input Instead an analog in...

Page 107: ...xt to this terminal block must be set to the ON position on the drives at the ends of the drive to drive link On intermediate drives the jumper must be set to the OFF position Shielded twisted pair cable 100 ohm for example PROFIBUS compatible cable must be used for the wiring For best immunity high quality cable is recommended The cable should be kept as short as possible the maximum length of th...

Page 108: ...he control cables along the control cable duct from bottom or top to the control unit 5 Ground the outer control cable shields 360 degrees at the cabinet lead through plate recommendation 6 Ground the control cables at the clamp plate as described in bullet 2 under Connecting the control cables to the terminals of the control unit on page 104 7 Connect the conductors to the appropriate detachable ...

Page 109: ... metal contact with the frame for example seams component fixing points on assembly plates back of control unit mounting plate are not finished with non conducting paint or material Degree of protection IPxx Drive option modules and other components Type and number of option modules and other equipment is correct Option modules and other equipment are not damaged Option modules and terminals are l...

Page 110: ...d against direct contact to at least IP2x Labels The type designation labels and warning and instruction stickers are made according to the local regulations and placed correctly Switches and doors Mechanical switches main disconnecting switch and cabinet doors function properly Installation of the cabinet The drive cabinet has been fixed to floor and also from top to the wall or roof The ambient ...

Page 111: ... conductors to check The motor cable and brake resistor cable if present has been routed away from other cables The brake resistor cable has been routed away from other cables No power factor compensation capacitors have been connected to the motor cable The control cables if any have been connected to the appropriate terminals and the terminals have been tightened Pull the conductors to check If ...

Page 112: ...Installation checklist 112 ...

Page 113: ...lation checklist and that the motor and driven equipment are ready for start 2 Perform the start up tasks instructed by the cabinet installer of the drive module 3 Switch the power on and set up the drive control program according to the start up instructions given in the drive firmware manual 4 Validate the Safe torque off function see Safe torque off function for ACSM1 ACS850 and ACQ810 drives a...

Page 114: ...Start up 114 ...

Page 115: ...ning and fault messages See the firmware manual for the descriptions causes and remedies of the control program warning and fault messages Where LED When the LED is lit JINT board V204 green 5 V voltage of the board is OK V309 red Not in use V310 green IGBT control signal transmission to the gate driver control boards is enabled BFPS board V79 green 5 V voltage of the board is OK ...

Page 116: ...Fault tracing 116 ...

Page 117: ...f needed See sections Cabinet and Heatsink on page 119 Every year when stored Reform the capacitors See Reforming the capacitors Every 3 years Check the condition of fiber optic cables See the fault logger If PPCC LINK faults have recurred change the fiber optic cables Every 6 years Every 3 years if the ambient temperature is over 40 C 104 F or cyclic heavy load or continuous nominal load Replace ...

Page 118: ...binet WARNING Follow the safety instructions page 14 Ignoring the instructions can cause physical injury or death or damage to the equipment WARNING Use a vacuum cleaner with antistatic hose and nozzle Using a normal vacuum cleaner creates static discharges which can damage circuit boards 1 Ensure that the drive is disconnected from the power line and all other precautions described under Safety i...

Page 119: ... with antistatic hose and nozzle Using a normal vacuum cleaner creates static discharges which can damage circuit boards 1 Ensure that the drive is disconnected from the power line and all other precautions described under Safety in installation and maintenance on page 14 have been taken into consideration 2 Undo the fastening screws of the handle plate of the drive module 3 Remove the handle plat...

Page 120: ...ans are available from ABB Do not use other than ABB specified spare parts Replacing the circuit board compartment cooling fan WARNING Follow the safety instructions page 14 Ignoring the instructions can cause physical injury or death or damage to the equipment 1 Remove the drive module out of the cabinet as described in section Replacing the drive module on page 122 2 Undo the fastening screw of ...

Page 121: ...ibed in section Replacing the drive module on page 122 2 Open the support legs of the pedestal 3 Undo the two screws that fasten the fan assembly plate 4 Tilt the fan assembly plate down 5 Disconnect the power supply wires of the fans 6 Remove the fan assembly from the drive module 7 Undo the fastening screws of the fan s and remove the fan s from the assembly plate 8 Install the new fan s in reve...

Page 122: ...ance on page 14 have been taken into consideration 2 Remove the left hand side upper and lower front covers of the drive module by undoing the fastening screws M4 8 combi screws 2 N m 3 Disconnect the drive module busbars from the input cabling panel Combi screw M12 70 N m 52 lbf ft 4 Disconnect the drive module busbars from the output cabling panel Combi screw M12 70 N m 52 lbf ft 5 Undo the scre...

Page 123: ...Maintenance 123 9 Pull the drive module carefully out of the cabinet preferably with help from another person 10 Install the new module in reverse order to the above 7 3 4 9 5 5 2 2 ...

Page 124: ...pacitors must be reformed if the drive module has been stored for a year or more See page 34 for information on finding out the manufacturing date For the reforming instructions see Converter modules with electrolytic DC capacitors in the DC link capacitor reforming instructions 3BFE64059629 English Memory unit When a drive module is replaced the parameter settings can be retained by transferring ...

Page 125: ...15 807A 5 G2 790 1020 807 450 785 450 625 355 875A 5 G2 860 1100 875 500 857 450 680 400 UN 500 V 387A 5 G1 380 470 387 200 377 250 300 160 500A 5 G1 490 560 500 250 480 250 355 250 580A 5 G1 570 680 580 355 570 355 414 250 650A 5 G1 640 730 650 400 634 400 477 315 710A 5 G2 690 850 710 500 700 500 566 400 807A 5 G2 790 1020 807 560 785 560 625 450 875A 5 G2 860 1100 875 560 857 560 680 450 UN 460...

Page 126: ...328 ft For a more accurate derating use the DriveSize PC tool PN Typical motor power in no overload use ILd Continuous rms output current 10 overload is allowed for 1 minute every 5 minutes PLd Typical motor power for light overload use IHd Continuous rms output current 50 overload is allowed for 1 minute every 5 minutes PHd Typical motor power for heavy duty use Note To achieve the rated motor po...

Page 127: ...640 1000 985000 690 Bussmann 170M6814D DIN3 710A 5 690 1250 2150000 690 Bussmann 170M8554D DIN3 807A 5 790 1600 4150000 690 Bussmann 170M8557D DIN3 875A 5 860 1600 4150000 690 Bussmann 170M8557D DIN3 aR fuses with flush end contact Drive type ACS850 04 Input current A Fuse A A2s V Manufacturer Size 710A 5 690 1400 1400000 690 Bussmann 170M7060 DIN4 807A 5 790 1400 1400000 690 Bussmann 170M7060 DIN...

Page 128: ... 65 43 68 50 12 01 12 95 19 88 20 28 439 807A 5 G2 65 43 68 50 12 01 12 95 19 88 20 28 439 875A 5 G2 65 43 68 50 12 01 12 95 19 88 20 28 439 H1 Height of the module with pedestal H2 Height of the module with pedestal and with optional cabling panels H383 Note The no pedestal option 0H354 reduces the height of the module by 125 mm 4 92 in W1 Width of the module W2 Width of the module with optional ...

Page 129: ...ing torque 50 75 N m Units with optional cabling panels H381 or H383 The maximum accepted cable size is 4 3 240 mm2 or 4 3 500 AWG The cabling panels are connected to the drive module busbars with M12 serpress nuts tightening torque 30 N m 20 lbf ft Input motor and brake resistor cable terminal sizes and tightening torques are given below Two hole 1 2 inch diameter cable lugs can be used Drive typ...

Page 130: ... load Motor connection data Motor types asynchronous AC induction motors permanent magnet motors ABB synchronous reluctance motors SynRM motors Voltage U2 0 to U1 3 phase symmetrical Umax at the field weakening point Frequency DTC mode 0 to 3 2 ff Maximum frequency 500 Hz 120 Hz with du dt or sine filter Low motor noise mode is recommended with high frequencies see also firmware manual ff ff frequ...

Page 131: ...s min DI6 XDI 6 can alternatively be used as an input for 1 3 PTC thermistors Note The input has no safety insulation see page 107 Imax 15 mA Start interlock input DIIL XDI A Wire size 1 5 mm2 24 V logic levels 0 5 V 1 15 V Rin 2 0 kohm Digital inputs outputs DIO1 and DIO2 XDIO 1 and XDIO 2 Input output mode selection by parameters DIO1 can be configured as a frequency input 0 16 kHz for 24 V leve...

Page 132: ...wire size 1 5 mm2 Physical layer RS 485 Termination by jumper Safe torque off connection XSTO Connector pitch 3 5 mm wire size 1 5 mm2 For the drive to start both connections OUT1 to IN1 and OUT2 to IN2 must be closed Control panel PC connection Connector RJ 45 Cable length 3 m Note The terminals on the board fulfil the Protective Extra Low Voltage PELV requirements The relay outputs of the drive ...

Page 133: ...ower cables are installed through the rubber grommet mounted on top of the module H381 24VI GND NO COM NC 1 2 1 2 3 NO COM NC 4 5 6 24VD DIGND 24VD 1 2 3 DIOGND 4 DI1 DI2 XDI 1 2 DI3 3 DI4 4 DIIL A DIO1 DIO2 1 2 VREF VREF AGND 1 2 3 AI1 4 AI1 AI2 5 6 AI2 7 AO1 AO1 AO2 1 2 3 AO2 4 B A BGND 1 2 3 OUT1 OUT2 IN1 1 2 3 IN2 4 XPOW XRO1 XRO3 XD24 XDIO XAI XAO XD2D XSTO DI5 5 DI6 6 NO COM NC 7 8 9 Ground ...

Page 134: ...idity 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 Chemical gases Class 3C2 Solid particles Class 3S2 Chemical gases Class 1C2 Solid particles Class 1S3 Chemical gases Class 2C2 Solid particles Class 2S2 Atmospheric pressure 70 to 106 kPa 0 7 to 1 05 atmospheres 70 to 106 kPa 0 7 to 1 05 atmospheres 60 to 106 kPa...

Page 135: ...pplicable standards The drive complies with the following standards EN 61800 5 1 2007 Adjustable speed electrical power drive systems Part 5 1 Safety requirements electrical thermal and energy EN 60204 1 2006 Safety of machinery Electrical equipment of machines Part 1 General requirements Provisions for compliance The final assembler of the machine is responsible for installing emergency stop devi...

Page 136: ...ry which as safety components are in the scope of the Machinery Directive These functions of the drive comply with European harmonized standards such as EN 61800 5 2 The declaration of conformity for the Safe torque off function is in the appropriate function specific manual Safe torque off function for ACSM1 ACS850 and ACQ810 drives application guide 3AFE68929814 English Compliance with EN 61800 ...

Page 137: ...bouring low voltage networks In some cases the inherent suppression in transformers and cables is sufficient If in doubt the supply transformer with static screening between the primary and secondary windings can be used 2 An EMC plan for preventing disturbances is drawn up for the installation A template is available from the local ABB representative 3 The motor and control cables are selected as...

Page 138: ...BB representative Suitable IEC class aR fuses and UL class J fuses for drive protection are listed on page 127 For installation in Canada branch circuit protection must be provided in accordance with the Canadian Electrical Code and any applicable provincial codes To fulfil this requirement use the UL classified fuses For installation in the United States branch circuit protection must be provided...

Page 139: ...gation with respect to any product which i has been improperly repaired or altered ii has been subjected to misuse negligence or accident iii has been used in a manner contrary to the manufacturer s instructions or iv has failed as a result of ordinary wear and tear ...

Page 140: ...Technical data 140 ...

Page 141: ...Dimension drawings 141 Dimension drawings What this chapter contains This chapter contains dimension drawings of the drive modules with optional parts for Rittal TS 8 cabinet assembly ...

Page 142: ...Dimension drawings 142 Frame G1 Drive module dimensions ...

Page 143: ...Dimension drawings 143 Frame G1 Drive module dimensions with optional cabling panels H381 ...

Page 144: ...Dimension drawings 144 ...

Page 145: ...Dimension drawings 145 Frame G1 Cabling panels H383 installed into a Rittal TS 8 cabinet ...

Page 146: ...Dimension drawings 146 Frame G2 Drive module dimensions ...

Page 147: ...Dimension drawings 147 Frame G2 Drive module dimensions with optional cabling panels H381 ...

Page 148: ...Dimension drawings 148 ...

Page 149: ...Dimension drawings 149 Frame G2 Cabling panels H383 installed into a Rittal TS 8 cabinet ...

Page 150: ...Dimension drawings 150 Frames G1 and G2 Bottom plate 3AUA0000082240 ...

Page 151: ...Dimension drawings 151 Frames G1 and G2 Air baffles 3AUA0000138986 ...

Page 152: ...Dimension drawings 152 ...

Page 153: ...Example circuit diagram 153 Example circuit diagram What this chapter contains This chapter shows an example circuit diagram for a cabinet installed drive module ...

Page 154: ... included in a basic delivery plus code options other options to be acquired by the customer Motor temperature supervision ACS CP U Control Panel Switch fuse disconnector Main contactor Supply Alarm Brake resistor Drive module JCU control unit 3 Motor Cabinet Common mode filter du dt filter Line filter Input and output signals see page 104 360 degree grounding recommended ...

Page 155: ...ate DC circuit whenever the voltage in the circuit exceeds its maximum limit Energy consumption by the resistor losses lowers the voltage until the resistor can be disconnected Planning the braking system Selecting the brake circuit components 1 Calculate the maximum power Pmax generated by the motor during braking 2 Select a suitable drive and brake resistor combination for the application accord...

Page 156: ... ft is not exceeded Arrange the cooling of the resistor in a way that no danger of overheating is caused to the resistor or nearby materials the temperature of the room the resistor is located in does not exceed the allowed maximum Supply the resistor with cooling air water according to the resistor manufacturer s instructions WARNING The materials near the brake resistor must be non flammable The...

Page 157: ...imensioned according to the input cable Selecting and routing the brake circuit cables Use the cable type used for drive input cabling see page 57 to ensure that the input fuses will also protect the resistor cable Alternatively two conductor shielded cable with the same cross sectional area can be used Minimizing electromagnetic interference Follow these rules in order to minimise electromagnetic...

Page 158: ...wisted shield of the cable protective earth conductor of the resistor assembly at both ends Connect the thermal switch of the brake resistor as described in section Thermal overload protection on page 157 Brake circuit commissioning Enable the brake chopper function Please note that a brake resistor must be connected when the chopper is enabled Switch off the overvoltage control of the drive Adjus...

Page 159: ... ohm ER kJ PRcont kW 380 500 V ACS850 04 387A 5 250 2 0 2 SAFUR125F500 2 7200 18 ACS850 04 500A 5 250 2 0 2 SAFUR125F500 2 7200 18 ACS850 04 580A 5 315 1 3 2 SAFUR200F500 1 35 10800 27 ACS850 04 650A 5 315 1 3 2 SAFUR200F500 1 35 10800 27 ACS850 04 710A 5 400 0 7 3 SAFUR200F500 0 90 16200 40 ACS850 04 807A 5 400 0 7 3 SAFUR200F500 0 90 16200 40 ACS850 04 875A 5 400 0 7 3 SAFUR200F500 0 90 16200 40...

Page 160: ...esistor braking 160 Dimensions and weights 234 300 1320 Ø 7 345 1270 ght FUR180F460 32 kg FUR125F500 25 kg FUR200F500 30 kg FUR210F575 27 kg Brake resistor type Weight kg SAFUR125F500 25 SAFUR200F500 30 ...

Page 161: ... table du dt filter types for the drive module types are given below Description installation and technical data of the FOCH filters See FOCH du dt Filters Hardware Manual 3AFE68577519 English Drive module type du dt filter type ACS850 04 387A 5 FOCH0610 70 ACS850 04 500A 5 FOCH0610 70 ACS850 04 580A 5 FOCH0610 70 ACS850 04 650A 5 FOCH0610 70 ACS850 04 710A 5 FOCH0610 70 ACS850 04 807A 5 FOCH0875 ...

Page 162: ...du dt filters 162 ...

Page 163: ...uct training For information on ABB product training navigate to www abb com drives and select Training courses Providing feedback on ABB Drives manuals Your comments on our manuals are welcome Go to www abb com drives and select Document Library Manuals feedback form LV AC drives Document library on the Internet You can find manuals and other product documents in PDF format on the Internet Go to ...

Page 164: ...3AUA0000081249 Rev C EN 2013 04 11 Contact us www abb com drives www abb com drivespartners ...

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