ABB ACS850 series Hardware Manual Download

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Operation principle and hardware description

Ordering information

For a complete listing of options and accessories available for the ACS850-04, refer
to

ACS850 Ordering Information

(available on request).

Summary of Contents for ACS850 series

Page 1: ...ACS850 Hardware Manual ACS850 04 Drive Modules 1 1 to 45 kW...

Page 2: ......

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Page 5: ...e unit Use of warnings and notes There are four types of safety instructions used in this manual Electricity warning warns of high voltage which can cause physical injury and or damage to the equipmen...

Page 6: ...the supply power switched off Before maintenance work on the drive disconnect the motor from the drive by using a safety switch prevent the start up of any other motors in the same mechanical system...

Page 7: ...ve is not field repairable Never attempt to repair a malfunctioning drive contact your local ABB representative or Authorized Service Center for replacement Make sure that dust from drilling does not...

Page 8: ...r or disconnecting device disconnecting means instead use the control panel or external commands via the I O board of the drive or a fieldbus adapter The maximum allowed number of charging cycles of t...

Page 9: ...17 Terms and abbreviations 19 Operation principle and hardware description What this chapter contains 21 Operation principle 21 Main circuit 21 Motor control 22 Product overview 22 Layout 23 Power con...

Page 10: ...uit in motor cable 40 Protection against short circuit in the supply cable or the drive 40 Operating time of the fuses and circuit breakers 40 Circuit breakers 40 Motor thermal protection 40 Ground fa...

Page 11: ...rol cables 62 Control connections to the JCU Control Unit 62 Jumpers 63 External power supply for the JCU Control Unit XPOW 63 DI6 XDI 6 as a thermistor input 64 Drive to drive link XD2D 65 Safe Torqu...

Page 12: ...nce with EN 61800 3 2004 category C3 89 Compliance with EN 61800 3 2004 category C4 89 Compliance with the Machinery Directive 89 C Tick marking 89 UL marking 90 UL checklist 90 Patent protection in t...

Page 13: ...103 Braking choppers 103 Braking resistor selection 103 Chopper data Resistor selection table 104 Resistor installation and wiring 105 Contactor protection of drive 105 Braking circuit commissioning...

Page 14: ...Table of contents 14...

Page 15: ...chnical data and dimensional drawings which concern only certain frame sizes are marked with the symbol of the frame size A B C or D The frame size is marked on the drive designation label The frame s...

Page 16: ...trical installation of the drive Maintenance lists periodic maintenance actions along with work instructions Technical data contains the technical specifications of the drive e g the ratings sizes and...

Page 17: ...age page 33 If the converter has been non operational for more than one year the converter DC link capacitors need to be reformed Ask ABB for more information Check the installation site Mechanical in...

Page 18: ...e 62 For optional equipment Mains chokes page 91 EMC filters page 93 Resistor braking page 103 Manuals for any optional equipment Check the installation Installation checklist page 69 Commission the d...

Page 19: ...r the ACS850 FPBA 0x Optional PROFIBUS DP adapter for the ACS850 Frame size Size of the drive module This manual deals with ACS850 04 frames A B C and D To determine the frame size of a drive module r...

Page 20: ...About this manual 20...

Page 21: ...he main circuit of the drive module is shown below Motor output Braking chopper see chapter Resistor braking on page 103 UDC UDC V1 W1 U1 V2 W2 U2 R R AC supply ACS850 04 Inverter Capacitor bank Recti...

Page 22: ...frame sizes use the same control unit type JCU Component Description Braking chopper Conducts the energy generated by a decelerating motor from the DC bus to a braking resistor The braking chopper is...

Page 23: ...JCU Control Unit with cover assembly removed Power unit JCU Control Unit with optional cover assembly External 24 V power input Slot 3 for optional fieldbus adapter Motor and braking resistor connect...

Page 24: ...ve to drive link XD2D Safe Torque Off XSTO 3 phase power supply AC motor U1 V1 W1 L1 L2 L3 PE PE U2 V2 W2 M 3 t R UDC R UDC For more information on these connections see page 62 For specifications see...

Page 25: ...EMC filter C3 2nd Environment Unrestricted Earthed network External with frames A and B internal with frames C and D Control panel and front cover options J 0C168 No drive module front cover no contr...

Page 26: ...eration principle and hardware description 26 Ordering information For a complete listing of options and accessories available for the ACS850 04 refer to ACS850 Ordering Information available on reque...

Page 27: ...he weight of the drive components control circuitry and other equipment installed in it The cabinet must protect the drive module against contact and meet the requirements for dust and humidity see th...

Page 28: ...s and free space requirements The modules can be installed side by side The dimensions of the drive modules as well as free space requirements are presented below For more details refer to chapter Dim...

Page 29: ...generating components such as other drives mains chokes and braking resistors nearby Cooling and degrees of protection The cabinet must have enough free space for the components to ensure sufficient c...

Page 30: ...ient in size Please note that in addition to the power loss of the drive module the heat dissipated by cables and other additional equipment must also be ventilated The internal cooling fans of the mo...

Page 31: ...et in the lower part of the front door and an extra exhaust fan on the roof of the cabinet Inside the cabinet Prevent hot air circulation inside the cabinet with leak proof air baffle plates No gasket...

Page 32: ...Planning the cabinet assembly 32...

Page 33: ...Mechanical installation 33 Mechanical installation Contents of the package The drive is delivered in a cardboard box To open remove any banding and lift the top off the box...

Page 34: ...ders on the JCU Control Unit and the power unit EMC filter E200 if ordered with frames A and B only control panel mounting kit J410 if ordered Printed Quick Guides printed manuals if ordered manuals C...

Page 35: ...th and 5th digits indicate the week Digits 6 to 10 are a running integer starting every week at 00001 Before installation Check the installation site according to the requirements below Refer to Dimen...

Page 36: ...d locations 3 Position the drive onto the screws on the wall Note Only lift the drive by its chassis 4 Tighten the screws DIN rail mounting Frames A and B only 1 Click the drive to the rail as shown i...

Page 37: ...allation 37 Mains choke installation See the chapter Mains chokes on page 91 EMC filter installation See the chapter EMC filters on page 93 Braking resistor installation See the chapter Resistor braki...

Page 38: ...Mechanical installation 38...

Page 39: ...o install a safety switch between the permanent magnet motor and the drive output in order to isolate the motor from the drive during maintenance work on the drive Supply connection Use a fixed connec...

Page 40: ...endations are given in the chapter Technical data When placed at the distribution board standard IEC gG fuses or UL type T fuses will protect the input cable in short circuit situations restrict drive...

Page 41: ...nd faults in the motor and the motor cable This is not a personal safety or a fire protection feature The ground fault protective function can be disabled with a parameter refer to the appropriate Fir...

Page 42: ...Off function does not disconnect the voltage of the main and auxiliary circuits from the drive Therefore maintenance work on electrical parts of the drive or the motor can only be carried out after i...

Page 43: ...requirements Symmetrical shielded motor cable must be used see the figure below to meet the EMC requirements of the CE and C tick marks A four conductor system is allowed for input cabling but shield...

Page 44: ...mission level and the bearing currents Protecting the relay output contacts and attenuating disturbances in case of inductive loads Inductive loads relays contactors motors cause voltage transients wh...

Page 45: ...e not at the relay output Considering the PELV requirements at sites above 2000 m 6562 ft The relay outputs of the drive do not fulfill the Protective Extra Low Voltage PELV requirements at installati...

Page 46: ...n 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 LFLEX by Lapp Kabel Germany has been tested and approved by AB...

Page 47: ...Aluminium tray systems can be used to improve local equalizing of potential A diagram of the cable routing is below Control cable ducts min 500 mm 20 Control cables min 200 mm 8 min 300 mm 12 Supply...

Page 48: ...Planning the electrical installation 48...

Page 49: ...drive is already connected to the supply wait for 5 minutes after disconnecting the input power Removing the cover assembly The cover assembly needs to be removed before the installation of optional m...

Page 50: ...Electrical installation 50 1 2 3 4 5...

Page 51: ...ulation resistance between each phase conductor and the Protective Earth conductor using a measuring voltage of 500 V DC The insulation resistance of an ABB motor must exceed 10 Mohm reference value a...

Page 52: ...l See the chapter EMC filters page 93 Notes If shielded supply input cable is used and the conductivity of the shield is not sufficient see section Selecting the power cables on page 43 use a cable wi...

Page 53: ...n the two cable clamp plates included to the drive see page 55 one at the top one at the bottom The clamp plates are identical Using the cable clamp plates as shown below will provide better EMC compl...

Page 54: ...r PE conductor s at the distribution board In case a mains choke and or an EMC filter is installed make sure the PE conductor is continuous from the distribution board to the drive Grounding the motor...

Page 55: ...th the drive The picture below depicts a frame size A drive the installation is similar with other frame sizes Note Pay attention to supporting the cables adequately within the installation enclosure...

Page 56: ...re shield with insulating tape Cable clamp on bare shield 1 5 N m 13 lbf in Above cable clamp cover bare shield with insulating tape Braking resistor cable 1 5 N m 13 lbf in Cable clamp on bare shield...

Page 57: ...are shield with insulating tape Cable clamp on bare shield 1 5 N m 13 lbf in Above cable clamp cover bare shield with insulating tape Cable clamp on bare shield 1 5 N m 13 lbf in Braking resistor cabl...

Page 58: ...er cables can be connected to the drive terminals by removing the screw lugs and using crimp lugs U1 V1 W1 Below cable clamp cover bare shield with insulating tape Cable clamp on bare shield 1 5 N m 1...

Page 59: ...oring mode One or more drives are connected to the AC supply depending on the power requirement In case two or more drives are connected to the AC supply each AC connection must be equipped with a mai...

Page 60: ...lectrical installation 60 Each drive has an independent DC capacitor pre charging circuit The ratings of the DC connection are given on page 82 UDC UDC V1 W1 U1 V2 W2 U2 ACS850 04 Pre charging circuit...

Page 61: ...presented below Mechanical installation Remove the cover assembly from on the JCU Control Unit refer to page 49 Remove the protective cover if present from the connector of the slot Insert the module...

Page 62: ...art DI1 1 Digital input 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 i...

Page 63: ...nalog 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 External power supply for the JCU Con...

Page 64: ...ected to the thermistor input Instead an analog input and an analog current output located either on the JCU or on an I O extension module are used as shown below The analog input must be set to volta...

Page 65: ...munity high quality cable is recommended The cable should be kept as short as possible the maximum length of the link is 50 metres 164 ft Unnecessary loops and running the cable near power cables such...

Page 66: ...e cable at the cable clamp so that the clamp presses on the bare shield At the terminal block use shrink tubing or insulating tape to contain any stray strands The shield especially in case of multipl...

Page 67: ...amp plate Remove outer jacket of cable at clamp to expose cable shield Tighten clamp to 1 5 N m 13 lbf in 0 7 N m 6 2 lbf in Routing the control cables Run cables through the cover mounting bracket Us...

Page 68: ...Electrical installation 68...

Page 69: ...and B and EMC VAR1 VAR2 frames C and D screws are removed if the drive is connected to an IT ungrounded supply network The capacitors are reformed if stored over one year ask local ABB representative...

Page 70: ...Installation checklist 70 The supply input power voltage cannot be applied to the output of the drive through a bypass connection Motor connection box and other covers are in place Check...

Page 71: ...forming See Reforming the capacitors on page 75 Every 6 to 12 months depending on the dustiness of the environment Heatsink temperature check and cleaning See Heatsink on page 72 Every year Inspection...

Page 72: ...be checked annually in a dusty environment more often Clean the heatsink as follows when necessary 1 Remove the cooling fan see section Cooling fan 2 Blow clean compressed air not humid from bottom to...

Page 73: ...recommended once these symptoms start appearing Replacement fans are available from ABB Do not use other than ABB specified spare parts Fan replacement Frames A and B Detach the power cable clamp plat...

Page 74: ...rrowed carefully using a screwdriver Pull the fan holder out Disconnect the fan cable Carefully bend the clips on the fan holder to free the fan Install new fan in reverse order Note The airflow direc...

Page 75: ...ory unit to a new drive module When a drive module is replaced the parameter settings can be retained by transferring the memory unit from the defective drive module to the new module WARNING Do not r...

Page 76: ...Maintenance 76...

Page 77: ...A 3 1 6 0 3 6 5 3 1 5 2 0 3 4 1 5 2 0 3 0 1 1 1 5 04A8 5 A 4 0 7 0 4 8 7 0 2 2 3 0 4 5 1 5 2 0 4 0 1 5 2 0 06A0 5 A 5 5 9 0 6 0 8 8 2 2 3 0 5 5 2 2 3 0 5 0 2 2 3 0 08A0 5 A 6 6 11 8 0 10 5 3 0 5 0 7...

Page 78: ...22 25 32 18 5 20 29 18 5 20 044A 5 C 36 44 53 30 30 41 22 30 35 22 25 050A 5 C 42 50 66 30 30 46 30 30 44 30 30 061A 5 D 55 61 78 37 40 57 37 40 52 30 40 078A 5 D 65 78 100 45 50 74 45 50 69 45 50 09...

Page 79: ...ing In the temperature range 40 55 C 104 131 F the rated output current is derated by 1 for every added 1 C 1 8 F as follows Altitude derating At altitudes from 1000 to 4000 m 3300 to 13123 ft above s...

Page 80: ...5 4 11 9 C 567 22 32 658 25 91 166 6 54 276 10 87 298 11 73 15 6 34 4 D 567 22 32 744 29 29 221 8 70 276 10 87 298 11 73 21 3 47 Drive type ACS850 04 Power loss W BTU h Air flow m3 h ft3 min Noise lev...

Page 81: ...l area of cable Rated current A Voltage V Class Rated current A Voltage V UL Class mm2 AWG 03A0 5 4 0 6 500 gG 6 600 T 1 5 4 16 12 03A6 5 6 0 6 500 gG 6 600 T 1 5 4 16 12 04A8 5 7 0 10 500 gG 10 600 T...

Page 82: ...e screw terminal block for 0 5 6 mm2 wire Frames C and D Screw lugs for 6 70 mm2 wire included Suitable crimp lugs can be used instead Motor connection Motor types Asynchronous induction motors synchr...

Page 83: ...Note The relay outputs of the drive do not fulfill the Protective Extra Low Voltage PELV requirements at installation sites above 4000 meters 13123 feet if used with a voltage greater than 48 V At ins...

Page 84: ...load 1 kohm Analog inputs AI1 and AI2 XAI 4 XAI 7 Current voltage input mode selection by jumpers See page 63 Connector pitch 3 5 mm wire size 1 5 mm2 Current input 20 20 mA Rin 100 ohm Voltage input...

Page 85: ...ly Degrees of protection IP20 UL open type See chapter Planning the cabinet assembly 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...

Page 86: ...cases Class 2C2 Solid particles Class 2S2 Sinusoidal vibration IEC 60721 3 3 Tested according to IEC 60721 3 3 mechanical conditions Class 3M4 2 9 Hz 3 0 mm 0 12 9 200 Hz 10 m s2 33 ft s2 Shock IEC 60...

Page 87: ...Edition 2 0 Insulation coordination for equipment within low voltage systems Part 1 Principles requirements and tests IEC 61800 3 2004 Adjustable speed electrical power drive systems Part 3 EMC requi...

Page 88: ...tic purposes Second environment includes all establishments other than those directly connected to a low voltage network which supplies buildings used for domestic purposes Drive of category C2 Power...

Page 89: ...neighbouring low voltage networks In some cases the natural suppression in transformers and cables is sufficient If in doubt a supply transformer with static screening between the primary and secondar...

Page 90: ...he drive provides overload protection in accordance with the National Electrical Code US Braking The ACS850 04 has an internal braking chopper When applied with appropriately sized braking resistors t...

Page 91: ...s in the input current reduces the r m s input current reduces supply disturbance and low frequency interference increases the allowed DC bus continuous power ensures even current distribution in comm...

Page 92: ...nductive surface Ensure the choke does not block the airflow through the drive module and that the air rising from the choke is deflected away from the air inlet of the drive module Keep the cable bet...

Page 93: ...order to meet the category C3 level with the ACS850 04 drive installation including a motor with a max 100 m cable This level corresponds to the A limits for Group 2 equipment according to EN 55011 W...

Page 94: ...s EMC filters for ACS850 04 Drive type ACS850 04 Filter type EN 61800 3 2004 Category C3 EN 61800 3 2004 Category C2 03A0 5 Option code E200 external filter JFI A1 JFI 02 03A6 5 04A8 5 06A0 5 08A0 5 0...

Page 95: ...filter is connected directly to the drive input connectors For optimal operation of the filter the drive and the filter must be mounted on the same conductive surface Connection diagram AC supply ACS...

Page 96: ...two screws 4 Tighten to 1 5 N m 13 lbf in Push the filter into place through the mounting bracket Fasten the filter to the mounting bracket with two screws 5 Tighten to 1 5 N m 13 lbf in Fasten the t...

Page 97: ...e filter into the connectors Fasten the filter to the drive module base with two screws 3 Tighten to 1 5 N m 13 lbf in Fasten the top edge of the filter to the mounting base with two screws 4 Fasten t...

Page 98: ...connection diagram below For optimal operation of the filter the drive and the filter must be mounted on the same conductive surface Ensure the filter does not block the airflow through the drive modu...

Page 99: ...flection properties of the motor cable and the terminals This in turn can cause additional stress on the motor and motor cable insulation Modern variable speed drives with their fast rising voltage pu...

Page 100: ...th motor manufacturer Yes Yes Random wound ABB HX_ and AM_ motor manufactured before 1 Jan 1998 UN 500 V Enamelled wire with fiberglass taping Check with motor manufacturer Random wound ABB HX_ and AM...

Page 101: ...tact your local ABB representative Installation Follow the instructions included with the filters Filter type Height mm inches Width mm inches Depth mm inches Weight kg lbs NOCH0016 60 195 7 68 140 5...

Page 102: ...du dt and common mode filtering 102...

Page 103: ...king 2 Calculate the continuous power based on the braking duty cycle 3 Calculate the braking energy during the duty cycle Pre selected resistors are available from ABB as shown in the table below If...

Page 104: ...braking power for 1 second within every 120 seconds Rmin The minimum allowed resistance of the braking resistor R Resistance of the listed resistor Pn Continuous power heat dissipation of the listed...

Page 105: ...s of degrees Celsius Protect the resistor against contact The maximum length of the resistor cable s is 20 m 65 ft For the connections see section Power cable connection on page 52 Contactor protectio...

Page 106: ...esistor must be connected when the chopper is enabled Switch off the overvoltage control of the drive Adjust any other relevant parameters in group 48 WARNING If the drive is equipped with a braking c...

Page 107: ...Dimension drawings 107 Dimension drawings What this chapter contains Dimension drawings of the ACS850 04 and related accessories are shown below The dimensions are given in millimetres and inches...

Page 108: ...Dimension drawings 108 Frame size A...

Page 109: ...Dimension drawings 109 Frame size B...

Page 110: ...Dimension drawings 110 Frame size C...

Page 111: ...Dimension drawings 111 Frame size D...

Page 112: ...94 100 3 94 dim D mm in 77 3 03 105 4 13 105 4 13 105 4 13 dim E mm in 114 4 49 148 5 83 148 5 83 148 5 83 F screw size M5 M5 M5 M5 Weight kg lbs 1 8 4 0 3 8 8 4 5 4 11 9 5 2 11 5 Wire size Main termi...

Page 113: ...Dimension drawings 113 EMC filters type JFI x1 JFI A1...

Page 114: ...Dimension drawings 114 JFI B1...

Page 115: ...Dimension drawings 115 EMC filters type JFI 0x...

Page 116: ...6 Dim G mm in 5 4 0 21 5 4 0 21 5 4 0 21 6 5 0 26 Dim H mm in 1 0 04 1 0 04 1 0 04 1 5 0 06 Dim I mm in 22 0 87 25 0 98 39 1 54 45 1 77 Dim J M5 M5 M6 M10 Dim K mm in 22 5 0 89 25 0 98 42 5 1 67 45 1...

Page 117: ...Dimension drawings 117 Braking resistors type JBR xx...

Page 118: ...D mm in 345 13 58 465 18 31 595 23 43 Dim E mm in 210 8 27 330 12 99 460 18 11 Dim F mm in 110 4 33 230 9 06 360 14 17 Weight kg lbs 0 75 1 7 0 8 1 8 1 8 4 0 3 0 6 6 3 9 8 6 Max wire size Main termina...

Page 119: ...ct 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 w...

Page 120: ...3AUA0000045496 REV D EN EFFECTIVE 2009 07 20 ABB Oy AC Drives P O Box 184 FI 00381 HELSINKI FINLAND Telephone 358 10 22 11 Fax 358 10 22 22681 Internet http www abb com...

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