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ABB ACSM1 Series, Hardware Manual

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ABB ACSM1 Series Hardware Manual Download Page 5

Safety instructions

5

Safety instructions

What this chapter contains

This chapter contains the safety instructions which you must follow when installing, 
operating and servicing the drive. If ignored, physical injury or death may follow, or 
damage may occur to the drive, the motor, or driven equipment. Read the safety 
instructions before you work on the 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 electrostatic discharge which 

can damage the equipment.

Hot surface warning

 warns of component surfaces that may become 

hot enough to cause burns if touched.

Summary of Contents for ACSM1 Series

Page 1: ...ACSM1 Hardware Manual ACSM1 04 Drive Modules 0 75 to 45 kW...

Page 2: ......

Page 3: ...ACSM1 04 Drive Modules 0 75 to 45 kW Hardware Manual 3AFE68797543 REV C EN EFFECTIVE 11 6 2007 2007 ABB Oy All Rights Reserved...

Page 4: ......

Page 5: ...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 equ...

Page 6: ...ed 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 s...

Page 7: ...ive 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: ...16 Installation and commissioning flowchart 17 Inquiries 18 Terms and abbreviations 19 The ACSM1 04 What this chapter contains 21 The ACSM1 04 21 Layout Frame A shown 21 Main circuit and control inter...

Page 10: ...ermal overload protection 38 Protection against short circuit in motor cable 38 Protection against short circuit in the supply cable or the drive 38 Operating time of the fuses and circuit breakers 38...

Page 11: ...the JCU Control Unit X1 59 Drive to drive link X5 59 Safe Torque Off X6 59 Thermistor input X4 8 9 60 Control cable grounding 61 Installation of options 62 Installation checklist Checklist 63 Mainten...

Page 12: ...irective 81 Definitions 81 Compliance with EN 61800 3 2004 category C2 81 Compliance with EN 61800 3 2004 category C3 82 Compliance with EN 61800 3 2004 category C4 82 Compliance with the Machinery Di...

Page 13: ...Braking circuit commissioning 94 Dimension drawings What this chapter contains 95 Frame size A 96 Frame size B 98 Frame size C air cooled module 100 Frame size C for cold plate mounting 102 Frame siz...

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

Page 15: ...and electrical schematic symbols This manual is written for readers worldwide Both SI and imperial units are shown wherever appropriate Categorization according to the frame size Some instructions te...

Page 16: ...lation 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 t...

Page 17: ...nts of the package page 31 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 sit...

Page 18: ...e auxiliary control cables Electrical installation Power cable connection page 49 and Connecting the control cables page 58 For optional equipment Mains chokes page 85 Mains filters page 87 Resistor b...

Page 19: ...S DP adapter for the ACSM1 Frame size Size of the drive module This manual deals with ACSM1 04 frame sizes A B C or D To determine the frame size of a drive module refer to the rating tables in chapte...

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

Page 21: ...ent The ACSM1 04 is available in several frame sizes depending on output power All frame sizes use the same control unit type JCU Layout Frame A shown AC supply connection DC connection 7 segment disp...

Page 22: ...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 contain...

Page 23: ...AC voltage and vice versa The motor is controlled by switching the IGBTs of the inverter Mains choke See page 85 Mains filter See page 87 Rectifier Converts the three phase AC voltage to DC voltage S...

Page 24: ...The ACSM1 04 24...

Page 25: ...e 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 the...

Page 26: ...nd free space requirements The modules can be installed side by side The main dimensions of the drive modules as well as free space requirements are shown below For more details refer to the chapter D...

Page 27: ...degrees of protection The cabinet must have enough free space for the components to ensure sufficient cooling Observe the minimum clearances given for each component The air inlets and outlets must be...

Page 28: ...ets 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 equipment must also be ventilated The inter...

Page 29: ...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 30: ...Planning the cabinet assembly 30...

Page 31: ...Mechanical installation 31 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 32: ...three cable clamp plates two for power cabling one for control cabling with screws screw type terminal blocks to be attached to the headers on the JCU Control Unit and the power unit Quick Guide Compa...

Page 33: ...the 4th 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...

Page 34: ...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 35: ...cold plate 2 using a cloth and methylated spirit 3 Apply a thin uniform layer of thermal compound e g WPS II from Austerlitz Electronic GmbH over the entire area of the drive module bottom plate 4 Use...

Page 36: ...Mechanical installation 36 Mains filter installation See the chapter Mains filters on page 87 Braking resistor installation See the chapter Resistor braking on page 91...

Page 37: ...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 38: ...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 39: ...ground 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...

Page 40: ...m 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 It is not recommended to stop th...

Page 41: ...ystem 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...

Page 42: ...nd 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 contacto...

Page 43: ...ACSM1 04 drives are suitable to be used with residual current devices of Type B Other measures for protection in case of direct or indirect contact such as separation from the environment by double or...

Page 44: ...run as twisted pairs Never mix 24 VDC and 115 230 VAC signals in the same cable Relay cable The cable type with braided metallic screen e g LFLEX by Lapp Kabel Germany has been tested and approved by...

Page 45: ...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 46: ...Planning the electrical installation 46...

Page 47: ...ance or insulation resistance tests e g hi pot or megger on any part of the drive as testing can damage the drive Every drive has been tested for insulation between the main circuit and the chassis at...

Page 48: ...e is connected to the resistor and disconnected from the drive output terminals R and R 2 At the drive end connect the R and R conductors of the resistor cable together Measure the insulation resistan...

Page 49: ...x mains filter optional See the chapter Mains filters page 87 Notes If shielded supply input cable is used and the conductivity of the shield is less than 50 of the conduc tivity of a phase conductor...

Page 50: ...will provide better EMC compliance as well as act as a strain relief for the power cables 4 Strip the power cables so that the shields are bare at the cable clamps 5 Twist the ends of the cable shiel...

Page 51: ...conductor is continuous from the distribution board to the drive Grounding the motor cable shield at the motor end For minimum radio frequency interference ground the cable shield 360 degrees at the...

Page 52: ...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 53: ...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 54: ...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 55: ...ugs included the conductors of power 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 Ca...

Page 56: ...ring 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 main...

Page 57: ...Electrical installation 57 Each drive has an independent DC capacitor pre charging circuit The ratings of the DC connection are given on page 76 UDC UDC V1 W1 U1 V2 W2 U2 ACSM1 04 Pre charging circuit...

Page 58: ...DGND 10 Digital input 5 DI5 11 Digital input 6 DI6 12 24 V DC 24VD 13 Digital I O ground DGND 14 Digital input output 1 DIO1 15 Digital input output 2 DIO2 16 24 V DC 24VD 17 Digital I O ground DGND...

Page 59: ...to terminal block X1 Using an external supply is recommended if the application requires fast start after connecting the drive to the main supply fieldbus communication is required when the input powe...

Page 60: ...664 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 termin...

Page 61: ...y stray 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...

Page 62: ...tions Options such as fieldbus adapters I O extensions and encoder interfaces are inserted into slots on the JCU Control Unit See page 22 for the available slots see the appropriate option manual for...

Page 63: ...allation The VAR screw is 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 for more information The...

Page 64: ...Installation checklist 64 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 65: ...l environment the 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 compr...

Page 66: ...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 67: ...ng clip arrowed 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 airf...

Page 68: ...the drawing below Pull the fan holder out and disconnect the wire plug 2 Remove the four screws 3 to release the fan from the holder Use the spacers 4 to mount the new fan Install new fan in reverse o...

Page 69: ...display on the JCU Control Unit The following table describes the indications given by the 7 segment display on the JCU Control Unit Multi character indications are displayed as repeated sequences of...

Page 70: ...Maintenance 70...

Page 71: ...4A 4 C 20 21 24 27 24 18 42 11 15 031A 4 C 27 26 31 35 31 20 54 15 20 040A 4 C 33 29 40 44 35 22 70 18 5 25 046A 4 C 39 35 46 50 38 24 80 22 30 060A 4 D 55 45 60 65 55 28 105 30 40 073A 4 D 65 51 73 8...

Page 72: ...t is derated linearly as follows Supply voltage derating With supply voltages above 400 V AC or 540 V DC the continuous output current is derated linearly as follows Altitude derating At altitudes fro...

Page 73: ...ine the point 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...

Page 74: ...1 2 K maximum The ACSM1 04Cx xxxx x has an internal fan to cool the circuit boards The heat dissipation into air is approximately 200 W Frame size Height without cable clamp plates Height with cable...

Page 75: ...Cross sectional area of cable Rated current A Voltage V Class Rated current A Voltage V UL Class mm2 AWG 02A5 4 3 2 6 500 gG 6 600 T 1 5 4 16 12 03A0 4 4 7 6 500 gG 6 600 T 1 5 4 16 12 04A0 4 5 7 10 5...

Page 76: ...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 asynch...

Page 77: ...ector pitch 3 5 mm wire size 1 5 mm2 As inputs Logic levels 0 5 V 1 15 V Rin 2 0 kohm Filtering Adjustable 0 25 ms min see also Firmware Manual As outputs Total output current limited by auxiliary vol...

Page 78: ...or 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 X7 Connector RJ 45 Cable length 3 m Efficiency Approxim...

Page 79: ...ases 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 600...

Page 80: ...dition 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 require...

Page 81: ...ltage 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 u...

Page 82: ...to neighbouring low voltage networks In some cases the natural suppression in transformers and cables is sufficient If in doubt a supply transformer with static screening between the primary and secon...

Page 83: ...ol connections For the connection diagram and tightening torques see section Connecting the control cables on page 58 Overload protection The drive provides overload protection in accordance with the...

Page 84: ...Technical data 84...

Page 85: ...ent achieve a reduction in the r m s input current reduce supply disturbance and low frequency interference increase the allowed DC bus continuous power ensure even current distribution in common DC c...

Page 86: ...same conductive 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 c...

Page 87: ...and EN 61000 6 3 4 do neither specify cable length nor require a motor to be connected as a load The emission limits are comparable according to the following table A mains filter is required in orde...

Page 88: ...See the 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 module...

Page 89: ...Mains filters 89 Connection diagram AC supply ACSM1 04 CHK xx mains choke if present JFI xx mains filter L1 L2 L3 L1 L2 U1 V1 W1 PE PE L3 L1 L2 L3...

Page 90: ...Mains filters 90...

Page 91: ...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 li...

Page 92: ...esistance 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 the l...

Page 93: ...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 49 Contactor pr...

Page 94: ...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 95: ...Dimension drawings 95 Dimension drawings What this chapter contains Dimension drawings of the ACSM1 04 and related accessories are shown below The dimensions are given in millimetres and inches...

Page 96: ...Dimension drawings 96 Frame size A...

Page 97: ...Dimension drawings 97...

Page 98: ...Dimension drawings 98 Frame size B...

Page 99: ...Dimension drawings 99...

Page 100: ...Dimension drawings 100 Frame size C air cooled module...

Page 101: ...Dimension drawings 101...

Page 102: ...Dimension drawings 102 Frame size C for cold plate mounting...

Page 103: ...Dimension drawings 103 Frame size D air cooled module...

Page 104: ...Dimension drawings 104 Frame size D for cold plate mounting...

Page 105: ...4 13 105 4 13 105 4 13 193 7 60 193 7 60 235 9 25 235 9 25 dim E mm in 114 4 49 148 5 83 148 5 83 148 5 83 118 4 65 169 6 65 125 4 92 147 5 79 F screw size M5 M5 M5 M5 M6 M6 M6 M6 Weight kg lbs 1 8 4...

Page 106: ...Dimension drawings 106 Mains filters type JFI xx...

Page 107: ...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 108: ...Dimension drawings 108 Braking resistors type JBR xx...

Page 109: ...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 110: ...Dimension drawings 110...

Page 111: ......

Page 112: ...3AFE68797543 REV C EN EFFECTIVE 11 6 2007 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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