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EN / ACS800-17 Hardware Manual

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2. PE terminal of the cabinet Electrical installation 69 About power cable busbars and use of cable lugs A view of power cable busbars of large drive units is shown below If necessary the same screw can be used for connecting two cable lugs on both sides of the busbar Cable lugs with one or two holes can be used Always use a torque wrench for tightening the busbar connections Note In inverter modules R6i and R7i only one cable lug can be connected to a busbar screw 3 Wee i j Ak d 7 EI AX Ss Electrical installation 70 Use of conductive sleeves of power cable lead throughs Conductive sleeves are supplied by ABB as an option to provide 360 high frequency earthing for motor cables Follow these instructions e If fire insulation is used make an opening to the mineral wool sheet according to the diameter of the cable Pull the cable into the cabinet through the conductive sleeve If a rubber grommet is used slide it onto the cable Connect phase conductors to terminals Twist the shield wires of the cable together and connect them to earth terminal or PE busbar Peel off 3 to 5 cm of the outer insulation of the cable above the ent
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4. Supply section Braking sections Drive section Auxiliary Incoming gt E ISU Supply Braking Unit Control Unit i E Unit optional SS ES Common DC Bus ACU ICU FIU RDCU roses RMIO I T e rs l l Supply le Inverter Z Unit 5 a i i l o x2 I i l l 24 V l WA l li 230 115 VAC Q 1 l AC Auxiliary control unit The following components are located in the Auxiliary Control Unit of the ACS800 17 Drive section Drive Control Unit RDCU which includes a Motor and UO Controller Board RMIO CDP 31x Control Panel control wiring and relays for e g optional prevention of unexpected start up optional modules I O extension and fieldbus adapter modules pulse encoder interface module etc other options The drive section contains parts listed below inverter inverter cooling fans Optical Branching Unit NPBU with parallel connected units du dt filters optional output cubicle with motor cable entry and exit through the top of the cabinet Hardware description 21 DC fuses not for all inverter sizes cabinet mechanics Example A block diagram of a R11i drive section is shown below Inverter LS Phase E Modules 7 Drive J X W Section Optional Motor Inverter The inverter includes an IGBT output bridge which forms controlled
5. Motor control and I O board RMIO 82 RMIO board specifications Analogue inputs Isolation test voltage Max common mode voltage between the channels Common mode rejection ratio Resolution Inaccuracy Constant voltage output With Standard Application Program two programmable differential current inputs 0 mA 4 mA 20 mA Ri 100 ohm and one programmable differential voltage input 10W 0V 2V 10 V Rin gt 200 kohm The analogue inputs are galvanically isolated as a group 500 VAC 1 min 115 VDC gt 60 dB at 50 Hz 0 025 12 bit for the 10 V 10 V input 0 5 11 bit for the O 10VandO 20 mA inputs 0 5 Full Scale Range at 25 C 77 F Temperature coefficient 100 ppm C 56 ppm F max Voltage Maximum load Applicable potentiometer Auxiliary power output 10 VDC 0 10 VDC 0 5 Full Scale Range at 25 C 77 F Temperature coefficient 100 ppm C 56 ppm F max 10 mA 1 kohm to 10 kohm Voltage Maximum current Analogue outputs 24 VDC 10 short circuit proof 250 mA without any optional modules inserted onto slots 1 and 2 Resolution Inaccuracy Digital inputs Two programmable current outputs 0 4 to 20 mA R lt 700 ohm 0 1 10 bit 1 Full Scale Range at 25 C 77 F Temperature coefficient 200 ppm C 111 ppm F max Isolation test voltage Logical thresho
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7. 9 d Vibration damper flat bar Use M10 or M12 screws Do not weld Mechanical installation 36 Joining the shipping splits Shipping splits are joined in the busbar joining section Special screws M6 for fastening the cabinets together are enclosed in a plastic bag inside the last cabinet of the shipping split The threaded bushings are already mounted on the post Y bushing LA Pee Working order Maximum tightening torque is 5 Nm 3 ft Ibs Fasten the front post of the joining section with seven screws to the front frame post of the next cabinet Mechanical installation 37 200 mm wide joining section Remove the intermediate plate hiding the back posts in the joining section 600 mm wide joining section Remove the partitioning plates Partitioning plate gt Busbar joining Intermediate plate Back posts accessible section Fasten the back post of the joining section with seven screws below the busbar joining part to the post of the next cabinet Replace the intermediate plate and the partitioning plate s in the upper part of it after connecting the DC Busbars see section Connecting the DC busbar and the PE busbar Connecting the DC busbar and the PE busbar Horizontal main DC busbars and the PE busbar are connected from the front of the 200 600 mm
8. Other drives or Medium voltage network Supply transformer Low voltage Other load than s DRIVE drives and motors Other drives and motors Planning the electrical installation 44 Checking the compatibility of the motor See Technical data for the drive ratings and the motor connection data the drive nominal input voltage The allowed range of the motor nominal current is WARNING Operation is not allowed if the motor nominal voltage is less than 1 2 of AN 1 6 2 x long of the drive in DTC control mode or 0 2 x lpg in scalar control mode Protecting the motor winding and bearings The output of the drive comprises regardless of output frequency pulses of approximately 1 35 times the 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 the motor cable properties This in turn can cause additional stress on the motor insulation Modern variable speed drives with their fast rising voltage pulses and high switching frequencies can cause current pulses through the motor bearings which can gradually erode the bearing races The stress on motor insulation can be avoided by using optional ABB du dt filters du dt filters also reduce bearing currents
9. Factory main earth bus Separate protective conductor Galvanised steel or copper armour Drive Section PE U2 V2 W2 Factory main earth bus Separate protective conductor A separate PE conductor system is used only if local safety regulations do not allow earthing of the drive and the motor merely through the cable shield This solution increases motor bearing currents compared to symmetrical shielded cable thus causing extra wear Electrical installation 64 Single inverters Motor cable connections with parallel symmetrical cables are represented below Inverter OUTPUT 2 v2 wa PE SBS 123 123 Electrical installation 65 Location of power cable terminals R6i R7i The cable connections of a bottom entry unit of frame size R7i are represented below In frame size R6i the terminals are located similarly X2 L3 Isolated stud terminals Busbars for input cable connection PE terminal for motor cable connection L1 L2 L3 of the cabinet U2 V2 W2 Electrical installation 66 Location of power cable terminals R8i R9i The cable connections of a bottom entry unit of frame size R9i are represented below In frame size R8i the terminals are located similarly Bottom entry unit Top entry unit Busbars for input and motor cable conn
10. Action Connecting voltage to the drive The possible supply disconnecting and switching options are shown below See the circuit diagrams delivered with the unit for the actual connections customized configurations Switch fuse 10 AGA 5 f AEA Auxiliary voltage Switch fuse and contactor Air circuit breaker T gts L1 L2 p eq EE Ze E Auxiliary i voltage KE voltage WARNING When the disconnecting device s of the Supply Section are closed the voltage will also be connected to the Auxiliary Control Unit and to auxiliary circuits also to the ones wired to drive sections The DC busbars will become live as will all the inverters connected to the DC busbars The DC busbars will be powered to a voltage of 1 35 U4 Make sure that it is safe to connect voltage to the Supply Section Ensure that Nobody is working on the unit or circuits that are wired from outside into the cabinets It is safe to start the motor All cabinet doors are closed Disconnect the 230 VAC cables that lead from the terminal blocks to the outside of the equipment and have not yet been checked and the connections which may not yet have been completed Disconnect the communication link to the overriding system by removing the fibre optic cables Be ready to trip the main breaker of the supply transformer in case something abnormal occurs Ensure that all cabinet doors are closed Close the main breaker of the supp
11. Planning the electrical installation 45 To avoid damage to motor bearings insulated N end non driven end bearings and output filters from ABB must be used according to the following table In addition the cables must be selected and installed according to the instructions given in this manual Three types of filters are used individually or in combinations optional du dt limitation protects motor insulation system and reduces bearing currents common mode filter mainly reduces bearing currents light common mode filter mainly reduces bearing currents The common mode filter is composed of toroidal cores installed onto the output busbars inside the drive at the factory Requirements table The following table shows how to select the motor insulation system and when optional ABB du dt limitation insulated N end non driven end motor bearings and ABB common mode filters are required The motor manufacturer should be consulted regarding the construction of the motor insulation and additional requirements for explosion safe EX motors Failure of the motor to fulfil the following requirements or improper installation may shorten motor life or damage the motor bearings Motor type Nominal mains Requirement for y voltage AC line Motor insulation ABB du dt limitation insulated N end bearing and ABB common voltage system mode filter 9 Py lt 100 kW 100 kW lt Py lt 350 kW Py gt 350 kW E
12. 33 Fastening the shipping split to the floor non marine units Fastening the shipping split to the floor is especially important in installations subjected to vibration or other movement Fastening clamps Insert the clamp into the longitudinal hole in the edge of the cabinet frame body and fasten it with a bolt to the floor Allowed maximum distance between the fastening clamps is 800 mm Fastening hole distances for the common cabinet are given below Fastening bolt M10 to M12 3 8 to 1 2 Cubicle Hole distance mm width LES 1L J ESPE COOC a gt Le b a 200 ca E mA 46 400 a 250 600 a 450 800 a 650 1000 a 350 b 150 a 350 1200 a 450 b 150 a 450 Dimensions of the fastening clamp 1500 a 350 b 150 a 350 b 150 a 350 Cabinet frame body 7 L3 ei Cabinet frame body Mechanical installation 34 Holes inside the cabinet The cabinet can be fastened to the floor using the fastening holes inside the cabinet if they are available and accessible The maximum allowed distance between the fastening points is 800 mm Fastening holes inside the cabinet Side plates of the cabinet 15 mm Back plate of the cabinet 10 mm Gap between the 200 mm 400 mm 600 mm 800 mm 1000 mm and 1500 mm cubicles IP 20 42 IP 54 amp 0 5 z1 Fastening hole distan
13. og ecc cba mo RC ACRI ROC RE ox rie moe AAT e CU C er DE vt as 23 Main circuit diagram uz avs used ela e Role ar tn Rue RO or LEUR EE 23 Voltages from the supply section vicios mene ten Be tebe dod Roe eise Oa en 25 Use of extra RDIO with frame size R12 2 see 25 Mechanical installation What this chapter contains 27 General sueta te sieur uM petes Shen S pu RN 27 Reguired tools cse nea x GER De TOR EEE a ed ace ed or Abe ADIP RUP VOR RO ete A d 27 Cabinet coristructloni s validas a eae aati UR MX re ate afa a c C a de ba RC cod 28 Table of contents 12 Moving of the shipping split I 3n 29 IER 29 Men c TE 30 by split rollers not allowed in marine versions oooooocooooooo oo 30 Final placement of the shipping splits llle 31 Removing the lifting lugs and bars oooooooooorroo oe 31 Working order of the mechanical installation 32 Fastening the shipping split to the floor non marine units 33 Fastening clamps xs gata ony dee os ENEE ey Poway ARA ASA EM E 33 Holes inside the cabinet 2 34 Fastening the shipping splits to the floor and wall marine units 2 35 Joining the shipping splits sasso raini ia e E EE eee ns 36 o o TEE ae Ctl Ce torta iM E Es us 36 Connecting the DC busbar and the PE busbar 0c eee eee eee 37 Kiftinig DAQUDIS TOO Sege Ee ee hito alos Sod lis ates Deena Mica Bos m aeo AE A 39 Miscellaneous d ier wae a eee ee
14. Imax I N4oc 100 96 1 96 h 1000 m 100 m 1 5 40 C Tamp where h altitude above sea level Naoc drive nominal current at 40 C Tamb maximum ambient temperature Note Imax lt Naoc and Tamp lt 40 C At 2000 4000 m optional varistors are needed 2 See section Output current temperature derating Technical data 102 Fuses Only ultra rapid fuses guarantee proper protection for the rectifier semiconductors AC fuses The a c fuses Bussmann used in the ACS800 17 supply sections are listed below Fuse Frequency Frame Supply section Gen converter type size type Un IN bald Type Size V A integral A s Supply voltage 400V IGBT supply ACS800 17 0120 3 R7i 690 350 10000 170M3818 IDIN 43620 DIN1 ACS800 17 0185 3 R8i E 660 630 31000 170M6810 DIN3 ACS800 17 0225 3 R8i E 660 630 31000 170M6810 DIN3 ACS800 17 0265 3 R8i z 660 630 31000 170M6810 DIN3 ACS800 17 0335 3 R9i E 660 1000 140000 170M6814 DIN3 ACS800 17 0405 3 R9i E 660 1000 140000 170M6814 DIN3 ACS800 17 0630 3 R11i ACA 635 0765 3 690 700 60500 170M5874 DIN43653 Q2 ACS800 17 0765 3 R11i ACA 635 0765 3
15. This type of cable is recommended for the pulse encoder signals also Employ one individually shielded pair for each signal Do not use common return for different analogue signals A double shielded cable is the best alternative for low voltage digital signals but single shielded twisted multipair cable Figure b is also usable pue mme mmm mme Double shielded twisted Single Ge twisted pair cable multipair cable Run analogue and digital signals in separate shielded cables Relay controlled signals providing their voltage does not exceed 48 V can be run in the same cables as digital input signals It is recommended that the relay controlled signals be run as twisted pairs Never mix 24 VDC and 115 230 VAC signals in the same cable Relay cable The cable type with braided metallic screen e g LFLEX LAPPKABEL Germany has been tested and approved by ABB Control panel cable In remote use the cable connecting the control panel to the drive must not exceed 3 metres 10 ft The cable type tested and approved by ABB is used in control panel option kits Coaxial cable for use with Advant Controllers AC 80 AC 800 e 75ohm RG59 diameter 7 mm or RG11 diameter 11 mm Maximum cable length 300 m 1000 ft Planning the electrical installation 56 Connection of a motor temperature sensor to the drive I O A WARNING IEC 60664 requires double or reinforced insulation between live parts and the surfa
16. Use separate conduits for input power motor brake resistors and control wiring Do not run motor wiring from more than one drive in the same conduit Armored cable shielded power cable The motor cables can be run in the same cable tray as other 460 V or 600 V power wiring Control and signal cables must not be run in the same tray as power cables 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 amp Cable Philsheath BICC General Corp Philsheath Rockbestos Co Gardex Oaknite CLX Shielded power cables are available from Belden LAPPKABEL LFLEX and Pirelli among others Planning the electrical installation 53 Power factor compensation capacitors Do not connect power factor compensation capacitors or surge absorbers to the motor cables between the drive and the motor They are not designed to be used with drives and will degrade motor control accuracy They can cause permanent damage to the drive or themselves due to the rapid changes in the drive output voltage If there are power factor compensation capacitors in parallel with the three phase input of the drive ensure that the capacitors and the drive are not charged simultaneously to avoid voltage surges which might damage the unit Equipment connected to the motor cable Installation of safety
17. e amp p ACS800 17 1385 6 R12i ACA 635 1385 6 690 700 60500 170M5874 2 PDM code 00145936 G Technical data IGBT supply unit DC fuses 103 The d c fuses Bussmann used in the IGBT supply units are listed below IGBT Supply IGBT Supply Section Frame a Size A Type Section Frame a Size 2 Type Type v A Type Di A 415 V and 500 V Range 690 V Range R11i 660V 3 1000 170M6814 R11i 1250V 3SHT 630 170M6205 R12i R12i Cable entries Tightening torque PDM code 00145936 G The tightening torques for screw connections applicable to zinc and chrome platings and screw strength class 8 8 are listed below pou Torque Nm Soft aluminium Alloyed aluminium and copper M5 3 5 3 5 M6 6 9 M8 17 20 M10 35 40 M12 55 70 M16 130 180 valid also for greased screws Marking Cable connections are marked in the following tables as explained below The terminals accept cable lugs according to DIN 46234 for copper cables and DIN 46329 for aluminium cables 8x 13x18 Jj Note Cable lugs can also be fastened using screws one size down from the hole size Example A cable lug with a hole diameter of 12 5 mm can be fastened with either a M12 or a M10 bolt Number of connection holes in terminal Connection hole or max screw diameter in mm Technical data 104 Connec
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19. the grommet must be sealed by Loctite 5221 catalogue number 25551 Side view Apply Loctite 5221 inside the grommet N V Connect the earthing wire to Fi the PE busbar Attach control pg cables to the supporting plate Electrical installation 77 Installation of optional modules and PC The optional module such as fieldbus adapter I O extension module and the pulse encoder interface is inserted in the optional module slot of the RMIO board and fixed with two screws See the appropriate optional module manual for cable connections Cabling of I O and fieldbus modules Module As short as possible Shield 00090 000 000090 0000 Ir e d P Alternative to a zi Se COCON Grounding wire of the outer shield Strain relief with a cable tie Pulse encoder installation See Pulse Encoder Interface Module RTAC 0x User s Manual 3AFE 64486853 English for the pulse encoder insulation requirements and connections The pulse encoder shall be insulated from the motor stator or rotor in order to prevent currents from finding their way out from the drive shaft through the encoder with resulting damage to the bearings in both the motor and the encoder Electrical installation 78 Pulse encoder module cabling ES Note1 If the encoder is of unisolated 8 Se type ground the encoder cable a
20. 0185 3 R8i IACN634 0265 3 R8i ACN634 0185 3 3650 6 0 1200 625 ACS800 17 0225 3R8i IACN634 0265 3 R8i ACN634 0225 3 3650 7 3 1200 625 ACS800 17 0265 3 R8i IACN634 0265 3 R8i ACN634 0265 3 3650 8 9 1200 625 ACS800 17 0335 3 R9i IACN634 0405 3 RO ACN634 0335 3 3650 11 2 1200 655 ACS800 17 0405 3 R9i IACN634 0405 3 RO ACN634 0405 3 3650 13 9 1200 655 ACS800 17 0630 3 R11i ACA 635 0765 3JACN634 0755 3 R11i ACN634 0635 3 7280 22 0 3600 1490 ACS800 17 0765 3 R11i ACA 635 0755 3 ACN634 0755 3 R11i ACN634 0755 3 7280 27 2 3600 1490 ACS800 17 0935 3 R12i ACA 635 1125 3 ACN634 1125 3 R12i ACN634 0935 3 10330 31 7 4600 2530 ACS800 17 1125 3 R12i ACA 635 1125 3 ACN634 1125 3 R12i ACN634 1125 3 10330 39 3 4600 2530 Supply voltage 500V IGBT supply ACS800 17 0100 5 R6i ACN 634 0140 5 R6i ACN634 0100 5 1920 3 4 730 305 ACS800 17 0140 5 R7i ACN 634 0140 5 R7i ACN634 0140 5 1920 4 9 730 305 ACS800 17 0215 5R8i ACN 634 0325 5 R8i ACN634 0215 5 3650 7 2 1200 625 ACS800 17 0255 5R8i ACN 634 0325 5 R8i ACN634 0255 5 3650 8 8 1200 625 ACS800 17 0325 5R8i ACN 634 0325 5 R8i ACN634 0325 5 3650 11 1 1200 625 ACS800 17 0395 5 R9i ACN 634 0495 5 R9i ACN634 0395 5 3650 13 7 1200 655 ACS800 17 0495 5 R9i ACN 634 0495 5 R9i ACN634 0495 5 3650 17 4 1200 655 ACS800 17 0770 5 R11i ACA 635 0935 5 ACN 634 0925 5 R11i ACN634 0775 5 7280 27 3 3600 1490 ACS80
21. 597 3 x 3x185Al 57Cu 3x49 579 3 x 3x120 70 3x41 696 4 x 3x150Al 41Cu 4 x 44 602 2 x 3x240 120 2x55 705 3 x 3x240Al 72Cu 3x54 669 3 x 3x150 70 3x44 796 4 x 3x185Al 57Cu 4 x 49 765 3 x 3x185 95 3 x 50 940 4 x 3x240Al 72Cu 4 x 54 772 4 x 3x120 70 4x41 995 5 x 3x185Al 57Cu 5 x 49 892 4 x 3x150 70 4x44 1175 5 x 3x240Al 72Cu 5 x 54 903 3 x 3x240 120 3 x 55 1020 4 x 3x185 95 4 x 50 Efficiency and cooling method Efficiency Approximately 96 Cooling method Internal fan flow direction from the bottom to the top Technical data Ambient conditions 101 Environmental limits of the drives are given below The drives are to be used in a heated indoor controlled environment Operation installed for stationary use Storage in the protective package Transportation in the protective package Installation site altitude Nominal output power at 0 to 1000 m 3300 ft above sea level 1 Air temperature 0 to 40 C 32 to 104 F 2 IP 21 22 42 54 0 to 35 C 32 to 95 F 2 IP 54R 40 to 70 C 40 to 158 F 40 to 70 C 40 to 158 F Relative humidity 5 to 95 Max 95 Max 95 No condensation allowed Maximum allowed relative humidity is 60 in the presence of corrosive gases Contamination levels IEC 721 3 3 No conductive dust allowed Boards without coating Chemical gases Cla
22. C IP 21 22 42 54 IP 54R 36 40 44 48 52 T C Input power connection Voltage Us 380 400 415 VAC 3 phase x 10 96 for 400 VAC units 380 400 415 440 460 480 500 VAC 3 phase 10 for 500 VAC units 525 550 575 600 660 690 VAC 3 phase x 10 96 for 690 VAC units Technical data 99 Short circuit capability IEC 439 1 The rated short time withstand current is given below Frame size lcwl4s l ok kA kA ACS800 17 R8i R9i 38 78 ACS800 17 R11i R12i 50 105 Frequency 48 to 63 Hz maximum rate of change 17 s Input voltage unbalance 3 EN 60204 1 Power factor cos 4 1 00 fundamental at nominal load l4 lims COS 4 gt 0 98 total where A is power factor 4 is fundamental input current rms value lms iS total input current rms value Motor connection Voltage U2 0 to U4 3 phase symmetrical Frequency DTC mode 0 to 3 2 ker Maximum frequency 300 Hz f Unmains f FWP 7 D Nmotor Nmotor fewr Frequency at field weakening point Unymains Mains input power voltage UnNmotor Rated motor voltage fumotor Rated motor frequency Scalar control mode 0 to 300 Hz With du dt filter DTC and Scalar Control modes 0 to 120 Hz Frequency resolution 0 01 Hz Continuous current 1 0 2y normal use Short term overload capacity According to rating tables on page 97 Field weakening point 8 to 300 Hz Switching frequency
23. Log E B S ES ae 1 1 y D No s 4 V Le 1X3 AMIN3 dOl 1X3 AYIN3 WOLLOS 8 L 9 S ud e 4 ional drawings IMensiona D 115 ZIS w09 N E AO Ansnpu gav a ee ss IC os 1168 1979 JM on 90g q ON 900 3502 Joes Nj uo pul At den dsey jAHQ3IONIS 164 18 awou yosfoug LE PM bulmoq uoisusuQ 069 005 007 1 008 1950v Z00z DCH wn dv au sawong 225 4 Y woy sap o ONIMVMO NOISNIWI enu 00 24491 Id VIN 139VH paiodeig uo pasog 23 c az 164 9 9870 G4 0 41 008 219S9v SEN 188 9 61 0 82 0 8070 41 008 19S0v E 168 G S6Y0 SE6L0 11 008 L19SDV Su 3 188 G 61 0 S220 8120 41 008 19S0v Pd us as 164 S0v0 GS 0 41 008 219S9v se me Jost os D A Sul s gy S9Z7 SZZ0 S810 1 008 19S9Y z T En 3 O we NE O OQgloogd 23 celo 8 je Sow CS as DCCL z oez i8 3 a rer ni GP EE 008 002 a T ii a se qpo Ajddns 3 S Da 3 cl 7 S9 q02 2010 sec d 3 Sy e ii SSS Si il
24. and or or frame size lt IEC 315 frame size gt IEC 315 frame size gt IEC 400 Py lt 134 HP 134 HP lt Py lt 469 HP Py gt 469 HP and frame size lt or frame size gt NEMA 500 NEMA 500 A Random Un lt 500 V Standard N N CMF B A 500 V lt Uy lt 600 V Standard du dt du dt N du dt N LCMF an B B or Reinforced N N CMF 600 V lt Un lt 690 V Reinforced du dt du dt N du dt N LCMF Form wound 380 V lt Un lt 690 V Standard n a N CMF N CMF HXR and AM_ Old form 380 V lt Uy lt 690 V Check with the du dt limitation with voltages over 500 V N CMF wound HX_ motor and modular manufacturer Random 380 V lt Un lt 690 V Check with the du dt limitation with voltages over 500 V N CMF wound HXR motor and AM_ manufacturer Planning the electrical installation 46 Motor type Nominal mains Requirement for E voltage AC line Motor insulation ABB du dt limitation insulated N end bearing and ABB common voltage system mode filter 9 Py 100 kW 100 kW Py 350 kW Py gt 350 kW E and or or frame size lt IEC 315 frame size gt IEC 315 frame size gt IEC 400 Py lt 134 HP 134 HP lt Py lt 469 HP Py gt 469 HP and frame size lt or frame size gt NEMA 500 NEMA 500 N Random Un lt 420 V Standard L N o
25. but an AC motor cannot rotate without the field generated by an AC voltage The operator activates the prevention of unexpected start function using a switch mounted on a control desk When the function is activated the switch is opened and an indicator lamp will light voltage of the main and auxiliary circuits from the drive Therefore maintenance work on electrical parts of the drive can only be carried out after isolating the drive system from the main supply WARNING The prevention of unexpected start function does not disconnect the Selecting the power cables General rules Dimension the mains input power and motor cables according to local regulations The cable must be able to carry the drive load current See chapter Technical data for the rated currents The cable must be rated for at least 60 C maximum permissible temperature of conductor in continuous use For US see Additional US requirements The inductance and impedance of the PE conductor cable grounding wire must be rated according to permissible touch voltage appearing under fault conditions so that the fault point voltage will not rise excessively when an ground fault occurs 600 VAC cable is accepted for up to 500 VAC For 690 VAC rated equipment the rated voltage between the conductors of the cable should be minimum 1 kV For drive frame size R5 and larger or motors larger than 30 kW symmetrical shielded motor cable must be used
26. cabinets must be avoided Moving of the shipping split is to be done only with the cabinets upright by split rollers not allowed in marine versions Remove the bottom wooden frame which is part of the shipment Lay the shipping split on the rollers and move the unit carefully until it is close to its final location Remove the rollers by lifting the shipping split using a crane or fork lift truck as described above Mechanical installation 31 Final placement of the shipping splits ae e E E Marine units R MM oe einigen II II Tr WARNING Marine units are equipped with vibration ls dampers below the cabinets which may be damaged when moving Be careful when moving the cabinets The cabinets can be moved into their final position by using an iron bar and a wooden piece at the bottom edge of the cabinet Care is to be taken to properly place the wooden piece so as not to damage the cabinet frame Removing the lifting lugs and bars Remove th
27. dux Fab xac ae ea a 40 Cable conduit in the floor below the cabinet 40 Electric welding iss ed leger beeen baw oe a a lea ee 41 Planning the electrical installation What this chapter contains 43 SUDDply iia ha ien Deb ee n an a ee RR e Ee at a A tha Ata tae 43 Checking the compatibility of the motor auaa cee ene 44 Protecting the motor winding and bearings 44 Requirements table 44 ts wisi n Yun En d RC pa ed p e P RR n 45 Permanent magnet synchronous motor 48 Thermal overload and short circuit protection 48 USCS PR MP 48 Earth fault Ground fault protection 2 0 ce SNE KEEN NEE ER Re REIR KREE EE A oa E 48 Emergency SIOD dBVICGS ooh ones Re We secs ROS RUNE A Ea eR ha RC ROI d x We 49 Immediate removal of power Category 0 o ooooccoccococ ee 49 Controlled emergency stop Category 1 49 Restarting after an emergency stop 49 Prevention of unexpected start 50 selecting the power cables i22 zlii a Ga EXT AA RIT 50 GenesralTUl8s ss curie oe tur or e oe A ed e Re Qa Y RA T ene 50 Alternative power Cable types 51 Motor cable stlileld 2 vase lace eee A Elei ER cedo Y Y ais 52 Additional US requirements o ooooooooooo nes 52 Power factor compensation capacitors o o ooooooooocooooo ees 53 Equipment connected to the motor cable lille 53 Installation of safety switches contactors connection boxes ei 53 Before opening a contactor DTC control mode seleched 0000
28. gt 40 ON gt HOO5N U phase V phase R8i R9i NINT NXPP HO9NIE YdON gt E Q O bs V YCONL gt SON don gt z HON lt Z O A phase phase phase Control board interconnection frame size R12i RDCU RMIO NXPP Z INT be NXPP Power plate _ HOENL YGON sl HONG YIIN gt 40 ON gt YdonN gt HO9NIE YadON gt YdoOnN gt Z gt SdOON HN HO95N gt HOON 4 HO95N HOONIE NOOSNI 40 ON gt gt YdON S Two NGDR boards contror B one power plate P P U phase V phase W phase Hardware description 23 Power plate This photo shows one power plate with the NGDR boards connected amp NGDR board P1 P2 terminal Power plate terminal Insulated base plate Main circuit diagram Frame size R8i R9i Frame R8i R9i contains three phase modules each producing one of the three phases driving the motor Power Plate Common DC bus 1 Inverter Optional du dt filter U phase Hardware description 24 Frame size R12i Frame R12i contains three pha
29. o o 0 0 S 3 i i E ui HON OS9Z aer Cent in E 3d y Luz E in E E Sc E e Tia EM E rat a ta Sg Sve WS z8 SEL x Fra 6 S6 G6 UTE Ro 2 S 3 ILLYXL 1OLEXL 16NXL IBYXL OSZi e3 yun Buruoou S 8 BIBIGND OUlUa JO10 N Hu Suonoauuoo zm 2 ajqoo jo Buluoisuawiq m 8 L 9 S H e 4 L 120 drawings Imensiona D 121 i Wo AO Ansnpuj gav ou py BaV e MES CICC CLY9 JAVE ow vg LA ON 90g m0 S N3 Dunn y puny cop dean dO JAINGFIONIS ZIY ONINSINION awou 12efoug e f D yv DCL 20210 uomueut L1 008 L1989 2002 de EZ gj ddy Z00Z eqec yy Payo 19103809 4 S CT wo 91095 sop 009 ONIMVMO NOISNINIO enu Z00Z 99007 AYAI VHIV pouodog uo pesog L gt 9 S8 1 1 008 19 SOV 9 Sv01 1 008 L19 S Y 688 1 1 008 19 S Y 6601 41 008 18 S Y 2 ge TS AO PED 2 2 2 u m s P Zw Cw Pd E P P P 2 scr Zt 008 Era S V p pd CN LL Ca 2 E P J 6960 1 008 19 S Y E X 3 aoos i S SN OO agga FER I I I Gan Kb ERR E on a C 009 1 OO Ulu Sele EA SE EP a E dL Eg o E 9 S 009 0081 ooz 0081 009 009 009 SL 35 ATA pee 9 ESO jid 2 og Nd d o 388 E l e U AA d HL i I I I I E Y I I I I I LI I p a i s SS a 5 C 8 E I DS E 8s 2 c 2 8 Ex de z Gag M ER 5 n e E E E 8 2 H PN 1 t e Ka g Y 5 S m gi 5 Al 8 L 9 S Y E Z
30. of the motor insulation and additional requirements for explosion safe EX motors Note 3 High output motors and IP 23 motors For motors with higher rated output than what is stated for the particular frame size in IEC 50347 2001 and for IP 23 motors the requirements of range 100 kW lt Py lt 350 kW apply to motors with Py lt 100 kW The requirements of range Py gt 350 kW apply to motors with Py within the range of 100 kW lt Py lt 350 kW Note 4 HXR and AMA motors All AMA machines manufactured in Helsinki to be supplied by a drive have form wound windings All HXR machines manufactured in Helsinki since 1997 have form wound windings Note 5 Drives with an IGBT supply unit If voltage is raised by the drive select the motor insulation system according to the increased intermediate circuit DC voltage level especially in the 500 V 10 supply voltage range Note 6 ABB motors of types other than M2 M3_ HX and AM Select according to non ABB motors Note 7 Resistor braking of the drive When the drive is in braking mode for a large part of its operation time the intermediate circuit DC voltage of the drive increases the effect being similar to increasing the supply voltage by up to 20 percent The voltage increase should be taken into consideration when determining the motor insulation requirement Example Motor insulation requirement for a 400 V application must be selected as if the drive were sup
31. or can be connected to the drive inadvertently Check also by measuring that no voltage is actually connected If the motor has a safety switch make sure that it is open If the motor has no safety switch open the circuit Prevention of Unexpected Start if available Find out the following data for each drive section and note down any differences in the delivery documents Motor pulse encoder and cooling fan rating plate data correspond to the values in the motor list Motor temperature measurement method Pt 100 PTC or other Cooling of separately ventilated motors Ensure that the fan motor always starts prior to the drive Check the current drawn by the fan the overcurrent protection setting and the functioning of the fan start stop circuit Direction of motor rotation Maximum and minimum speeds fixed speeds Speed scaling factor gear ratio roll diameter etc Acceleration and deceleration times Inertia compensation Means of stopping the machinery Can the free rotation of the driven machine be stopped if necessary e g in power cut Check the mechanical brakes Operating modes stop mode etc Check that the fan motor protection switches F10 x and 24 V auxiliary voltage optional switch F13 are on See the circuit diagrams of the drive system See the circuit diagrams delivered with the device Start up 89
32. screening between the primary and secondary windings is strongly recommended Medium voltage network Supply transformer Neighbouring network Static screen Point of measurement Low voltage Equipment victim Equipment Equipment 2 The drive is installed according to the instructions given in the Hardware Manual 3 The motor and control cables used are selected as specified in the Hardware Manual Equipment warranty and liability The manufacturer warrants the equipment supplied against defects in design materials and workmanship for a period of twelve 12 months after installation or twenty four 24 months from date of manufacturing whichever first occurs The local ABB office or distributor may grant a warranty period different to the above and refer to local terms of liability as defined in the supply contract The manufacturer is not responsible for any costs resulting from a failure if the installation commissioning repair alternation or ambient conditions of the drive do not fulfil the requirements specified in the documentation delivered with the unit and other relevant documentation units subjected to misuse negligence or accident units comprised of materials provided or designs stipulated by the purchaser In no event shall the manufacturer its suppliers or subcontractors be liable for special indirect inciden
33. system within its locality The Trans Tasman Electromagnetic Compatibility Scheme EMCS was introduced by the Australian Communication Authority ACA and the Radio Spectrum Management Group RSM of the New Zealand Ministry of Economic Development NZMED in November 2001 The aim of the scheme is to protect the radiofrequency spectrum by introducing technical limits for emission from electrical electronic products First environment includes establishments connected to a low voltage network which supplies buildings used for domestic purposes Second environment includes establishments connected to a network not supplying domestic premises Restricted distribution mode of sales distribution in which the manufacturer restricts the supply of equipment to suppliers customers or users who separately or jointly have technical competence in the EMC requirements of the application of drives Unrestricted distribution mode of sales distribution in which the supply of equipment is not dependent on the EMC competence of the customer or user for the application of drives Technical data 112 Compliance with IEC 61800 3 Second environment The drive complies with the limits of IEC 61800 3 with the following provisions 1 Itis ensured that no excessive emission is propagated to neighbouring low voltage networks In some cases the natural suppression in transformers and cables is sufficient If in doubt the supply transformer with static
34. the cabinet cooling air flow from below is prevented by bottom plates around the cable entries See chapter Mechanical installation L1 Mains voltage cannot be applied to the output of the drive with bypass connection Installation checklist 87 Start up What this chapter contains This section describes the hardware commissioning of an ACS800 17 drive section General Perform the drive section commissioning according to this section For the drive control firmware commissioning refer to the application program Firmware Manual Perform the supply section commissioning according to the instructions given in the IGBT Supply Sections User s Manual 3BFE 64013700 English qualified electrician The Safety Instructions on the first pages of this manual must WARNING The work described in this chapter must only be carried out by a be followed Ignoring the safety instructions can cause injury or death WARNING When the main disconnecting device of the Supply Section is closed A DC busbar is live never remove or insert the fuses of a drive section Note The drive section must only be energised de energised by operating the main disconnecting device in the supply section Start up 88 Action Information Checks with no voltage connected A WARNING Ensure that the disconnector of the supply transformer is locked to open position i e no voltage is
35. times according to O parameters 22 02 and 22 03 1 parameters 22 04 and 22 05 3 See par group 12 CONSTANT SPEEDS DI5 DI6 Operation O O Set speed through Al1 1 O Constant speed 1 0 1 Constant speed 2 1 1 Constant speed 3 4 See parameter 21 09 START INTRL FUNC Gi Fault X2 X20 35 1 VREF Reference voltage 10 VDC 1 kohm lt R lt 36 2 AGND 10 kohm X21 7 1 1 VREF Reference voltage 10 VDC 1 kohm lt R lt 2 dcum AGND 10 kohm 13 3 Al1 Speed reference 0 2 10 V Rin gt l l4 14 Al1 200 kohm 5 5 Al2 By default not in use 0 4 20 mA Rin 6 TEE Al2 100 ohm 7 7 Al3 By default not in use 0 4 20 mA Rip 8 leg AI3 100 ohm 9 9 AO1 Motor speed 0 4 20 mA 0 motor nom 10 110 AO1 speed FR lt 700 ohm 11 11 AO2 Output current 0 4 20 mA 2 0 motor 1 112 12 AO2 nom current R lt 700 ohm ES X22 13 1 DI1 Stop Start 14 2 DI2 Forward Reverse 1 15 3 DI3 Not in use 16 4 DI4 Acceleration amp deceleration select 17 5 DI5 Constant speed select 3 18 6 DI6 Constant speed select 3 20 7 24VD 24 VDC max 100 mA 21 8 24VD 22 9 DGND1 Digital ground 23 10 DGND2 Digital ground 19 11 DIL Start interlock 0 stop 4 X23 24 1 24V Auxiliary voltage output non isolated 25 Haasa GND 24 VDC 250 mA X25 26 1 RO1 Relay output 1 r
36. to the vibration dampers may damage electronic circuits in the cabinets or the vibration damper bolts may weld to the cabinet frame The vibration dampers will be damaged if their temperature exceeds 120 degrees Celsius WARNING If the welding return wire is connected improperly the welding circuit Mechanical installation 42 Mechanical installation 43 Planning the electrical installation What this chapter contains Supply A This chapter contains the instructions that you must follow when selecting the motor the cables the protections the cable routing and the way of operation for the drive system Always follow local regulations Note If the recommendations given by ABB are not followed the drive may experience problems that the warranty does not cover WARNING Drive systems larger than 500 kVA must be supplied with a transformer dedicated to drives and motors or equipment of equal or higher power or with a transformer equipped with two secondary windings one of which is dedicated to drives and motors Resonances might occur if there is capacitive load e g lighting PC PLC small power factor compensation capacitors in the same network as the drive The resonance current may damage a unit in the network Medium voltage network Supply transformer Neighbouring network Low voltage Low voltage Other load than Motors DRIVE drives and motors
37. 0 17 0120 3 63 ACS800 17 0100 5 63 ACS800 17 0120 6 63 AACS800 17 0185 3 63 ACS800 17 0140 5 63 ACS800 17 0205 6 63 AAC S800 17 0225 3 63 ACS800 17 0215 5 63 ACS800 17 0255 6 63 AAC S800 17 0265 3 63 ACS800 17 0255 5 63 ACS800 17 0315 6 63 AACS800 17 0335 3 63 ACS800 17 0325 5 63 ACS800 17 0375 6 63 AAC S800 17 0405 3 63 ACS800 17 0395 5 63 ACS800 17 0485 6 63 AAC S800 17 0630 3 68 ACS800 17 0495 5 63 ACS800 17 0750 6 68 AAC S800 17 0765 3 68 ACS800 17 0770 5 68 ACS800 17 0900 6 68 AAC S800 17 0935 3 71 ACS800 17 0935 5 68 ACS800 17 1045 6 71 AAC S800 17 1125 3 71 ACS800 17 1090 5 71 AACS800 17 1385 6 71 AACS800 17 1385 5 71 Applicable standards The drive complies with the following standards The compliance with the European Low Voltage Directive is verified according to standards EN 50178 and EN 60204 1 EN 50178 1997 Electronic equipment for use in power installations EN 60204 1 1997 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 EN 60529 1991 Degrees of protection provided by enclosures IP code IEC 60529 EC 60664 1 1992 Insulation coordination for equipment within low voltage systems Part 1 Principles requirements and tests e EN 61800 3 1996 EMC product standard including spec
38. 0 17 0935 5 R11i ACA 635 0935 5 ACN 634 0925 5 R11i ACN634 0925 5 7280 31 7 3600 1490 ACS800 17 1090 5 R12i ACA 635 1385 5 ACN 634 1385 5 R12i ACN634 1095 5 10330 38 9 4600 2530 ACS800 17 1385 5 R12i ACA 635 1385 5 ACN 634 1385 5 R12i ACN634 1385 5 10330 48 7 4600 2530 Supply voltage 690V IGBTsupply ACS800 17 0120 6 R7i ACN 634 0120 6 R7i ACN634 0120 6 1920 4 1 730 305 ACS800 17 0205 6 R8i ACN 634 0315 6 R8i ACN634 0205 6 3650 7 2 1200 625 ACS800 17 0255 6 R8i ACN 634 0315 6 R8i ACN634 0255 6 3650 8 8 1200 625 ACS800 17 0315 6 R8i ACN 634 0315 6 R8i ACN634 0315 6 3650 10 9 1200 625 ACS800 17 0375 6 R9i ACN 634 0485 6 R9i ACN634 0375 6 3650 13 4 1200 655 ACS800 17 0485 6 R9i ACN 634 0485 6 R9i ACN634 0485 6 3650 17 2 1200 655 ACS800 17 0750 6 R11i ACA 635 0900 6 ACN 634 0905 6 R11i ACN634 0755 6 7280 27 0 3600 1730 ACS800 17 0900 6 R11i ACA 635 0900 6 ACN 634 0905 6 R11i ACN634 0905 6 7280 31 3 3600 1730 ACS800 17 1045 6 R12i ACA 635 1385 6 ACN 634 1385 6 R12i ACN634 1045 6 10330 38 1 4600 2530 ACS800 17 1385 6 R12i ACA 635 1385 6 ACN 634 1385 6 R12i ACN634 1385 6 10330 48 7 4600 2530 PDM code 00145936 G with cable top entry exit additional 200 mm is required in frame sizes R11i and R12i Technical data 108 Noise The noise values of the ACS800 17 units are given below Noise Noise Noise Type dB Type dB Type dB ACS80
39. 0 e eee ees 53 Relay output contacts and inductive loads 54 Selecting the control Cables d cance trm PI e dE nete b RR PE pec bos 55 Relay cable reret li AE bd Wem eh asd UR sate ne E oat ates dr ERE Rod eee p AR 55 Control panel cable db VR evene a eS E ECCO E REP RA Ea d 55 Coaxial cable for use with Advant Controllers AC 80 AC G001 oo 55 Connection of a motor temperature sensor Ioibedriveli es 56 Table of contents ROUTING the Cables EE EE EE 56 Eopttroleabledugele da 57 Electrical installation What this chapter contains o o oooooooooo ett 59 la Elei Ree 59 Motor and motor cable oers iraire ree ad Eea sr 59 Input power cable wiring diagramS o trea wie od Pe RS a CC IR RUE RED UR dod a 60 LOW power supply osc ha EENEG na AURA REA oa ald ACER OR VAR 60 High power supply or ori tr ARR EO La ER REC Y ed VI d e EH NOR s 61 Motor cable wiring diagramS 15 3 3 e a a dot Dif RR ee iD EES EE 63 Single E 2 2 05 Bate ce y chased Mq es haw Dos e I delit eh ate ae P iei oad 64 Location of power cable terminals R6i Ro 65 Location of power cable terminals R8i Rou 66 Location of motor cable terminals R11i and R12i bottom entry 67 Location of motor cable terminals R11i and R12i top exit llle 68 About power cable busbars and use of cablelugs ooooccocoooccc ee 69 Use of conductive sleeves of power cable lead throughs ssileel sells 70 Use of common mode filters on the moto
40. 00 ACS800 17 0765 3 R11i 1094 765 630 821 1231 751 1502 ACS800 17 0935 3 R12i 1336 935 710 1002 1503 901 1802 ACS800 17 1125 3 R12i 1624 1125 900 1218 1827 1126 2252 Supply voltage range 380 400 415 440 460 480 or 500 V ACS800 17 0100 5 R6i 112 100 75 84 126 84 168 ACS800 17 0140 5 R7i 164 140 110 135 203 135 270 ACS800 17 0215 5 R8i 246 215 160 185 277 164 328 ACS800 17 0255 5 R8i 295 255 200 221 332 200 400 ACS800 17 0325 5 R8i 368 325 250 276 414 240 480 ACS800 17 0395 5 R9i 448 395 315 336 504 300 600 ACS800 17 0495 5 R9i 565 495 400 424 636 365 730 ACS800 17 0770 5 R11i 887 770 630 665 998 570 1140 ACS800 17 0935 5 R11i 1073 935 710 805 1208 694 1388 ACS800 17 1095 5 R12i 1263 1095 900 947 1421 855 1710 ACS800 17 1385 5 R12i 1593 1385 1120 1195 1793 1040 2080 Supply voltage range 525 550 575 600 660 or 690 V ACS800 17 0120 6 R7i 105 120 90 88 132 88 176 ACS800 17 0205 6 R8i 176 205 160 132 198 127 254 ACS800 17 0255 6 R8i 210 255 200 158 236 150 300 ACS800 17 0315 6 R8i 264 315 250 198 297 179 358 ACS800 17 0375 6 R9i 310 375 315 233 349 225 450 ACS800 17 0485 6 R9i 410 485 400 308 461 265 530 ACS800 17 0750 6 R11i 1630 750 630 473 709 428 856 ACS800 17 0900 6 R11i 755 900 710 566 849 504 1008 ACS800 17 1045 6 R12i 874 1045 800 656 983 641 1282 ACS800 17 1385 6 R12i 1156 1385 1120 867 1301 755 1510 Technical data 98 Normal Use Duty Cycle lon Rated rms output current max
41. 00 units which employ the RMIO board Note for terminal blocks X2 and 2TB The terminals of the RMIO board are wired to optional terminal block X2 or 2TB if present Note for external power supply WARNING If the RMIO board is supplied from an external power source the loose A end of the cable removed from the RMIO board terminal must be secured mechanically to a location where it cannot come into contact with electrical parts If the screw terminal plug of the cable is removed the wire ends must be individually insulated Motor control and I O board RMIO 80 External control connections non US External control cable connections to the RMIO board for the ACS 800 Standard Application Program Factory Macro are shown below For external control connections of other application macros and programs see the appropriate Firmware Manual Terminal block size X20 to X27 cables 0 3 to 3 3 mm 22 to 12 AWG X2 0 5 to 2 5 mm 22 to 14 AWG 7 Tightening torque X20 to X27 0 2 to 0 4 Nm 0 2 to 0 3 Ibf ft X2 0 4 to 0 6 Nm 0 3 to 0 4 Ibf ft n ech a 1 Only effective if par 10 03 is set to REQUEST by the user 2 0 open 1 closed J DI4 Ramp
42. 2 p gixel es Ire OL Es7xY Iszi st joy eae i8 Y TEET El ys ER 009 iS 009 za CH amp 90000 E E Tr BIXEL gt gt Zal 2 iS D 01X001 n5 alla cl 2 ald S A 7373 S JEU drat la 33 A ext EE S H s suscita Bs ES H 1 83 00000 H SC SE e sa OS9TL 921 C 6v 5 E ti EE al E Das a EES El SC won E E z B E E a H fm Re S 3 Ol peers H Toi El al ve SSS 0L el el el el 3 Al EENS PREISEN Ei d Ja qp ele oosz 009 3 yun Bunuoou 8 N Suonosuuoo z 3 a qpo jo Suluoisuawig S Lt E Lt X S a o e us 009 D 5 O D SIN e Ej O EUR IC ont F i TE S oign2 ouiuJe 4010 N Se ely re 8 L 9 S y c L drawings Imensiona D AA ED ER P ED Ip 3AFE 64681338 Rev B EN EFFECTIVE 10 3 2003 ABB Oy AC Drives P O Box 184 FIN 00381 HELSINKI FINLAND Telephone 358 10 22 11 Telefax 358 10 22 22681 Internet http www abb com ABB Inc Drives and Power Electronics 16250 West Glendale Drive New Berlin WI 53151 USA Telephone 262 785 3200 800 243 4384 Telefax 262 780 5135
43. 3 kHz Maximum recommended motor cable length For cables longer than 500 metres 1640 ft cumulative length in case of parallel connected motors an ABB representative must be consulted With pulse encoder speed measurement the maximum cable length is 300 m With du dt filters refer to du dt Filters Installation Guide 3AFE 58933368 English For additional EMC requirements on cable length refer to section CE marking below Technical data 100 Motor bearings Insulated bearing at the non driven end is recommended Cable types The tables below give the copper and aluminium cable types for different load currents Lmax A correction factor of K 0 70 has been used max 9 cables laid on a cable ladder side by side three ladders on top of each other ambient temperature 30 C 86 F EN 60204 1 and IEC 364 5 523 COPPER CABLES WITH ALUMINIUM CABLES WITH A CONCENTRIC COPPER SCREEN A CONCENTRIC COPPER SCREEN l max Cable type Diameter Imax Cable type Diameter A mm A mm 255 3x185 95 50 SE 2 x 3x95Al 29Cu 2 x 38 274 2 x 3x70 35 2 x 32 302 2 x 3x120Al 41Cu 2x41 301 3x240 120 55 986 2 x 3x150AI 41Cu 2x44 334 2 x 3x95 50 2x 38 398 2 x 3x185Al 57Cu 2x49 386 2 x 3x120 70 2x41 470 2 x 3x240Al 72Cu 2x54 446 2 x 3x150 70 2x44 522 3 x 3x150AI 41Cu 3 x 44 510 2 x 3x185 95 2x50
44. 690 700 60500 170M5874 2 ACS800 17 0935 3 R12i ACA 635 1125 3 690 900 125000 170M5876 lad ee ACS800 17 1125 3 R12i ACA 635 1125 3 690 900 125000 M70M5876 2 Supply voltage 500V IGBT supply ACS800 17 0100 5 R6i E 660 200 2200 170M3815 DIN 43620 DIN1 ACS800 17 0140 5 R7i s 690 350 10000 170M3818 DIN1 ACS800 17 0215 5 R8i 5 660 630 31000 170M6810 DIN1 ACS800 17 0255 5 R8i E 660 630 31000 170M6810 DIN1 ACS800 17 0325 5 R8i E 660 630 31000 170M6810 DIN1 ACS800 17 0395 5 R9i E 660 1000 140000 170M6814 DIN3 ACS800 17 0495 5 R9i E 660 1000 140000 170M6814 DIN3 ACS800 17 0770 5 R11i ACA 635 0935 5 690 700 60500 170M5874 DIN43653 D ACS800 17 0935 5 R11i ACA 635 0935 5 690 700 60500 170M5874 2 ACS800 17 1095 5 R12i ACA 635 1385 5 690 900 125000 170M5876 la amp p ACS800 17 1385 5 R12i ACA 635 1385 5 690 900 125000 170M5876 2 Supply voltage 690V IGBT supply ACS800 17 0120 6 R7i E 660 200 2200 170M3815 DIN 43620 DIN1 ACS800 17 0205 6 R8i a 1250 400 19500 170M6303 3SHT ACS800 17 0255 6 R8i E 1250 400 19500 170M6303 3SHT ACS800 17 0315 6 R8i 1250 400 19500 170M6303 3SHT ACS800 17 0375 6 R9i S 1250 630 83500 170M6205 3SHT ACS800 17 0485 6 R9i 2 1250 630 83500 1170M6205 3SHT ACS800 17 0750 6 R11i ACA 635 0900 6 690 900 125000 170M5876 DIN43653 l2 ACS800 17 0900 6 R11i ACA 635 0900 6 690 900 125000 170M5876 2 ACS800 17 1095 6 R12i ACA 635 1385 6 690 700 60500 170M5874
45. 8 6 12 270x911 6 ACS800 17 1385 5 R12i ACA 635 1385 5 8x 13x18 6 12 270x911 6 Supply voltage 690V IGBT supply ACS800 17 0120 6 R7i 3 75x239 3 ACS800 17 0205 6 R8i 4x 13x18 6 75x239 6 ACS800 17 0255 6 R8i 4x 13x18 6 75x239 6 ACS800 17 0315 6 R8i 4x 13x18 6 75x239 6 ACS800 17 0375 6 RSi 4x 13x18 6 75x239 6 ACS800 17 0485 6 R89i 4x 13x18 6 75x239 6 ACS800 17 0750 6 R11i ACA 635 0900 6 6x 13x18 6 9 270x911 6 ACS800 17 0900 6 R11i ACA 635 0900 6 6x 13x18 6 9 270x911 6 ACS800 17 1095 6 R12i ACA 635 1385 6 8x 13x18 12 195x501 12 ACS800 17 1385 6 R12i ACA 635 1385 6 8x 13x18 12 195x501 12 Isolated stud terminals for the motor cable maximum number of cable connections per phase 1 cable cross section 25 120 mm 3 250 MCM tightening torque 30 Nm 265 Ibf in Mains cable terminal M10 bolt 1 The number of holes when common output cubicle is used for top exit is as follows Frame size Number of holes per phase R11i R12i 8 Technical data 105 Cabinet Below are the cabinets degrees of protection and free space requirements Degree of Space Space Space on Space in Protection above below left right front back mm mm mm mm IP 21 IP 22 IP 42 IP 54 IP 54 R 500 0 0 DU 1 DIP21 standard R air outlet duct 2 200 between cabinets when installed back to back W P4 r2 Technical data 106 Cool
46. ACS 800 Hardware Manual ACS800 17 Drives 75 to 1120 kW AA ED ED FADD ED ACS800 17 Drives 75 to 1120 kW Hardware Manual 3AFE 64681338 Rev B EN EFFECTIVE 10 3 2003 2003 ABB Oy All Rights Reserved Safety instructions What this chapter contains This chapter contains safety instructions 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 two types of safety instructions throughout this manual warnings and notes Warnings caution you about conditions which can result in serious injury or death and or damage to the equipment and advise on how to avoid the danger Notes draw attention to a particular condition or fact or give information on a subject The warning symbols are used as follows Dangerous voltage warning warns of high voltages which can cause physical injury and or damage to the equipment electricity which can result in physical injury and or damage to the equipment General warning warns about conditions other than those caused by Electrostatic discharge warning warns of electrostatic discharge which A can damage the equipment Safety instructions Installation and maintenance work These warnings are intended for all who work on the drive motor cable or m
47. Pozidrive and Torx 2 5 6 mm screwdrivers for the tightening of the frame screws torque wrench 19 mm wrench set for tightening the DC horizontal busbars between shipping splits 17 mm wrench set for tightening the PE busbars between shipping splits Mechanical installation 28 Cabinet construction In marine versions the cabinet includes in addition vibration dampers and handles on the doors I Marine Applications ACS 800 MarineDrive ACS800 17 ACS800 17 frame size R7i frame size R9i Mechanical installation 29 Moving of the shipping split by crane Use the steel lifting lugs attached to the top of the cabinets Insert the lifting ropes or slings into the holes of the lifting lugs The lifting lugs can be removed not mandatory once the cabinets are in their final location If the lifting lug is removed the bolts for each lug must be refastened to maintain the degree of protection of the cabinet Ut DOLL GOU monnunum ET La ACS800 17 IP 54 Allowed minimum height of lifting ropes or slings for IP 54 shipping splits is 2 metres Mechanical installation 20 by fork lift The centre of gravity may be quite high Be therefore careful when transporting the shipping splits Tilting of the
48. V ach S N N Electrical installation Bee LES ESTIZET LEZ 73 External control cable connections Connect the control cables to the appropriate terminals on terminal block X2 or 2TB see Motor control and I O board RMIO or other options on the DIN rail Connect the twisted shield as short as possible to the earthing terminal C Supply unit control connections The supply unit is controlled using the local control devices mounted on the cabinet door No external control connections by the user are needed However the user can connect certain external devices to the supply module It is possible to control the supply unit through the remote control inputs On Start Reset External fault halt the supply unit by an external emergency stop button if the unit is equipped with a local emergency stop button read supply unit s status information through the relay outputs Fault Running Earth fault emergency stop Refer to the circuit diagrams delivered with the drive for the connection terminals for the external control devices For additional information on the control connections see the ACA631 633 Cabinet installed Diode Supply Unit DSU User s Manual Code 64735501 English available through ABB representatives EMC earthing at the cable entry 360 high frequency earthing of the control cable shield at the cable entry is availab
49. a c voltage from the intermediate circuit d c voltage An inverter controls one motor Frame Size An Inverter Unit ACN 634 xxxx includes R6i to R9i one inverter module ACN 634 xxxx gt one inverter ES R11i R12i three phase modules ACN 634 xxxx one inverter ES Control boards One phase module block includes the following boards main circuit interface board NINT This board gives the control commands and sends measurement signals two control distribution boards NXPP in frame size R11i and up These boards distribute the control commands given by the NINT board gate driver boards NGDR These boards amplify the control pulses for the insulated gate bipolar transistors IGBTs Hardware description 22 power supply board for gate drivers NGPS in V phase module power supply board NPOW 62 in V phase module Control board interconnection frame sizes R6i to R9i RDCU RMIO A NINT HON e HON U V W R6i R7i Two NGDR boards Power plate _ control one power plate Control board interconnection frame size R111 Power plate _ Two NGDR boards control M HN one power plate RDCU RMIO 1 RDCU RMIO NINT HOENL sl YadON S
50. allation checklist 86 INSTALLATION CHECKLIST The appropriate DC fuses are installed See chapter Technical data The motor is of correct voltage The motor star delta connection at the motor terminal box is correct Motor cable routing Check that the toroidal cores are properly installed on the motor cable when a common mode filter is required The motor connections at U2 V2 and W2 are OK The unused conductive sleeves at cable entries are tied up with cable ties There are no power factor compensation capacitors in the motor cable The control connections inside the frame are OK UD DD DD DD If a pulse encoder is used check the encoder cables and correct direction of rotation see chapter Electrical installation and Pulse Encoder Interface Module RTAC 0x User s Manual 3AFE 64486853 English Thermistor cables The connections are appropriate for the sensor used in the motor Prevention of Unexpected Start cables Emergency stop cables UD DD If other external cables are used make sure that both ends of the cables are connected and the cables do not cause any damage or danger when power is being switched on O Cleanliness of the cabinet and surroundings eg there are no tools or other foreign objects inside the cabinet or waste left from installation e g cable trimmings there is no garbage under the cabinet the cooling air fan will draw the garbage inside the cabinet When there is a cable conduit below
51. ation code 64556568 English available on request for other available earth fault protection options Planning the electrical installation 49 The EMC filter if present includes capacitors connected between the main circuit and the frame These capacitors and long motor cables increase the earth leakage current and may cause fault current circuit breakers to function Emergency stop devices For safety reasons install the emergency stop devices at each operator control station and at other operating stations where emergency stop may be needed Pressing the stop key Q on the control panel of the drive or turning the operating switch of the drive from position 1 to 0 does not generate an emergency stop of the motor or separate the drive from dangerous potential An emergency stop function is optionally available for stopping and switching off the whole drive Two modes are available immediate removal of power Category O and controlled emergency stop Category 1 Note The emergency stop function must not be used for stopping the drive in normal use Immediate removal of power Category 0 After the emergency stop button is pushed the power semiconductors of the inverter unit are blocked coast stop and the main contactor or air circuit breaker is opened immediately No attention is paid to deceleration of the motor and the driven machinery Controlled emergency stop Category 1 The installer must make
52. cables in a cable tray This derating factor must be taken into account as per the local electrical safety codes Electrical installation 62 Single core cables with concentric protective shields When single core cables equipped with concentric protective shields metal are used the phase current will induce voltage to the cable shield If the shields are connected to each other at both ends of the cable current will flow in the cable shield In order to prevent this and to ensure personal safety the cable shield must be connected only to PE at the transformer side and insulated on the converter side The connection is represented below Transformer Converter L1 AAA LI L2 L2 L3 L3 N PE PE Concentric shield Factory main earthing bus Electrical installation Motor cable wiring diagrams Motor cable connections for different cable types are represented below For minimum radio frequency interference RFI at the motor end earth the cable shield 360 degrees at the lead through or earth the cable by twisting the shield flattened width gt 1 5 length 63 A oo Concentric Al Cu shield PE Drive Section U2 V2 W2 Factory main earth bus Oz Concentric Al Cu shield and steel or aluminium armour Drive Section PE U2 V2 W2
53. ce of accessible parts of electrical equipment which are either non conductive or conductive but not connected to the protective earth To fulfil this requirement the connection of a thermistor and other similar components to the digital inputs of the drive can 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 analogue 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 insulation of the relay must be rated for the same voltage level as the main circuit of the drive For connection see the Firmware Manual 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 parallel runs of motor cables with other cables in order to decrease electromagnetic interference caused by the rapid changes in the drive output voltage Where control cables must cross power cables make sure they are arranged at an angle as near to 90 degrees as possible Do not run extra cables through the drive The cable trays must have good electrical bonding to each o
54. cer eee 88 Connecting voltage to the drive 0 cee e he 89 Checks with voltage connected to the drive sechon 0 000 e eee es 90 Orisdoad checks viaria AEN wth EE AS RO RU E ae da ba lea A 90 Checks of the overriding control link if musel 90 Preventive maintenance What this chapter contains 91 Gen etal ENEE 91 EISES est eed send Bw steed dE eet Mckee Rone Oy yada eee eae EE glk Bed dees 91 Heatsink A eher Z Eet dtes Susana ee ao se ae boats lace Sa EELER 91 Relays oue oce et Me Meee dll Me ak espe E E etica E ege E dee 91 FAN Li rss Re a Roe e EE 91 Spare modules ef xe Re Ace say AUR ORG CRURA GLA SCA AERA RID ab ENEE Ee RR a 92 Capacitors ses usc ies dues uot CRAT EROR REIHE RES Uo SUE RD Et Pape Urn deed E LA D M ICE den Gok be 92 Reforming Lor oes debe Do O verd ees He ethics Sape x ha AAA 92 Technical data What this chapter contains 97 Ratings an e aa Ee ade te EE ROG a t e tubum ua MO UE EE 97 Output current temperature derating 98 Derating Belle TE RER 98 Input power connection sss ssas rr 98 Motor connection isi vise seb ada a Be RARO CBE edP VOR aa e AER ED 99 Efficiency and cooling method 2 dune oes EE a dc ege Pen a 100 Ambient conditons sees ers cR o noe te A dee a ae ald kale ES REOR RC UA T 101 gir 102 ACTUSOS 4 1 emn bessere 2 Vi Jove EES 102 IGBT supply unit DC fuses 103 Cable entries ovr a a ED eu mox Reed etie e sce 103 Tightening Torque Lu fest eor ROREM daa etu M TR 103 c
55. ces for the common cabinet are given below Fastening bolt M10 to M12 3 8 to 1 2 Cubicle width Hole distance mm s oes ii 31 mm 200 a 50 400 a 250 600 a 450 800 a 650 1000 a 350 b 150 a 350 1200 a 450 b 150 a 450 1500 a 350 b 150 a 350 b 150 a 350 Mechanical installation 35 Fastening the shipping splits to the floor and wall marine units The shipping split must be fastened to the floor and roof wall in marine versions as follows Fasten the shipping split to the floor with M10 or M12 bolts through the holes in Use a clamp not included the vibration damper flat bar Back CONU EES 2 If there is not enough room behind the A Do cabinets for installation use the N fastening method shown in figure 2 O O 2 S 3 Fasten the upper vibration dampers A A For the positions of the upper T ON A vibration dampers see the mU a zeg deeem nave oH o accompanying dimension drawing of EGRESOS the shipping eal Fasten the support arms to the upper vibration dampers and roof wall Side view 2 Support am not included 4 3 p 4 LEUR Selflocking nut M12 DIN985 Torque 13 Nm a Top view ek Upper vibration dampers Use M12 screws
56. creased gradually with e g 100 V steps Maximum recommended reforming current is 500 mA An appropriate reforming voltage is 1 35 V2 U The reforming circuit is shown below See Figure 1 for reforming time Preventive maintenance 95 WARNING The converter supply must be disconnected while the reforming circuit is connected DC Power or phase module Supply Disconnect from W2 W1 supply 1 35 Us Se V2 V1 U2 U1 Converter R 100 Ohm 500 W Preventive maintenance 96 Preventive maintenance 97 Technical data What this chapter contains This chapter describes the technical data concerning the ACS800 17 Ratings The ratings for the ACS800 17 with 50 Hz and 60 Hz supplies are given below Normal use Duty cycle 1 5min Duty cycle 10 60s Drive 2N SN PN l2hd l2hd Ing I2hd Drive type frame 4 5min 1 5min 50 60s 10 60s size A kVA kW A A A A Supply voltage range 380 400 or 415 V ACS800 17 0120 3 Ra 178 120 90 147 221 147 294 ACS800 17 0185 3 R8i 259 185 132 194 291 178 356 ACS800 17 0225 3 R8i 312 225 160 234 351 216 432 ACS800 17 0265 3 R8i 379 265 200 284 426 260 520 ACS800 17 0335 3 R9i 474 335 250 356 533 316 632 ACS800 17 0405 3 R9i 576 405 315 432 648 395 790 ACS800 17 0630 3 R11i 907 630 500 680 1020 600 12
57. ctor system PE Tai three phase conductors CQO and a protective conductor Not allowed for motor cables Not allowed for motor cables with phase conductor cross section larger than 10 mm motors gt 30 kW Planning the electrical installation 52 Motor cable shield To effectively suppress radiated and conducted radio frequency emissions the shield conductivity must be at least 1 10 of the phase conductor conductivity The requirements are easily met with a copper or aluminium shield The minimum requirement 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 The better and tighter the shield the lower the emission level and the bearing currents Insulation jacket Copper wire screen Helix of copper tape Inner insulation Additional US requirements Cable core Type MC continuous corrugated aluminum armor cable with symmetrical grounds or shielded power cable must be used for the motor cables if metallic conduit is not used For the North American market 600 VAC cable is accepted for up to 500 VAC 1000 VAC cable is required above 500 VAC below 600 VAC For drives rated over 100 amperes the power cables must be rated for 75 C 167 F Conduit Where conduits must be coupled together bridge the joint with a ground conductor bonded to the conduit on each side of the joint Bond the conduits also to the drive enclosure
58. d circuit boards contain components sensitive to electrostatic discharge Wear a grounding wrist band when handling the boards Do not touch the boards unnecessarily Safety instructions Grounding These instructions are intended for all who are responsible for the grounding of the drive Incorrect grounding can cause physical injury death or equipment malfunction and increase electromagnetic interference WARNING e Ground the drive the motor and adjoining equipment to ensure personnel safety in all circumstances and to reduce electromagnetic emission and pick up e Make sure that grounding conductors are adequately sized as required by safety regulations e Ina multiple drive installation connect each drive separately to protective earth PE e Do not install a drive equipped with an EMC line filter to an ungrounded power system or a high resistance grounded over 30 ohms power system Note e Power cable shields are suitable for equipment grounding conductors only when adequately sized to meet safety regulations e As the normal leakage current of the drive is higher than 3 5 mA AC or 10 mA DC stated by EN 50178 5 2 11 1 a fixed protective earth connection is required Fibre optic cables WARNING grab the connector not the cable itself Do not touch the ends of the fibres with bare hands as the fibre is extremely sensitive to dirt The maximum allowed bend radius is 25 mm 1 in i e Hand
59. disconnecting device means instead use the control panel keys XI and Q or commands via the I O board of the drive The maximum allowed number of charging cycles of the DC capacitors i e power ups by applying power is five in ten minutes Note If an external source for start command is selected and it is ON the drive with Standard Application Program will start immediately after fault reset unless the drive is configured for 3 wire a pulse start stop When the control location is not set to Local L not shown in the status row of the display the stop key on the control panel will not stop the drive To stop the drive using the control panel press the LOC REM key and then the stop key Q Safety instructions 10 Permanent magnet motor These are additional warnings concerning permanent magnet motor drives WARNING Do not work on the drive when the permanent magnet motor is rotating Also when the supply power is switched off a rotating permanent magnet motor feeds power to the intermediate circuit of the drive and also the supply connections become live even when the inverter is stopped Installation and maintenance work Disconnect the motor from the drive with a safety switch and additionally if possible lock the motor shaft and ground the motor connection terminals temporarily by connecting them together as well as to the PE Operation Do not run the motor above the rated speed Motor ove
60. e lifting bars if used after lifting as they disturb the cooling of the unit Remove the lifting lug of marine versions Refasten the original bolts or fasten the upper vibration dampers if used in order to maintain the degree of protection of the cabinet p Mechanical installation 32 Working order of the mechanical installation LLLL LW LS LUC WEM P M pum or 200 mm when installed ack to back Fasten the first shipping split to the floor with fastening clamps or through the holes inside the cabinet See section Fastening the shipping split to the floor non marine units In marine versions fasten the first shipping split to the floor and roof wall as described in section Fastening the shipping splits to the floor and wall marine units Note Any height adjustment of the cabinets must be done before fastening the cabinets together Height adjustment can be done by using metal shims between the bottom frame and floor Remove the lifting bars if used and the lifting lugs in marine applications Place the original bolts or upper vibration dampers to the holes Fasten the first shipping split to the next shipping split Each shipping split includes a 200 600 mm joining cabinet Fasten the second shipping split to the floor Connect the DC busbars and the PE busbar Lift the upper part of the cabinet roof up if a double roof exists Mechanical installation
61. e motor is running or not The brake control terminals UDC UDC R and R terminals carry a dangerous DC voltage over 500 V Depending on the external wiring dangerous voltages 115 V 220 V or 230 V may be present on the relay outputs of the drive system The Prevention of Unexpected Start function does not remove the voltage from the main and auxiliary circuits Safety instructions A Ate WARNING Make sure that dust from drilling does not enter the drive when installing Electrically conductive dust inside the unit may cause damage or lead to malfunction Fastening the cabinet by riveting or welding is not recommended However if the cabinet is fastened by welding connecting the return wire improperly may damage electronic circuits in the cabinet Ensure that welding fumes are not inhaled Ensure sufficient cooling If the drive is equipped with a double roof ensure that the roof is lifted up from the transportation position to enable the cooling air flow before starting the drive Air flow from below from a cable conduit to the cabinet must be prevented to ensure the degree of protection and fire protection Cooling fans may continue to rotate for a while after the disconnection of the electrical supply Some parts inside the drive cabinet such as heatsinks of power semiconductors remain hot for a while after the disconnection of the electrical supply WARNING The printe
62. eady 27 2 RO1 m 28 3 RO1 m X26 29 1 RO2 m Relay output 2 running 30 2 RO 31 3 RO X27 32 1 RO3 Relay output 3 fault 1 33 2 RO3 34 3 RO3 Motor control and I O board RMIO 81 External control connections US External control cable connections to the RMIO board for the ACS 800 Standard Application Program Factory Macro US version are shown below For external control connections of other application macros and programs see the appropriate Firmware Manual 2TB X20 Terminal block size 35 1 VREF Reference voltage 10 VDC 1 kohm lt R lt X20 to X27 cables 0 3 to 3 3 mm 22 to 36 zur AGND 10 kohm 12 AWG x21 X2 0 5 to 2 5 mm m 1 Seseli VREF Reference voltage 10 VDC 1 kohm lt R lt 22 to 14 AWG V 12 MR AGND 10 kohm Tightening torque 13 3 Al1 Speed reference 0 2 10 V Rin gt X20 to X27 0 2 to 0 4 Nm 1 4 4 AM 200kohm 0 2 to 0 3 Ibf ft 5 5 Al2 By default not in use 0 4 20 mA Rin X2 0 4 to 0 6 N
63. ection X2 Busbars for input cable connection PE terminal L1 L2 L3 ofthe cabinet Busbars for motor cable connection U2 V2 W2 Electrical installation 67 Location of motor cable terminals R11i and R12i bottom entry The cable connections of a bottom entry unit of frame size R11i are represented below In frame size R12i the terminals are located similarly The input cables are lead via the Incoming Unit To gain access to the motor cable terminals remove the cooling fans as follows 4 Disconnect the cables detachable terminal 5 Undo the fastening screws 6 Lift the fan from the cabinet 7 Remove the shrouds IGBT Supply Unit DC fuses Busbars for motor PE terminal cable connection of the cabinet U2 V2 W2 Electrical installation 68 Location of motor cable terminals R11i and R12i top exit This cubicle is used for motor cable entry and exit through the top of the cabinet Cable entry from the bottom is shown below The top entry is accomplished in the same way except that cables are entering or exiting the cabinet from the top These busbars connect inverter units parallel Busbar for motor cable connection ef Cable lugs T gt V2 Motor cable PE conductor shield of the cable
64. eo X E Id OH 9 E o a o i 5 Z io r B Do em zm i ZS 10 1938 BAG ozz 001 d LI 1 zl H d an S mE e OH 3 Bx ee al nsi 1 13 El H te x i N c i S o rl 2 N SE Ild z E H PIE we TFE 9 9o 3 3 l bad nol sd Ea 1 g woo i E oo os EM 2 os 3 a uonoas MOV DS okor El El 18 2 del eme ty E of GAR E els B i ER Ss 92 di 6006 190 vC H Isle lel Ya 2006 10 vC pappo ga ubnojj poot 9 als 22 fo Kasnpui gay uappiqio Anoujs si Ajuoujno ssejdxo ou san pi PAU 07 BANSOIOSIP jo esn uononpoldew ueJou paujiuoo uonbuuojui OU uj PUD iuetunoop SU U SJU p Sue oM bwo v0 GG000 E m o o u Dimensional drawings 118
65. f a Supply Section and a Drive Section This manual covers Hardware description of the Drive Section Mechanical and electrical installation of the Supply Section and the Drive Section Commissioning of the Drive Section Note For Supply Section commissioning parameters fault tracing and product information see GBT Supply Sections User s Manual 3BFE 64013700 English Preventative maintenance and hardware based fault tracing Note Fault and warning messages given by the software are described in the Firmware Manual or in the IGBT Supply Sections User s Manual 3BFE 64013700 English Other manuals IGBT Supply Sections User s Manual 3BFE 64013700 English Firmware Manual for ACS 800 Standard Application Program 64527592 English Application Guide for the Adaptive Programming 64527274 English Option manuals appropriate manuals is delivered with the option Delivery check Check that there are no signs of damage Before attempting installation and operation check the information on the drive nameplate to verify that the unit is of the correct model Each drive is fitted with a nameplate for identification purposes The nameplate data includes a type code and a serial number which allow individual recognition of each unit The type code contains information on the size and voltage rating The first digit of the serial number refers to the manufacturing plant The next four digits refer to the uni
66. figure below A four conductor system can be used up to frame size R4 with up to 30 kW motors but shielded symmetrical motor cable is recommended Planning the electrical installation 51 A four conductor system is allowed for input cabling but shielded symmetrical cable is recommended To operate as a protective conductor the shield conductivity must be as follows when the protective conductor is made of the same metal as the phase conductors Cross sectional area of the phase Minimum cross sectional area of the conductors corresponding protective conductor S mm Sp mm S lt 16 S 16 lt S 36 16 35 lt S S 2 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 screen should be kept as short as possible in order to reduce electromagnetic emission as well as capacitive current Alternative power cable types Power cable types that can be used with the drive are represented below Recommended Symmetrical shielded cable three phase conductors A separate PE conductor is required if the conductivity and a concentric or otherwise symmetrically of the cable shield is lt 50 of the conductivity of the constructed PE conductor and a shield phase conductor PE conductor hield and shield Shiela PE ett Shield A four condu
67. i ala e SIE E i i ES u ES m FE I I I 1 I T I ed EC 3 79 SA 5928 Si 3 S189 E N E 1 El NR de Y E Suonosuuoo aqu 1X3 AMIN3 WOLLOB8 8 il 9 S H e 4 wings onal dra Imernsti D 116 AQ isnou Gay edid ON PU BY oes ZLE eus 1168 19v9 jJV eu vog qB dE W ON 000 15M 25 3 N3 Du 9 Pu en yep dsey 3AIBQT19NIS 163 ewou ele BE vv DC ung voisuei q 069 006 00v 1 008 7 198v Z00Z POTZ AN uddy en suono 52
68. ific test methods Amendment A11 2000 UL 508C UL Standard for Safety Power Conversion Equipment second edition CSAC22 2 No 14 95 Industrial control equipment Materials Enclosure Coating Colour thickness hot dip zinc coated steel sheet 1 0 to 2 5 mm with 60 um RAL 7035 light beige semigloss polyester thermosetting powder coating in visible surfaces Flat busbars aluminium standard copper optional tin plated copper optional Package wood or plywood seaworthy package Plastic covering of the package PE LD bands PP or steel Technical data 109 Transportation Length max 4 metres weight max 2400 kg Position upright Max crate dimensions length shipping length 100 mm depth shipping split depth 150 mm height cabinet height 80 mm Max seaworthy dimensions length shipping length 200 mm depth shipping split depth 185 mm height 2200 mm Disposal The drive contains raw materials that should be recycled to preserve energy and natural resources The packing materials of the drive units and options are environmentally compatible and recyclable All metal parts can be recycled The plastic parts can either be recycled or burned under controlled circumstances according to local regulations If recycling is not feasible all parts excluding electrolytic capacitors can be landfilled The DC capacitors of the unit contain electrolyte which is classified as hazardo
69. imum continuous long Rated rms output current output current Sn Rated apparent output power Px Typical motor power The power ratings in kW apply to most IEC 34 motors The current ratings are the same regardless of the supply voltage within one voltage range The rated current of the drive must be higher than or equal to the rated motor current to achieve the rated motor power given in the table Note 1 The load capacity current and power decreases if the installation site altitude exceeds 1000 metres or if the ambient temperature exceeds 40 C units with degree of protection IP 21 22 42 54 Note 2 Usually du dt filters are needed at the output of 525 V to 690 V units with random wound motors No du dt filters are usually required with form wound motors Output current temperature derating The output current is calculated by multiplying the current given in the rating table by the derating factor Temperature derating factor for degree of protection IP 21 22 42 54 General rule Above 40 C the rated output current is decreased 1 5 for every additional 1 C up to 50 C Example 1 If the ambient temperature is 50 C the derating factor is 100 1 5 SC 10 C 85 or 0 85 The output current is then 0 85 lon or lon Derating diagram The effect of ambient temperature on the continuous load capacity of the AC800 17 is shown below Current 100 95 90 85 80 11 5 per each
70. ing air dimensions This table gives the depth of the cabinet The height of the switch fuse handle is 45 mm from the cabinet door Depth mm Depth of the frame 600 Depth of the roof 644 Depth including the door the frame and the back plate 637 Depth including the door the frame the back plate and 678 the flash barrier Added depth including air circuit breaker spacer frame 60 and door frame measured from door Added depth of air circuit breaker spacer frame door 178 frame and transparent cover measured from door Added depth of switch fuse measured from door 45 This table gives the height of the cabinet Height mm Height of the cabinet with a double lifted roof 2121 Height of the ACS800 17 cabinet IP 21 2062 Height of the IP 54R cabinet 2072 Technical data Air flow requirements 107 Below are cooling air flow requirements heat losses dimensions and weights of ACS800 17 A EE IGBT Supply s section e flow Heat loss Width Weight Stee Section type Module type size Module type m h kW mm kg Supply voltage 400V IGBT supply ACS800 17 0120 3 R7i IACN634 0120 3 R7i ACN634 0120 3 1920 4 1 730 305 ACS800 17
71. lds Input current Filtering time constant With Standard Application Program six programmable digital inputs common ground 24 VDC 15 to 20 and a start interlock input Group isolated can be divided in two isolated groups see Isolation and grounding diagram below Thermistor input 5 mA lt 1 5 kohm 1 normal temperature gt 4 kohm 0 high temperature open circuit 0 high temperature Internal supply for digital inputs 24 VDC short circuit proof An external 24 VDC supply can be used instead of the internal supply 500 VAC 1 min 8VDC 0 gt 12 VDC 1 DI1 to DI 5 10 mA DI6 5 mA 1 ms Motor control and I O board RMIO Relay outputs 83 Switching capacity Minimum continuous current Maximum continuous current Contact material Isolation test voltage DDCS fibre optic link Three programmable relay outputs 8 A at 24 VDC or 250 VAC 0 4 A at 120 VDC 5 mA rms at 24 VDC 2 Arms Silver Cadmium Oxide AgCdO 4 kVAC 1 minute 24 VDC power input With optional communication adapter module RDCO Protocol DDCS ABB Distributed Drives Communication System Voltage Typical current consumption without optional modules Maximum current consumption 24 VDC 10 250 mA 1200 mA with optional modules inserted The terminals on the RMIO board as well as on the optional modules attachable to the board fulfil the Protective Extra Low V
72. le as an option from ABB figure below Side view Top view Lead through plate TA E EMI conductive cushions c C a J A i v Holes for a position screws Base plate E f E 7A Electrical installation 74 Special for top entry When each cable has its own rubber grommet sufficient IP and EMC protection can be achieved However if very many control cables come to one cabinet plan the installation beforehand as follows Make a list of the cables coming to the cabinet Sort the cables going to the left into one group and the cables going to the right into another group to avoid unnecessary crossing of cables inside the cabinet Sort the cables in each group according to size Group the cables for each grommet as follows Cable diameter in mm Max number of cables per grommet lt 13 4 lt 17 3 lt 25 E 225 1 Divide the bunches so that cables will be arranged according to size between the EMI conductive cushions View from below Thinnest cable Thickest cable Electrical installation 75 Bottom and top entry Proceed as follows Loosen the ead through plate position screws Pull the two parts apart Bottom entry Lead the cable inside the cabinet through the EMI conductive cushions Top entry Lead the cable inside the cabinet through the gro
73. le the fibre optic cables with care When unplugging optic cables always Safety instructions Operation These warnings are intended for all who plan the operation of the drive or operate the drive Ignoring the instructions can cause physical injury or death or damage the equipment WARNING A If the drive is equipped with an optional brake unit make sure there are inverters connected to the intermediate circuit before start As a rule of thumb the sum capacitance of the inverters connected must be at least 30 of the sum capacitance of all inverters Close the switch fuses of all parallel connected inverters before start Do not open the DC switch fuse of an inverter when the inverter is running Do not use the Prevention of Unexpected Start feature for stopping the drive when the inverter unit s is running Give a Stop command instead WARNING Before adjusting the drive and putting it into service make sure that the motor 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 automatic fault reset functions of the Standard Application Program if dangerous situations can occur When activated these functions will reset the drive and resume operation after a fault Do not control the motor with the
74. ly transformer Close the main disconnecting device of the Supply Section Close the main disconnecting switch of the auxiliary circuit if present Close the main contactor breaker of the Supply Unit Information See the circuit diagrams delivered with the device Start up 90 Action Checks with voltage connected to the drive section Set the drive parameters according to the application Firmware Manual Check that the Prevention of Unexpected Start if available is working Stop the drive by a Stop command and wait until the drive has stopped Open the Prevention of Unexpected Start switch by opening the switch on the control desk the circuit will open The lamp if fitted on the desk should be lit Give a Start command The drive should not start Reset the drive Information See the circuit diagrams delivered with the device On load checks Check that the cooling air fans rotate freely in the right direction and the air flows upwards Check the rotation direction of the motor Check the pulse encoder functioning if present Check the emergency stop function of the system from each operating place A paper sheet set on the lower gratings stays The fan runs noiselessly See Pulse Encoder Interface Module RTAC Ox User s Manual 3AFE 64486853 English Checks of
75. m 0 3 to 0 4 Ibf ft CEA 7 7 Al3 By default not in use 0 4 20 mA Rin 8 18 Al3 100 ohm ech 18 9 AO1 Motor speed 0 4 20 mA 2 0 motor nom 10 110 AO1 speed FR lt 700 ohm AA AA 11 11 AO2 Output current 0 4 20 mA 2 0 motor Y 12 12 AO2 Mom current R lt 700 ohm ER X22 p 9 9 13 1 DI1 Start T 1 Only effective if par 10 03is setto 2 2 14 2 DI2 Stop 1 REQUEST by the user 15 3 DI3 Forward Reverse 1 SC 16 4 DI4 Acceleration amp deceleration select 2 2 0 open 1 closed 00 E17 5 DIS Constant speed select 2 f ES A DI4 Ramp times according to 18 6 DI6 Constant speed select 2 0 parameters 22 02 and 22 03 20 GET 24VD 24 VDC max 100 mA 1 parameters 22 04 and 22 05 GER vue 8 24VD DENM CEN 22 9 DGND1 Digital ground GE 23 10 DGND2 Digital ground DIS ne Opec 19 11 DIL Startinterlock 0 stop O O Set speed through Al1 X23 1 To Constant speed 1 24 1 24V Auxiliary voltage output non isolated 0 1 Constant speed 2 25 ase 12 GND 24 VDC 250 mA 1 1 Constant speed 3 X25 26 1 RO1 Relay output 1 ready 4 See parameter 21 09 START INTRL 27 2 RO1 ee FUNC 8 28 3 RO1 X26 29 1 RO2 Relay output 2 running 30 2 RO2 r amp 9 43 3 Ro2 X27 Gi 32 1 RO3 4 Relay output 3 fault 1 Fault 33 2 ROS 7 34 BEER ROS rt
76. ments are available from ABB Do not attempt operation with other than ABB specified spare parts Reforming Converter DC link capacitors need to be reformed re aged if the converter has been non operational for more than one year Without reforming capacitors may be damaged when the converter starts to operate The reforming methods introduced here require that the converter has been stocked clean and dry It is recommended to reform the capacitors once a year How to check the converter age Converter serial number defines the week when the converter has been built e 8 digit e g 18250125 1 denotes manufacturing country 1 Finland 8 manufacturing year 1998 25 manufacturing week and 0125 running manufacturing number 10 digit e g 1983200725 1 denotes manufacturing country 98 manufacturing year 32 manufacturing week and 00725 running manufacturing number Reforming time The intermediate circuit of the converter is kept at its nominal voltage for the reforming time to wake up the capacitors The reforming time required depends on how long the converter has been stocked non operational Preventive maintenance 93 Reforming time hours 6 T A 3 2 1 0 1 2 3 4 5 6 Non operational time years Method 1 Method 2 Figure 1 Capacitor reforming time for Method 1 and Method 2 Converters stocked non operational for less than 2 years Swi
77. mmet and the EMI conductive cushions If you have several cables bunch them together at the grommet but ensure that each cable has a proper contact to the cushions on both sides Strip off the cable plastic sheath above the base plate just enough to ensure proper connection of the bare shield and the EMI conductive cushions Earth the shield between the EMI conductive cushions If the outer surface of the shield is conductive Push the two parts of the ead through plate together so that the EMI conductive cushions press tightly round the bare shield If the outer surface of the shield is covered with non conductive material Stripped cable Conductive surface of Stripped part covered the shield exposed with copper foil Cable shield 4 Shielded twisted pair Earthing wire Cutthe shield at the midpoint of the bare part Be careful not to cut the conductors Turn the shield inside out to expose its conductive surface Cover the turned shield and the stripped cable with copper foil to keep the shielding continuous Note The earthing wire if present must not be cut Push the two parts of the ead through plate together so that the EMI conductive cushions press tightly round the foil covered shield Lock the two parts of the lead through plate by tightening the positioning screws Electrical installation 76 Top entry If more than one cable go through a grommet
78. node number of this RDIO module is 7 Other optional modules can be chained with it to channel CH1 as usual For more information refer to ACA 610 Modification Instruction 3AFE 64163671 English Hardware description 26 Hardware description 27 Mechanical installation What this chapter contains General This chapter provides instructions for moving the shipping splits fastening them to the floor and joining them together Instructions concerning only some types are marked See chapter Technical data for allowed operating conditions and requirements for free space around the unit The drive cabinets should be installed in an upright vertical position The floor that the unit is installed on should be of non flammable material as smooth as possible and strong enough to support the weight of the unit The floor flatness must be checked with a spirit level before the installation of the cabinets into their final position The maximum allowed deviation from the surface level must be lt 5 mm measured every 3 m The installation site should be levelled if necessary as the cabinet is not equipped with adjustable feet The wall behind the unit should be of non flammable material Required tools The tools required for moving the shipping splits to their final location fixing them to the floor and tightening the connections are listed below iron bar and roller tubes or similar for moving a shipping split e
79. not used if the supply cable shield operates as a protective conductor Electrical installation 61 High power supply Busbar connection A high current gt 300 A busbar connection is represented below Metal conduit shield Transformer 7 Converter AO AE ay E Tu L2 I3 N El E d d 2 gt 2 If L3 57 LA pte Eee tem emm m Es Ni EEN E Se o EE ES 0 1 Connect the metal PE l PE conduit of the busbar 2 S system or the metal of the bus duct to PE at either one end or both ends Factory main earthing bus Note The paint should be removed to allow a good connection to the cabinet frames throughout the whole perimeter of the metal conduit or a bus duct The metal conduit or the bus duct metal should be electrically continuous throughout its complete length Cable bus system The connection of a high current gt 300 A cable bus system that consists of several cables is represented below In this system less conductor material is needed due to better cooling of separate conductors Transformer Converter b db UE ETH E It is recommended to arrange the cables as shown alongside to achieve a current distribution as accurate as possible Air between cables is required for cooling Factory main earthing bus Note Current derating of the cables is required when installing the
80. of sales distribution in which the supply of equipment is not dependent on the EMC competence of the customer or user for the application of drives Compliance with the EMC Directive Second environment The requirements of the EMC Directive can be met as follows 1 The motor and control cables are selected as specified in the Hardware Manual 2 The drive is installed according to the instructions given in the Hardware Manual 3 Maximum cable length is 100 metres When the cable length is over 100 metres the requirements of the EMC Directive can be met as follows for restricted distribution 1 Itis ensured that no excessive emission is propagated to neighbouring low voltage networks In some cases the natural suppression in transformers and cables is sufficient If in doubt the supply transformer with static screening between the primary and secondary windings can be used Medium voltage network Supply transformer Neighbouring network Static screen Point of measurement Low voltage Equipment victim Equipment Equipment 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 Hardware Manual 4 The drive is installed according to the instructions given in the Hardware Manual Machinery Di
81. oltage PELV requirements stated in EN 50178 provided that the external circuits connected to the terminals also fulfil the requirements Motor control and I O board RMIO 84 Isolation and grounding diagram Test voltage 500 V AC X20 1 VREF 2 AGND X21 1 VREF 2 AGND 3 Ais A AM Common mode 3 NEE E iis Gate A 6 Al2 7 Al3 8 Al3 9 AO1 10 AO1 11 AO2 x 12 AO2 X22 1 DM 2 DI2 3 DI3 E je 4 DI4 9 DGND1 5 DI5 1 6 DI6 o 7 24VD lt gt 8 24VD FE 11 DIIL 10 DGND2 4 X23 1 24 V 2 GND lt X25 1 RO1 4 2 ROT 3 RO1 X26 1 RO2 4 2 RO2 Li 3 RO2 L X27 1 RO3 4 2 ROS Li 3 RO3 Test voltage 4 kV AC Jumper J1 settings 1 o All digital inputs share a common a ground This is the default setting Grounds of input groups DI1 DI4 and DI5 DI6 DIIL are separate isolation voltage 50 V Ground der e NY Motor control and I O board RMIO 85 Installation checklist What this chapter contains This chapter represents the installation checklist General It is advisable to go through the checklist belo
82. otor Ignoring the instructions can cause physical injury or death WARNING A Only qualified electricians are allowed to install and maintain the drive Never work on the drive the motor cable or the motor when main power is applied After switching off the input power always wait for 5 min to let the intermediate circuit capacitors discharge before you start working on the drive the motor or the motor cable Measure the voltage between terminals UDC and UDC with a multimeter impedance at least 1 Mohm to ensure that the drive is discharged before beginning work Apply temporary grounding before working on the unit 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 to exist inside the drive even when the main power of the drive is switched off Do not make any insulation tests without disconnecting the drive from the cabling first When reconnecting the motor cable always check that the phase order is correct When joining shipping splits if any check the cable connections at the joints before switching on the supply voltage Live parts on the inside of the doors are protected against direct contact Special attention shall be paid when handling metallic shrouds Note The motor cable terminals on the drive are at a dangerously high voltage when the input power is on regardless of whether th
83. ow direction must be from bottom to top Also use a vacuum cleaner at the air outlet to trap the dust Fan rotation must be prevented in order to prevent bearing damage Relays should be checked for function and all connections should be inspected and checked for tightness Any signs of corrosion especially in ground components shall be cleaned off The cooling fan lifespan is approximately 40 000 hours The actual lifespan depends on the drive usage and ambient temperature Fan failure can be predicted by increasing noise from fan bearings and gradual rise in the heatsink temperature in spite of heatsink cleaning If the drive is used in a critical part of a process fan replacement is recommended once these symptoms appear Preventive maintenance 92 Spare modules It is recommended to reform the capacitors of the spare modules once a year by e g replacing the cabinet modules with their spare modules This also equalizes wear on the modules See section Capacitors below Capacitors The drive intermediate circuit employs several electrolytic capacitors The lifespan of the capacitors is approximately 100 000 hours depending on the drive loading and the ambient temperature Capacitor life can be prolonged by lowering the ambient temperature It is not possible to predict a capacitor failure Capacitor failure is usually followed by a mains fuse failure or a fault trip Contact ABB if capacitor failure is suspected Replace
84. plied with 480 V Note 8 Calculating the rise time and the peak line to line voltage The peak line to line voltage at the motor terminals generated by the drive as well as the voltage rise time depend on the cable length The requirements for the motor insulation system given in the table are worst case requirements covering the drive installations with 30 metre and longer cables The rise time can be calculated as follows At 0 8 j du dt Read j and du dt from the diagrams below 4 4 3 5 T 3 5 3T 3 t 251 25 UL Un all duldt kV us D ae e 1 57 1 5 1 1 0 5 7 0 5 y IN UR i O 4 0 100 200 300 400 368 don 300 Aon Cable length m Cable length m Without du dt Filter With du dt Filter Planning the electrical installation 48 Permanent magnet synchronous motor Only one permanent magnet motor can be connected to the inverter output Install a safety switch between a permanent magnet synchronous motor and the motor cable The switch is needed to isolate the motor during any maintenance work in the drive Wire the position information of the safety switch to the drive Before starting any maintenance work on the drive the safety switch must be opened and the open position acknowledged by the drive application program Thermal overload and short circuit protection A The drive protects itself and the input and motor cables against thermal overload when the cable
85. r CMF N CMF O wound and 1300 V n form wound 40 V lt Uy lt 500 V Standard j du dt du dt N du dt N CMF 1300 V or A du dt CMF B or B Reinforced U N or CMF N CMF 1600 V 0 2 microsecond rise time 500 V lt Uy lt 600 V Reinforced du dt du dt N du dt N LCMF 1600 V or du dt CMF or Reinforced Du N or CMF N CMF 1800 V 600 V lt Uy lt 690 V Reinforced j du dt du dt N du dt N LCMF 1800 V Form wound 600 V lt Un lt 690 V Reinforced j n a N CMF N CMF 2000 V 0 3 microsecond rise time manufactured before 1992 Note 1 The abbreviations used in the table are defined below Abbreviation Definition Un nominal voltage of the supply network Ou peak line to line voltage at motor terminals which the motor insulation must withstand Py motor nominal power du dt du dt filter at the output of the drive or internal du dt limitation CMF common mode filter E208 3 toroidal cores LCMF light common mode filter E209 1 toroidal core N N end bearing insulated motor non driven end bearing na Motors of this power range are not available as standard units Consult the motor manufacturer Planning the electrical installation 47 Note 2 Explosion safe EX motors The motor manufacturer should be consulted regarding the construction
86. r cable 6 0 saana ee ee 71 Control cable connections at shipping split joints 72 External control cable connections 73 Supply unit control connections 73 EMC earthing at the cable ent 73 Installation of optional modules and PC 77 Cabling of I O and fieldbus modules 77 Pulse encoder installation lll 7T Fibre optlG linc ss oen e eR ead o ea te atn tob e Re e Ten fatto ET 78 Motor control and I O board RMIO What this chapter contains 79 To which products this chapter applies 0000 cee 79 Note for terminal blocks X2 and 27 mp tte 79 Note for external power supply 79 External control connections non US elles 80 External control connections US 81 RMIO board specifications 82 Analogue le Le EE EE 82 Constant voltage Output tooo ane Ge wa bad ba as ong a Oe a a 82 Auxiliary power output o 82 Analogue Outputs 4 weng Se ee Poe SEENEN A AAA Se Sede A hee 82 Digital Inpllls es saie d ad ea Sree Maes TEE EEN 82 Relay QUIPULS eed egre nina Raa Ee ER A Hox de Wn Sg eRe AS mares tes 83 DDCS fibre Optic link a dao 83 ZA VDC power input 4 uo NN TEE AA loan EC C ee i aa 83 Table of contents 14 Installation checklist What this chapter contains aaas asana ccs 85 General s AA A UY Wee na avn a abe diate AV UN CA aaa ab healed Ata os 85 Start up What this chapter contains 87 GOT Chal EEN EE 87 Checks with no voltage connected ocooooooc
87. rective The drive complies with the European Union Machinery Directive 98 37 EC requirements for an equipment intended to be incorporated into machinery Technical data 111 CSA marking The CSA marking is often required in North America CSA marked ACS800 17 drives are available on request up to 600 V The drive is suitable for use in a circuit capable of delivering not more than 65 kA rms symmetrical amperes at 600 V maximum The drive provides overload protection in accordance with the CSA standard C22 2 No 14 and the National Electrical Code US See ACS 800 Firmware Manual for the parameter setting The setting is OFF by default it must be activated at start up The drive is to be used in a heated indoor controlled environment See section Ambient conditions for specific limits C tick marking C tick marking is required in Australia and New Zealand A C tick mark is attached to each drive in order to verify compliance with the relevant standard IEC 61800 3 1996 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test methods mandated by the Trans Tasman Electromagnetic Compatibility Scheme Definitions EMC stands for Electromagnetic Compatibility It is the ability of electrical electronic equipment to operate without problems within an electromagnetic environment Likewise the equipment must not disturb or interfere with any other product or
88. relay contacts of the RMIO board are protected with varistors 250 V against overvoltage peaks In spite of this it is highly recommended to equip inductive loads with noise attenuating circuits varistors RC filters AC or diodes DC in order to minimize the EMC emission at switch off If not suppressed the disturbances may connect capacitively or inductively to other conductors in the control cable and form a risk of malfunction in other parts of the system Install the protective component as close to the inductive load as possible Do not install the protective components at the terminal block Terminal block RMIO board X2 optional Relay outputs Varistor X25 X25 a 1 RO1 NC 1 RO1 Ste o 4 230 VAC 2 RO C 2 RO C 3 RO1 NO 3 RO1 NO RC filter X26 XS CH 1 RO2 NC 1 RO2 NC 4 230vac 1 2 RO2 C 2 RO2 C E 3 RO2 NO 3 RO2 NO Diode X27 x A 1 RO3 NC 1 RO3 NC O Wi shee 24 VDC 2 RO3 C 2 ROS C 3 RO3 NO 3 RO3 NO Planning the electrical installation 55 Selecting the control cables All control cables must be shielded Use a double shielded twisted pair cable Figure a e g JAMAK by NK Cables Finland for analogue signals
89. rspeed leads to overvoltage which may result in explosion of the capacitors in the intermediate circuit of the drive Application program Controlling a permanent magnet motor is only allowed using the ACS 800 Permanent Magnet Synchronous Motor Drive Application Program or using other application programs in scalar control mode only Safety instructions 11 Table of contents Safety instructions What this chapter contains o oooooooo eee es 5 Use Or warnings end ales or se oe E A ole som esa cea a eee sree tre ek See ye 5 Installation and maintenance work 6 E le Le Wee c say ea blas dle Eo aia ES ad Sue deb d 8 Al A EE EE 8 Operation ctetu rk epica Wei ES Oe wale EE d E E REA ER 9 Permanent magnet motor 25i e dde AUR eR elo EE Ee AE Ron ei og c A 10 Installation and maintenance work 10 Operation SCC CRT uc 10 Application progra Mres sainia a as 10 Table of contents Introduction Overview of the manual 17 iere Ela E EE eate aaa o ia ud genta ees oce Bret oer 17 Delivery check ro Aen Se idres NON 17 ele UU 18 Hardware description What this chapter contains aineis menean a E S da es 19 Main components of the ACGpOU1 es 19 Frame sizes ROIO ROI ics sse ast A RO eae tai dh ord ad ak eA 19 Frame sizes R11i and R12i cd coco 19 Auxillary Control Unit sie ceo e ER d Ob tee oe dace PROS Oe wee CERA AR qd E 20 Drive TEE 20 E une EE 21 lk 21 Control boards i eae Rd e FT a AO A A 21 Power plate
90. ry plate for the 360 high frequency earthing Fasten the conductive sleeve to the cable shield with a cable tie Seal the slot between the cable and mineral wool sheet if used with sealing compound e g CSD F ABB brand name DXXT 11 code 35080082 Tie up the unused conductive sleeves with cable ties Cable entry from below for power cables of drive IP 21 and IP 22 is shown below Tighten the EMC sleeve on the stripped part of the cable with cable ties For IP 54 units add a rubber grommet on the cable under the lead through plate Strip this part of the cable TER Base plate AAA Lead through plate Electrical installation 71 Use of common mode filters on the motor cable If common mode filter or light common mode filter is required see Planning the electrical installation Checking the compatibility of the motor Requirements table lead the motor cable phase conductors through the toroidal cores as follows e e Connect the twisted cable shield to the PE terminal Wrap the phase conductors together with the silicon rubber tape delivered with the toroidal cores to provide thermal insulation for the conductor insulator Cover the part of the cable which will be left inside the core s 20 mm below Approximately 1 5 metres of tape is needed per cable Each turn must overlap the previous turn by half the width of the tape Bind the conductors tightly wi
91. s are dimensioned according to the nominal current of the drive No additional thermal protection devices are needed WARNING If the drive is connected to multiple motors a separate thermal overload switch or a circuit breaker must be used for protecting each cable and motor These devices may require a separate fuse to cut off the short circuit current The drive protects the motor cable and the motor in a short circuit situation when the motor cable is dimensioned according to the nominal current of the drive Fuses A Fuses are needed to protect the supply section and the inverter of the drive in case of an internal short circuit The ACS800 17 is equipped with internal input fuses introduced in chapter Technical data If a fuse is blown it must be replaced with a similar ultrarapid fuse WARNING Circuit breakers are not capable of providing sufficient protection because they are inherently slower than fuses Always use fuses with circuit breakers Earth fault Ground fault protection Both the supply unit and the inverter unit are equipped with an internal earth fault protective function to protect the drive against earth faults in the motor and the motor cable This is not a personal safety or a fire protection feature Both earth fault protective functions can be disabled refer to User s Manual of the supply unit and the Firmware Manual of the drive application program respectively See the ACS800 Ordering Inform
92. se modules each producing one of the three phases driving the motor Each phase module consists of three parallel connected power plates Six IGBTs with free wheeling diodes are integrated to a single power plate The figure below shows the connection of one phase Power Plate Phase Module Common DC bus Note DC fuses are included in frames 2 x R11i 2 x R12i and 4 x R11i only Hardware description 25 Voltages from the supply section The supply section supplies the inverter via the DC busbar The inverter also takes energy from the DC busbar to make control voltages for the control boards and auxiliary voltage for I O board Voltage for the inverter cooling fans is taken from a 230 115 V a c transformer in the Auxiliary Control Unit via thermal protection switch The 24 V auxiliary voltage source is powered from the 230 115 V a c transformer in the Auxiliary Control Unit The emergency stop and the optional uninterrupted power supply UPS are wired from the Auxiliary Control Unit Use of extra RDIO with frame size R12i Note This section concerns drive frame size R12i with ACS 800 Standard Application Program An additional Digital I O Extension Module RDIO is installed in the drives at the factory The configuration blocks inverter pulses in case of a 230 115 V auxiliary power supply failure thus preventing incorrect control of the IGBTs The
93. ss 3C1 Solid particles Class 352 Boards with coating Chemical gases Class 3C2 Solid particles Class 352 Boards without coating Chemical gases Class 1C2 Solid particles Class 193 Boards with coating Chemical gases Class 1C2 Solid particles Class 1S3 Boards without coating Chemical gases Class 2C2 Solid particles Class 252 Boards with coating Chemical gases Class 2C2 Solid particles Class 252 Atmospheric 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa under 100 kg 220 Ibs 100 mm 4 in for weight over 100 kg 220 Ibs pressure 0 7 to 1 05 atmospheres 0 7 to 1 05 atmospheres 0 6 to 1 05 atmospheres Vibration Max 0 3 mm 0 01 in Max 1 5 mm 0 06 in Max 3 5 mm 0 14 in IEC 68 2 6 2 to 9 Hz 2 to 9 Hz 2 to 9 Hz max 1 m s 3 3 ft s max 5 m s 16 4 ft s max 15 m s 49 ft s 9 to 200 Hz sinusoidal 9 to 200 Hz sinusoidal 9 to 200 Hz sinusoidal Shock Not allowed Max 100 m s 330 ft s Max 100 m s 330 ft s IEC 68 2 29 11 ms 11 ms Free fall Not allowed 250 mm 10 in for weight 250 mm 10 in for weight under 100 kg 220 lbs 100 mm 4 in for weight over 100 kg 220 Ibs 1 At sites over 1000 m 3300 ft above sea level the maximum output current is derated as follows If the installation site is higher than 2000 m 6600 ft above sea level please contact your local ABB distributor or office for further information
94. sure that the overriding control fulfils the requirements of EN 60204 1 category 1 Uponreceiving the emergency stop signal each inverter starts braking ramp stop within torque limits and acknowledges the reception of the signal by closing a relay output After a pre set delay the main contactor or air circuit breaker is opened The time delay should be set slightly longer than the inverter stop ramps to ensure controlled braking of all motors Incase the acknowledgement is not received from all inverters within 2 seconds the main contactor or air circuit breaker is opened immediately Restarting after an emergency stop After an emergency stop the emergency stop button must be released and a reset performed before the main contactor or air ciruit breaker can be closed and the drive started Planning the electrical installation 50 Prevention of unexpected start The drive can be equipped with an optional prevention of unexpected start function according to standards EN 292 1 1991 EN 292 2 1991 A1 1995 EN 954 1 1996 EN 60204 1 1 1992 Corr 1993 and EN 1037 1995 The function is achieved by disconnecting the control voltage to the power semiconductors of the inverters of the drive Thus it is not possible for the power semiconductors to switch and generate the AC voltage needed to rotate the motor In case of faulty main circuit components the DC voltage from the busbars can be conducted to the motor
95. surements make sure A WARNING Insulation checks must be performed before connecting the drive to the that the drive is disconnected from the mains Motor and motor cable Check that the motor cable is disconnected from the drive output terminals U2 V2 and W2 Measure the insulation resistances of motor cable and the motor between each phase and Protective Earth using a measuring voltage of 1 kV d c The insulation resistance must be higher than 1 MQ PE R gt 1MO Electrical installation 60 Input power cable wiring diagrams This section describes the input power cable connections of the drive The following Motor cable wiring diagrams section provides some basic instructions for the routing and mechanical connection of cables The mechanical cable connections are basically the same whether for the incoming supply or an inverter different are the cabinet dimensions and the location of the terminals for the cables The cabling direction may also vary top or bottom The N conductor is not normally used with drives although it is visible in the following diagrams Low power supply A low current lt 300 A cable connection when one cable is sufficient is represented below Transformer Converter F TA 9 E er N 2 Gap Ge SS 1 11 SE pe O OG 2 Factory main earthing bus 1 as short as possible low inductance 2
96. switches contactors connection boxes etc To minimize the emission level when safety switches contactors connection boxes or similar equipment are installed in the motor cable i e between the drive and the motor EU Install the equipment in a metal enclosure with 360 degrees grounding for the shields of both the incoming and outgoing cables or in another way connect the shields of the cables together US Install the equipment in a metal enclosure in a way that the conduit or motor cable shielding runs consistently without breaks from the drive to the motor Bypass connection WARNING Never connect the supply power to the drive output terminals U2 V2 and W2 If frequent bypassing is required employ mechanically connected switches or contactors Mains line voltage applied to the output can result in permanent damage to the unit Before opening a contactor DTC control mode selected Stop the drive and wait for the motor to stop before opening a contactor between the output of the drive and the motor when DTC control mode is selected See the Firmware Manual of the drive for the required parameter settings Otherwise the contactor will be damaged In scalar control the contactor can be opened with the drive running Planning the electrical installation 54 Relay output contacts and inductive loads Inductive loads such as relays contactors motors cause voltage transients when switched off The
97. t the drive end only If the encoder is galvanically isolated from the motor shaft and the stator frame ground the encoder cable shield at the drive and the encoder end nOnnupooouy As short as possible Note 2 Twist the pair cable wires Note 3 The grounding wire of the outer shield of the cable can alternatively be connected to the SHLD terminal of the RTAC module IN Clamp as close to terminals as possible Strain relief with a cable tie Fibre optic link A DDCS fibre optic link is provided via the RDCO optional module for PC tools master follower link NDIO NTAC NAIO AIMA I O module adapter and fieldbus adapter modules of type Nxxx See RDCO User s Manual 3AFE 64492209 English for the connections Observe colour coding when installing fibre optic cables Blue connectors go to dark grey terminals and black connectors to light grey terminals Transmitter Receiver black blue When installing multiple modules on the same channel connect them in a ring Electrical installation 79 Motor control and I O board RMIO What this chapter contains This chapter shows external control connections to the RMIO board for the the ACS 800 Standard Application Program Factory Macro specifications of the inputs and outputs of the board To which products this chapter applies This chapter applies to ACS8
98. tal or consequential damages losses or penalties If you have any questions concerning your ABB drive please contact the local distributor or ABB office The technical data information and specifications are valid at the time of printing The manufacturer reserves the right to modifications without prior notice Technical data 113 Dimensional drawings What this chapter contains This chapter contains the dimensional drawings of ACS800 17 frame sizes R6i to R12i Dimensional drawings 114 SE 3 AQ usnpu Gay emdmud oN uS ess LE ma 1979 14V ou ze EW DN 900 570 lee a Ng buoy p pu idep say ZANQ3IONIS ILY 198 awou oe oug Zei Fu 0 1 Suimosqg uoisuswiq A00S 00b 41 008 419S3v Z00Z 190 PZ Mn 20 39905 suono Be 4 SP C uu sep 200 ONIMVMQ NOISN3AIQ enu 007 JOW 9c Id vam 139vH pejodeug uo pasog 3 148 S OvLO ZL 008 Z1L9SOV T IS 194 8 0010 41 008 19S2v 2 28 2d 1 94 0210 Z1 008 Z19S9v a ER ux BN 2 o o d po A AA A We Eeer J ER MEM LLL corpus i zi e 23 28 a 2 2 SS 88 E S Es ao u E 1 Es al L F Sa Oss z 004 S 009 P aU E ES DEL e ocd 3 A bei Es 00 unu anit ooze 2 oou UP 00 p unu er o lu 5 ra CH n 3 N M j d d o e ole ole C El c 3 ij fe S 10 Sin f Sin f GE TEN SIE MES DIEI te o o x FS x ge a Se CH g KEE ERE po i o 779 HS gt Sole Zoe 3 ENER 3 GC
99. tch the power on to the converter for a time given in Figure 1 Method 1 The converter wakes up its capacitors by itself Power the converters up once a year to keep the capacitors in operational condition Converters stocked non operational for 2 years and over Use Method 2 A or Method 2 B both explained below for capacitor reforming if the converter has been stocked or non operational for two or more years Method 2 A Capacitor reforming is realised by connecting a rectifier and a resistor circuit to the converter DC link The reforming circuit and component values for different voltages are given below See Figure 1 for reforming time WARNING The converter supply must be disconnected while the reforming circuit is connected Preventive maintenance 94 Disconnect from supply 1 35 U4 U1 or phase module Converter Supply Voltage Recommended Components A R Cc 380 V lt U4 lt 415 V SKD 82 16 220 Ohm 700 W 22 nF 2000 V 380 V lt U4 lt 500 V SKD 82 16 470 Ohm 1200 W 22 nF 2000 V 525 V lt U4 lt 690 V SKD 82 16 680 Ohm 1700 W 22 nF 2000 V rectifier bridge by Semikron 82 A 1600 V or equivalent Method 2 B Capacitor reforming is based on a DC power supply connected to the converter DC link Power supply current charges the converter capacitors If power supply cannot limit the current voltage is in
100. th non conductive electrical tape and a heat resisting non metallic cable tie in order to prevent conductor insulation damage caused by the core edges Slide the core s onto the taped part of the phase conductors Bind the cores together and onto the taped part of the phase conductors with heat resisting non metallic cable ties JY Light Common Mode Filter Code 64315439 B Electrical installation 72 Control cable connections at shipping split joints Some control wires are chained through the shipping splits 230 115 V voltage transformer uninterrupted power supply UPS and emergency stop wires are chained via terminal blocks X25 at the upper left hand corner of the fields next to the busbar joining sections Connect the loose wires to the next X25 terminal block Connect the loose wires not coming from X25 to the destinations marked on the wire ends Ensure that no unconnected wire ends are left which will be powered when the supply voltage is switched on 230 115 V X25 X25 X25 H N UPS A eo d ACU Several shipping splits Shipping split Last shipping split Busbar joining section Normal voltage neutral e Normal voltage 230 V a c 115 V a c 9 gt lt UPS voltage neutral E s UPS voltage 230
101. the overriding control link if in use Disconnect all voltages open the main contactor breaker if present open the main disconnecting device Connect the communication link to the overriding system by connecting the fibre optic cables Power the unit up Check the start stop functions speed torque references alarm fault words function in case of a communication break updating interval of the drive software other items essential to the application See the circuit diagrams delivered with the device Start up 91 Preventive maintenance What this chapter contains General A Air filters Heatsink Relays Fan This chapter represents how to maintain the drive in operational condition WARNING The Safety nstructions on the first pages of this manual must be followed Negligence of these instructions can cause injury or death If installed in an appropriate environment the drive requires very little maintenance An annual check up for dust and corrosion accumulation on the surfaces inside the cabinet is recommended When having filtering for cooling air check and clean or replace filter mats if dirty Wash dirty filter mats with water 60 C and detergent The drive can run into overtemperature faults if the heatsink is not clean In normal environment the heatsink should be checked and cleaned annually Use compressed air to remove dust from the heatsink The airfl
102. ther and to the grounding electrodes Aluminium tray systems can be used to improve local equalizing of potential A diagram of the cable routing is below Motor cable Drive Pawar table min 300 mm 12 in min 300 mm 12 in Input power cable Motor cable min 200 mm 8 in 90 E min 500 mm 20 in Control cables Planning the electrical installation 57 Control cable ducts 24V 230 V 24V 230V Not allowed unless the 24 V Lead 24 V and 230 V control cable is insulated for 230 V or cables in separate ducts inside insulated with an insulation the cabinet sleeving for 230 V Planning the electrical installation 58 Planning the electrical installation 59 Electrical installation this chapter Follow the Safety instructions on the first pages of this manual Ignoring A WARNING Only qualified electricians are allowed to carry out the work described in the safety instructions can cause injury or death What this chapter contains This chapter describes the electrical installation of the drive Insulation checks Every drive has been tested for insulation between main circuit and cabinet 2500 V rms 50 Hz for 1 minute at the factory Therefore there is no need to check the insulation of the unit again When checking the insulation of the assembly proceed in the following manner mains Before proceeding with the insulation resistance mea
103. tion holes The connection holes for mains and motor cable lugs are given below Holes for cable Number of cable Bottom plate Number of cable Drive type Frame Supply section lugs per phase entries at bottom opening entries at top size type diameter 60 mm dimensions diameter 1 mains motor mm 60 mm Supply voltage 400V IGBT supply ACS800 17 0120 3 R7i j 3 75x239 3 ACS800 17 0185 3 R8i 4x 13x18 6 75x239 6 ACS800 17 0225 3 R8i 4x 13x18 6 75x239 6 ACS800 17 0265 3 R8i 4x 13x18 6 75x239 6 ACS800 17 0335 3 R9i 4x 13x18 6 75x239 6 ACS800 17 0405 3 R9i 4x 13x18 6 75x239 6 ACS800 17 0630 3 R11i ACA 635 0765 3 6x 13x18 6 9 270x911 6 ACS800 17 0765 3 R11i ACA 635 0765 3 6x 13x18 6 9 270x911 6 ACS800 17 0935 3 R12i ACA 635 1125 3 8x 13x18 12 195x501 12 ACS800 17 1125 3 R12i ACA 635 1125 3 8x 13x18 12 195x501 12 Supply voltage 500V IGBT supply ACS800 17 0100 5 R6i E 3 75x239 3 ACS800 17 0140 5 RTi 3 75x239 3 ACS800 17 0215 5 R8i 4x 13x18 6 75x239 6 ACS800 17 0255 5 R8i 4x 13x18 6 75x239 6 ACS800 17 0325 5 R8i 4x 13x18 6 75x239 6 ACS800 17 0395 5 R9i 4x 13x18 6 75x239 6 ACS800 17 0495 5 R9i 4x 13x18 6 75x239 6 ACS800 17 0770 5 R11i ACA 635 0935 5 6x 13x18 6 9 270x911 6 ACS800 17 0935 5 R11i ACA 635 0935 5 6x 13x18 6 9 270x911 6 ACS800 17 1095 5 R12i ACA 635 1385 5 8x 13x1
104. ts manufacturing year and week respectively The remaining digits complete the serial number so that there are no two units with the same serial number Introduction 18 Inquiries Any inquiries about the product should be addressed to the local ABB representative quoting the type code and the serial number of the unit If the local ABB representative cannot be contacted inquiries should be addressed to ABB Oy Helsinki Finland Introduction 19 Hardware description What this chapter contains This chapter describes the hardware of the ACS800 17 Main components of the ACS800 17 Frame sizes R6i to R9i The main components of the drive converter frame sizes R6i to R9i are shown below The control panels are optional RDCU LCL Filter RMIO ETT mem Supply Inverter Y Unit wa y QD 230 115 VAC The main components of the drive converter frame sizes R11i and R12i are shown in the figure below The Supply Unit is equipped with an IGBT input bridge The Braking Unit is an optional device The control panels are optional For a more detailed description of the Supply Unit refer to the GBT Supply Sections User s Manual Frame sizes R11i and R12i Hardware description 20
105. ui C cT 103 Connection holes x obey xh a e x fate ale nee AEN E Dea E TERT RR cn 104 Cabinet sre a e us PR M UE e OR Ee HH Ear d de ER e dodo FUR DER ed 105 Cooling air dimensions 106 Air flow requirements 0 0 0 rrr rra 107 Noises usc accio dv er ao f Set e SERGE 108 Applicable standards cel v Vr e x Ae TERRE OUR Dea eed ior bel e oe v 108 Materials ct uoce c atas de bx c o de BOE Recta dc e ex HOC API Wa 108 Table of contents Transportation xa o e anten Ie AA mae top ai aeons aw a 109 Disp salkm ER TI Mon LIT m 109 CE marking buie carey ei dodo fua low e ge ae ee Dot este 109 DSTINITIONS yo e eve cst ots i ee AN ds e V cte Sae eg DU As tok aU 109 Compliance with the EMC Directive 110 Machinery Directive oiii oce 5 ote ee cod eodeni Ax b Rei Ros SU Oe e aod AO B Rcs 110 CSA marking si besar S A a ed 111 SACK marking TER 111 RG Lu le EE 111 Compliance with IEC GIo00 3 teens 112 Equipment warranty and liability 5 case a Rer em eee Pade ee ee abode eee Le 112 Dimensional drawings What this chapter contains 113 Table of contents 16 Table of contents 17 Introduction Overview of the manual Study this manual carefully before installing commissioning operating or servicing the drive We expect that you have a basic knowledge of physical and electrical fundamentals electrical wiring practices electrical components and electrical schematic symbols ACS800 17 drives consist o
106. us waste They must be removed and handled according to local regulations For further information on environmental aspects please contact your local ABB distributor CE marking A CE mark is attached to the drive to verify that the unit follows the provisions of the European Low Voltage and EMC Directives Directive 73 23 EEC as amended by 93 68 EEC and Directive 89 336 EEC as amended by 93 68 EEC Definitions EMC stands for Electromagnetic Compatibility It is the ability of electrical electronic equipment to operate without problems within an electromagnetic environment Likewise the equipment must not disturb or interfere with any other product or system within its locality The EMC Directive defines the requirements for immunity and emissions of electrical equipment used within the European Union The EMC product standard EN 61800 3 Amendment A11 2000 covers requirements stated for drives First environment includes establishments connected to a low voltage network which supplies buildings used for domestic purposes Second environment includes establishments connected to a network not supplying domestic premises Restricted distribution mode of sales distribution in which the manufacturer restricts the supply of equipment to suppliers customers or users who separately or jointly have technical competence in the EMC requirements of the application of drives Technical data 110 Unrestricted distribution mode
107. w the 400 mm wide middle part of the cabinet The cabinet weight lies on the two 100 mm wide transverse sections which the floor must carry With heavy cabinets support the structural C sections from below Viewed from above Side view This area can be used for a cable conduit Prevent the cooling air flow from the cable conduit to the cabinet by bottom plates To ensure the degree of protection for the cabinet use the original bottom plates delivered with the unit With user defined cable entries take care of the degree of protection and fire protection Cables 7 Id Sr Mechanical installation 41 Electric welding It is not recommended to fasten the cabinet by welding Cabinets without vibration dampers Ifthe preferred fastening methods clamps or holes inside the cabinet can not be used proceed as follows Connect the return conductor of the welding equipment low to the cabinet frame within 0 5 metres of the welding point Cabinets with vibration dampers Ifthe fastening cannot be done with screws proceed as follows e Weld only the flat bar under the cabinet never the cabinet frame itself Clamp the welding electrode onto the flat bar about to be welded or onto the floor within 0 5 metres of the welding point Do not clamp the electrode on any part of the cabinet frame Cool the flat bar with a wet cloth so that the heat is not conducted
108. w together with another person The mechanical and electrical installation must be checked before start up Study carefully the Safety Instructions on the first pages of this manual before working on the unit O O a O O MECHANICAL INSTALLATION ELECTRICAL INSTALLATION See chapter Electrical installation INSTALLATION CHECKLIST Check The ambient operating conditions are allowable See chapter Technical data The unit is fixed properly See chapter Mechanical installation The cooling air will flow freely the lifting bars if used are removed See chapter Mechanical installation the cabinet roof is lifted up if a double roof See chapter Mechanical installation The applicability of the motor and the driven equipment See Safety instructions and chapter Technical data Joining of the shipping splits if the drive is split The DC busbars and PE busbars are properly connected See chapter Mechanical installation The control cables are properly connected See chapter Mechanical installation The converter unit is earthed properly The mains voltage matches the frequency converter nominal input voltage The setting of the internal 220 115 V transformer corresponds to the supply voltage The transformer is located in the Auxiliary Control Unit The mains input power connections at U1 V1 and W1 are OK The appropriate mains fuses are installed See chapter Technical data Inst
109. wide busbar joining cabinet All necessary materials are located in the joining cabinet Remove the front metal partitioning plate located in the busbar joining cabinet Unscrew the bolts of the joint pieces Connect the busbars with the joint pieces see figure below For aluminium busbars joint grease e g TK Penetral made by Framatome Connectors USA Inc Burndy Electrical must be used to avoid corrosion and to ensure good electrical connection The oxide layer must be scrubbed off from the joints before applying the grease Replace the front metal plate into its original position because of safety of personnel Mechanical installation 38 DC busbar The DC busbar connection is shown below 1 Joint pieces Tighten the bolts with a torque wrench to 55 70 Nm 40 50 ft Ibs Side view of single busbar connection PE busbar The PE busbar connection is shown below U wt0 Tightening torque 35 40 Nm 25 30 ft Ibs Mechanical installation 39 Lifting a double roof When the drive is equipped with a double roof Lift the upper part of the roof plate up from the transportation position Lock the roof to its final position with the M6 screws Mechanical installation 40 Miscellaneous Cable conduit in the floor below the cabinet A cable conduit can be constructed belo
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