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ABB ACSM1-04 Series, Hardware Manual

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Table of contents

10

Mechanical installation

Contents of the package  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Delivery check and drive module identification   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Before installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Connection to an IT (ungrounded) or a corner-grounded power system  . . . . . . . . . . . . . . . . 30

Installation procedure   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Direct wall mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Push-through mounting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Hole dimensions for push-through mounting   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Braking resistor installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Planning the electrical installation

What this chapter contains   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Motor selection and compatibility   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Supply connection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Supply disconnecting device  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Europe  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Other regions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Thermal overload and short circuit protection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Thermal overload protection   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Protection against short-circuit in motor cable  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Protection against short-circuit in the supply cable or the drive  . . . . . . . . . . . . . . . . . . . . . . . 39

 Operating time of the fuses and circuit breakers  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Circuit breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Motor thermal protection   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Ground fault protection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Emergency stop devices  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Safe Torque Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Selecting the power cables  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

General rules  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Alternative power cable types   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Motor cable shield  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Protecting the relay output contacts and attenuating disturbances in case of inductive loads  . . . . 43
Residual current device (RCD) compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Selecting the control cables   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Relay cable   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Control panel cable   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Connection of a motor temperature sensor to the drive I/O   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Control cable ducts   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Electrical installation

What this chapter contains   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Checking the insulation of the assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Summary of Contents for ACSM1-04 Series

Page 1: ...ACSM1 Hardware Manual ACSM1 04 Drive Modules 55 to 110 kW ...

Page 2: ......

Page 3: ...ACSM1 04 Drive Modules 55 to 110 kW Hardware Manual 3AFE68912130 REV A EN EFFECTIVE 14 01 2008 2008 ABB Oy All Rights Reserved ...

Page 4: ......

Page 5: ...e unit Use of warnings and notes There are four types of safety instructions used in this manual Dangerous voltage warning warns of high voltage 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 to the equipment Electrostatic discharge warning warns of electr...

Page 6: ...and 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 lock the motor shaft measure that the motor is in fact de energised then connect the U2 V2 and W2 terminals of the drive to each other and to the PE Do not work on the control cables when power is ...

Page 7: ...tive or Authorized Service Center Make sure that dust from drilling does not enter the drive during the installation Electrically conductive dust inside the drive may cause damage or lead to malfunction Ensure sufficient cooling WARNING The printed circuit boards contain components sensitive to electrostatic discharge Wear a grounding wrist band when handling the boards Do not touch the boards unn...

Page 8: ...after a fault Do not control the motor with an AC contactor 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 the DC capacitors i e power ups by applying power is one per two minutes Drives controlling a permanent magnet motor Do not run the motor over ...

Page 9: ...BB Drives manuals 13 Contents 14 Installation and commissioning flowchart 15 Terms and abbreviations 17 The ACSM1 04 What this chapter contains 19 The ACSM1 04 19 Layout 19 Main circuit and control interfaces 20 Operation 21 Type code 21 Planning the cabinet assembly What this chapter contains 23 Cabinet construction 23 Disposition of the devices 23 Grounding of mounting structures 23 Main dimensi...

Page 10: ...ircuit protection 38 Thermal overload protection 38 Protection against short circuit in motor cable 38 Protection against short circuit in the supply cable or the drive 39 Operating time of the fuses and circuit breakers 39 Circuit breakers 39 Motor thermal protection 39 Ground fault protection 39 Emergency stop devices 40 Safe Torque Off 41 Selecting the power cables 42 General rules 42 Alternati...

Page 11: ...ontrol Unit 58 Jumpers 59 External power supply for the JCU Control Unit X1 60 Thermistor input X4 8 9 60 Drive to drive link X5 61 Safe Torque Off X6 61 Control cable grounding 62 Installation of options 63 Installation checklist Checklist 65 Maintenance What this chapter contains 67 Safety 67 Maintenance intervals 67 Heatsink 67 Cooling fan 68 Fan replacement 68 Capacitors 68 Reforming 68 Changi...

Page 12: ...ry C2 79 Compliance with EN 61800 3 2004 category C3 80 Compliance with EN 61800 3 2004 category C4 80 Compliance with the Machinery Directive 80 C Tick marking 80 Compliance with IEC 61800 3 2004 80 UL marking 81 UL checklist 81 Product protection in the US 81 Resistor braking What this chapter contains 83 Braking choppers and resistors with the ACSM1 04 83 Braking choppers 83 Braking resistor se...

Page 13: ...ategorization according to the code The instructions technical data and dimensional drawings which concern only certain optional selections are marked with codes e g L500 The options included in the drive can be identified from the codes visible on the type designation label of the drive The code selections are listed in chapter The ACSM1 04 under Type code Product and service inquiries Address an...

Page 14: ...instructs how to place and mount the drive Planning the electrical installation instructs on the motor and cable selection the protections and the cable routing Electrical installation instructs on how to wire the drive Installation checklist contains a list for checking the mechanical and electrical installation of the drive Maintenance lists periodic maintenance actions along with work instructi...

Page 15: ...e 29 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 installation Before installation page 30 Technical data page 71 If the drive is about to be connected to an IT ungrounded or corner grounded system check that the internal EMC filtering of the drive has been d...

Page 16: ... the control cables page 58 For optional equipment Resistor braking page 83 Manuals for any optional equipment Check the installation Installation checklist page 65 Commission the drive Appropriate Firmware Manual Commission the braking chopper if required Resistor braking page 83 Operating of the drive start stop speed control etc Appropriate Firmware Manual Task See ...

Page 17: ...hernet IP adapter for the ACSM1 FPBA 0x Optional PROFIBUS DP adapter for the ACSM1 Frame size Size of the drive module This manual deals with ACSM1 04 frame size E IGBT Insulated Gate Bipolar Transistor a voltage controlled semiconductor type widely used in inverters due to their easy controllability and high switching frequency I O Input Output JBR xx Series of optional braking resistors for the ...

Page 18: ...About this manual 18 ...

Page 19: ...se the same control unit type JCU This manual only deals with ACSM1 04 frame size E Layout AC supply DC braking resistor and motor connections Slots 1 and 2 for optional I O extensions and encoder resolver interface Slot 3 for optional fieldbus adapter JCU Control Unit JCU Control Unit Cooling air inlet with fan Cooling air outlet Digital inputs outputs Relay output External 24 V power input 7 seg...

Page 20: ...c Slot 1 Power unit Slot 2 Slot 3 Control unit JCU installed onto the power unit Digital I O Analogue I O Thermistor input Drive to drive link Safe Torque Off connection Control panel optional or PC connection Memory unit JMU containing the application program see page 69 7 segment status display see page 69 Option 2 Connectivity as with Option 1 above Note No two I O extensions or feedback interf...

Page 21: ...it DC voltage Inverter Converts the DC voltage to AC voltage and vice versa The motor is controlled by switching the IGBTs of the inverter Rectifier Converts the three phase AC voltage to DC voltage Selection Alternatives Product series ACSM1 product series Type 1 04 Drive module When no options are selected IP20 no control panel internal EMC filter internal mains choke braking chopper coated boar...

Page 22: ...The ACSM1 04 22 ...

Page 23: ...struction The cabinet frame must be sturdy enough to carry the 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 chapter Technical data Disposition of the devices For easy installation and maintenance a spacious layout is recommended Sufficient cooling ai...

Page 24: ... entering the unit must not exceed the maximum allowed ambient temperature see Ambient conditions in the chapter Technical data Consider this when installing heat generating components such as other drives mains chokes and braking resistors nearby 415 16 34 313 5 12 34 700 27 56 Including options installed on the JCU Control Unit Note that the wiring to some option modules requires approximately 5...

Page 25: ...irements given in chapter Technical data are met cooling air flow Note The values in Technical data apply to continuous nominal load If the load is less than nominal less cooling air is required allowed ambient temperature Make sure the air inlets and outlets are sufficient in size Please note that in addition to the power loss of the drive module the heat dissipated by cables and other additional...

Page 26: ...t sides of the cabinet cool air inlet 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 make sure the air vents of the drive module remain clear No gaskets are usually required HOT AREA Main airflow out Main airflow in COOL AREA Cabinet side view Air baffle plat...

Page 27: ... non tightened touch contact of the metal surfaces is not sufficient so a conductive gasket between the surfaces is required The maximum recommended distance between assembly screws is 100 mm Sufficient high frequency grounding network must be constructed in the cabinet to avoid voltage differences and forming of high impedance radiator structures A good high frequency grounding is made with short...

Page 28: ...he cable shield from both directions Cabinet heaters Use a cabinet heater if there is a risk of condensation in the cabinet Although the primary function of the heater is to keep the air dry it may also be required for heating at low temperatures When placing the heater follow the instructions provided by its manufacturer Shielding cushion conductive Cable Cable grommet Bare cable shield Cabinet b...

Page 29: ...identification Check that there are no signs of damage Before attempting installation and operation check the information on the type designation label of the drive module to verify that the unit is of the correct type The label is located on the left hand side of the drive module The first digit of the serial number refers to the manufacturing plant The 2nd and 3rd digit indicate the year of manu...

Page 30: ...tion to an IT ungrounded or a corner grounded power system The internal EMC filter must be disconnected if the drive is to be supplied from a corner grounded power system or an IT power system an ungrounded power system or a high resistance grounded over 30 ohms power system As the procedure involves the removal of drive module covers it is convenient to perform it before the drive is installed Se...

Page 31: ...ng The kit enables the installation of the drive module in the wall of a cooling air duct so that part of the module protrudes into the duct Keep the screws removed during the procedure they will later be used to fasten the push through mounting parts Lower collar Lateral supports Upper collar Lifting lug ...

Page 32: ...its back on a level surface 2 Remove the grounding terminals 3 2 screws as well as the three screws nearby 3 Remove the arrowed screws on each side of the module cover The middle row of screws is used later to attach the lateral supports of the mounting kit ...

Page 33: ...installation 33 4 Attach the grounding terminals to the lower collar 5 Slide the lower collar onto the drive module into the position shown Fasten through the holes arrowed using the three screws removed at step 2 ...

Page 34: ...er collar onto the drive module into the position shown 7 Attach the lateral supports to the drive module and the collars Each support is fastened to the collars by four nuts and to the drive module by three out of six screws removed at step 3 ...

Page 35: ... drawing below to cut the hole in the duct Fasten the module to the edges using screws WARNING With the kit attached to the drive module do not lift the module by one lifting lug only Always use at least two lifting lugs Note If the drive is exposed to vibration it must be fastened also by the standard mounting holes on the heat sink ...

Page 36: ...Mechanical installation 36 Hole dimensions for push through mounting Braking resistor installation See the chapter Resistor braking on page 83 ...

Page 37: ...maintenance work on the drive Protecting the motor insulation and bearings The output of the drive comprises regardless of output frequency pulses of approximately 1 35 times the equivalent mains 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 th...

Page 38: ...itching devices to break the load circuit before the opening of the main contacts of the disconnector EN 60947 3 a circuit breaker suitable for isolation in accordance with EN 60947 2 Other regions The disconnecting means must conform to the applicable safety regulations Thermal overload and short circuit protection Thermal overload protection The drive protects itself and the input and motor cabl...

Page 39: ...hermal protection According to regulations the motor must be protected against thermal overload and the current must be switched off when overloading is detected The drive includes a motor thermal protection function that protects the motor and switches off the current when necessary Depending on a drive parameter value the function either monitors a calculated temperature value based on a motor t...

Page 40: ...all the emergency stop devices at each operator control station and at other operating stations where emergency stop may be needed Note Pressing the stop key on the control panel of the drive does not generate an emergency stop of the motor or separate the drive from dangerous potential ...

Page 41: ...ive WARNING The Safe Torque 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 isolating the drive system from the main supply Note If a running drive is stopped by using the Safe Torque Off function the drive will cut off the motor supply voltage and t...

Page 42: ...system is allowed for input cabling but shielded symmetrical cable is recommended Compared to a four conductor system the use of symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as motor bearing currents and wear The motor cable and its PE pigtail twisted shield should be kept as short as possible in order to reduce electromagnetic emission Alternative ...

Page 43: ...and tighter the shield the lower the emission 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 when switched off The relay output on the drive is protected with varistors 250 V against overvoltage peaks In addition it is highly recommended to equip inductive ...

Page 44: ...nvironment by double or reinforced insulation or isolation from the supply system by a transformer can also be applied Selecting the control cables It is recommended that all control cables be shielded Double shielded twisted pair cable is recommended for analogue signals For pulse encoder cabling follow the instructions given by the encoder or motor manufacturer Use one individually shielded pair...

Page 45: ...pproved by ABB is used in control panel option kits Connection of a motor temperature sensor to the drive I O See page 60 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 trays Avoid long paralle...

Page 46: ...min 300 mm 12 Supply cable Motor cable Motor cable min 500 mm 20 Braking resistor cable 90 90 Drive 90 min 200 mm 20 Supply cable 230 V 24 V 24 V 230 V Lead 24 V and 230 V control cables in separate ducts inside the cabinet Not allowed unless the 24 V cable is insulated for 230 V or insulated with an insulation sleeving for 230 V ...

Page 47: ...n this chapter may only be carried out by a qualified electrician Follow the Safety instructions on the first pages of this manual Ignoring the safety instructions can cause injury or death Make sure that the drive is disconnected from the supply input power during installation If the drive is already connected to the supply wait for 5 minutes after disconnecting the input power ...

Page 48: ...sulation 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 at 25 C or 77 F For the insulation resistance of other motors please consult the manufacturer s instructions Note Moisture inside the motor casing will reduce the insulation resistance If moisture is ...

Page 49: ...ernal EMC filtering of the drive must be disconnected If a drive with its internal EMC filtering connected is installed on an IT system or a corner grounded system the drive system will be connected to earth potential through the EMC filter capacitors of the drive This may cause danger or damage the unit Disconnection of internal EMC filtering 1 Place the drive module on its back on a level surfac...

Page 50: ...nstallation 50 3 Lift the left hand edge of the JCU control unit until the connector beneath disengages then move JCU to the left to remove it 4 Disconnect the two cables coming to the mounting base of the JCU 1 2 ...

Page 51: ...Electrical installation 51 5 Remove the screw in the middle of the air outlet grating 6 Remove the screws holding the drive module cover 8 on each side Lift off the cover bottom edge first ...

Page 52: ... grounding wire to a standoff right next to the EMC filter Cut off the lug Discard the screw and the tubular insulator 8 Insulate the end of the grounding wire reliably with insulating tape tube sleeving and a cable tie Standoff covered by insulator EMC filter ...

Page 53: ...cts the varistor board to the module cover 10 Refit the module cover top edge first and fasten using the screws removed at step 6 The screw in the middle of the air outlet grating that was removed at step 5 is no longer needed 11 Reconnect the cables that were disconnected at step 4 12 Refit the JCU control unit ...

Page 54: ...d is less than 50 of the conductivity of a phase conductor and the cable has no symmetrical ground conductors See also section Selecting the power cables on page 42 If there is a symmetrically constructed ground conductor in the motor cable in addition to the conductive shield connect it to the ground connectors at both the drive and motor ends Do not use an asymmetri cally constructed motor cable...

Page 55: ...drive module 3 Connect the phase conductors of the supply cable to the U1 V1 and W1 terminals and the phase conductors of the motor cable to the U2 V2 and W2 terminals The recommended stripping length is 28 mm 1 1 4 Secure the cables mechanically outside the drive module 5 Cut suitable slots on the edge of the plastic shroud to accommodate the power cables Refit the shroud 6 Ground the other end o...

Page 56: ... 56 Cable lug installation 16 to 70 mm2 AWG6 to AWG2 0 cables U1 V1 W1 U2 V2 W2 R UDC R UDC Input power cable Motor cable Insulate the ends of the cable lugs with tape or shrink tube 30 44 N m 22 32 lbf ft PE 8 N m 5 9 lbf ft ...

Page 57: ...ttened shield is wider than 1 5 of its length a b U1 V1 W1 U2 V2 W2 R UDC R UDC Input power cable Motor cable a Connect the cable to the terminal Tighten the Allen screw to 20 40 N m 15 30 lbf ft b Connect the terminal to the drive Tighten to 30 44 N m 22 32 lbf ft WARNING If the wire size is less than 95 mm2 3 0 AWG a crimp lug must be used A cable of wire size less than 95 mm2 3 0 AWG connected ...

Page 58: ...put 5 Position ref set 1 2 DI5 11 Digital input 6 Homing start DI6 12 24 V DC 24VD 13 Digital I O ground DGND 14 Digital input output 1 Ready DIO1 15 Digital input output 2 Running DIO2 16 24 V DC 24VD 17 Digital I O ground DGND 18 Digital input output 3 Fault DIO3 19 X4 Reference voltage VREF 1 Reference voltage VREF 2 Ground AGND 3 Analogue input 1 Current or voltage selectable by jumper J1 Spee...

Page 59: ...input J2 Determines whether Analogue input AI2 is used as a current or voltage input J3 Drive to drive link termination Must be set to the ON position when the drive is the last unit on the link AI1 AI2 8 7 AI1 AI2 8 7 Current Voltage AI1 AI2 8 7 AI1 AI2 8 7 Current Voltage T Termination ON Termination OFF T ...

Page 60: ...emperature can be measured using PTC or KTY84 sensors connected to the thermistor input WARNING As the thermistor input on the JCU Control Unit is not insulated according to IEC 60664 the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor If the assembly does not fulfil the requirement the I O board terminals must be protecte...

Page 61: ...ded 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 as motor cables must be avoided The cable shields are to be grounded to the control cable clamp plate on the drive as shown on page 62 The following diagram shows the wiring of the drive to drive link Safe Torque Off X6 For the drive to...

Page 62: ...ay strands 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 capacitor e g 3 3 nF 630 V The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop betw...

Page 63: ...ptions Options such as fieldbus adapters I O extensions and encoder interfaces are inserted into slots on the JCU Control Unit See page 20 for the available slots see the appropriate option manual for specific installation and wiring instructions ...

Page 64: ...Electrical installation 64 ...

Page 65: ...ernal EMC filter is disconnected if the drive is connected to an IT ungrounded or corner grounded supply network The capacitors are reformed if stored over one year ask local ABB representative for more information The drive is grounded properly The supply input power voltage matches the drive nominal input voltage The supply input power is connected to U1 V1 W1 UDC UDC in case of a DC supply and ...

Page 66: ...Installation checklist 66 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 67: ...he heatsink should 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 top and simultaneously use a vacuum cleaner at the air outlet to trap the dust Note If there is a risk of the dust entering adjoining equipment perform the cleaning in another room...

Page 68: ...everse order Capacitors Reforming The capacitors must be reformed if the drive has been stored for a year or more See page 29 for information on finding out the manufacturing date For information on reforming the capacitors contact your local ABB representative Changing The drive intermediate circuit employs several electrolytic capacitors Their lifespan is from 45 000 to 90 000 hours depending on...

Page 69: ...l Unit Multi character indications are displayed as repeated sequences of characters Display Meaning L Loading application program or data from the memory unit This is the normal display immediately after powering up the drive Normal operation drive stopped Rotating display Normal operation drive running E followed by four digit error code System error 9001 9002 Control unit hardware failure 9003 ...

Page 70: ...Maintenance 70 ...

Page 71: ...5 75 135A 4 E 131 135 135 90 202 75 100 175A 4 E 171 175 175 115 282 90 125 210A 4 E 205 210 210 135 326 110 150 PDM 00425726 I1N Nominal input current rms at 40 C 104 F I2N Nominal output current at 40 C 104 F I2contxk Continuous output current at a switching frequency of 4 or 8 kHz at 40 C 104 F PN Typical motor power I2max Maximum short time output current See section Cyclic loads below To achi...

Page 72: ...e output current is derated linearly as follows AC supply voltage derating With AC supply voltages above 400 V AC the output current is derated linearly as follows Altitude derating At altitudes from 1000 to 4000 m 3300 to 13123 ft above sea level the derating is 1 for every 100 m 328 ft For a more accurate derating use the DriveSize PC tool Note If the installation site is higher than 2000 m 6600...

Page 73: ...nt I2rms I2peak on the graph below If the point falls within the region bordered by a solid line the load cycle is safe For I2contxk and I2max use the ratings stated for the drive type and switching frequency used If the point falls within the shaded area a more detailed study is required The above procedure can also be applied to longer load cycles by dividing the cycle into subcycles no longer t...

Page 74: ...idth Depth without options installed on JCU Depth with options installed on JCU Weight Noise mm in mm in mm in mm in kg lbs dB E 700 27 56 313 5 12 34 398 15 67 415 16 34 67 148 65 Drive type ACSM1 04xx Power loss Air flow Minimum effective area of air inlet Minimum effective area of air outlet IP22 IP54 IP22 IP54 W m3 h ft3 min cm2 in2 cm2 in2 cm2 in2 cm2 in2 110A 4 1060 405 240 1000 155 2000 310...

Page 75: ...otors permanent magnet servo motors Frequency 0 500 Hz Current See section Ratings Switching frequency Selectable between 1 8 kHz Default 4 kHz above which output current derated Maximum motor cable length 50 m 164 ft with screened cable 75 m 246 ft with unscreened cable Terminals With cable sizes from 16 to 70 mm2 AWG6 to AWG2 0 Posts for crimp lugs lugs not included With cable sizes from 95 to 1...

Page 76: ...ange Thermistor input X4 Connector pitch 3 5 mm wire size 1 5 mm2 Input devices PTC or KTY84 thermistor Up to three PTCs can be connected in series KTY84 thermistor Inaccuracy 5 C No safety insulation see page 60 Analogue outputs AO1 and AO2 X4 Connector pitch 3 5 mm wire size 1 5 mm2 AO1 current 0 20 mA Rload 500 ohm AO2 voltage 10 10 V Rload 1 kohm Frequency range 0 800 Hz Resolution 11 bit sign...

Page 77: ...owed According to IEC 60721 3 3 Chemical gases Class 3C2 Solid particles Class 3S2 The drive must be installed in clean air according to enclosure classification Cooling air must be clean free from corrosive materials and electrically conductive dust According to IEC 60721 3 1 Chemical cases Class 1C2 Solid particles Class 1S2 According to IEC 60721 3 2 Chemical cases Class 2C2 Solid particles Cla...

Page 78: ... installations IEC 60204 1 2005 modified Safety of machinery Electrical equipment of machines Part 1 General requirements Provisions for compliance The final assembler of the machine is responsible for installing an emergency stop device a supply disconnecting device the ACSM1 04 into a cabinet EN 60529 1991 IEC 60529 Degrees of protection provided by enclosures IP code IEC 60664 1 2007 Edition 2 ...

Page 79: ...mediate transformers to a low voltage network which supplies buildings used for domestic 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 drive system with rated voltage less than 1000 V which is neither a plug in device nor a movable device and when us...

Page 80: ...n in transformers and cables is sufficient If in doubt a supply transformer with static screening between the primary and secondary windings can be used 2 An EMC plan for preventing disturbances is drawn up for the installation A template is available from the local ABB representative 3 The motor and control cables are selected as specified in the chapter Planning the electrical installation 4 The...

Page 81: ...ecting the control cables on page 58 Overload protection The drive provides overload protection in accordance with the National Electrical Code US Braking The ACSM1 04 has an internal braking chopper When applied with appropriately sized braking resistors the braking chopper will allow the drive to dissipate regenerative energy normally associated with quickly decelerating a motor Braking resistor...

Page 82: ...Technical data 82 ...

Page 83: ...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 the listed resistor is not sufficient for the application a custom resistor can be selected within the limits imposed by the internal braking chopper of the ACSM1 04 The following rules apply The resistanc...

Page 84: ... chopper will withstand this braking power for 1 second within every 10 seconds Note The listed resistors will withstand this 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 resistor when cooled naturally in a vertical position Epulse Energy pulse t...

Page 85: ...hundreds 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 54 Contactor protection of drive It is highly recommended to equip the drive with a main contactor for safety reasons Wire the contactor so that it opens in case the resistor overheats This is essential for safety s...

Page 86: ...resistor 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 chopper but the chopper is not enabled by parameter setting the braking resistor must be disconnected because the protection against resistor overheating is then not in use ...

Page 87: ...Dimension drawings 87 Dimension drawings What this chapter contains Dimension drawings of the ACSM1 04 frame size E and related accessories are shown below ...

Page 88: ...Dimension drawings 88 Drive module ...

Page 89: ...Dimension drawings 89 Drive module continued from previous page ...

Page 90: ...560 2 460 1 Other JBR 09 dimensions Max wire size Main terminals 50 mm2 AWG1 Tightening torque Main terminals 10 N m 7 4 lbf ft Max wire size Thermal switch terminals 4 mm2 AWG12 Tightening torque Thermal switch terminals 0 6 0 8 N m 5 3 7 1 lbf in ...

Page 91: ......

Page 92: ...3AFE68912130 REV A EN EFFECTIVE 14 01 2008 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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