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ACS800-104-hw-031201.. - Ortman Drives and Controls Distributors

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7. 4 5 90 187 E Control S 0 5 15 3 1 H 5 Power e 2 9 e IS 5 5 Cil i 5 1 S 5 GL E 2 3 ap Batt G 8 lt lt 88 4 EH H 59 DDCS S S S i 5 t 9 a 2 2 2 LO 68 2 68 29 1 14 126 4 96 41 1 6171 198 NPBU 42C branching unit NPBU 42 NPBU 42 PPCS BRANCHING UNIT 4 CH 69 sv 1 24V DC 63986313 265 6 APBU 44C branching unit i A NANA wii 96 N 1 59 APBU 44C BOARD ___ 3 A e d 1 e OJ
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10. Rear upper guide 1 2 ic 4 6 T 8 i Z 5 ae jt t 15 5 i 2 0 5 Li g P 3 i H egXepcs H 3 gt i QJ BH E 1e 146 HH 170 B A HB 5 5 04 e E gt NOTES D MATERIAL PER SPECIFICATION 150 3575 7275 02 h HOT DIP ZINC COATED STEEL 20 mm OR 14 GA 10074772 5 2 DIMENSIONAL ACCURACY PER TOLERANCE SPEC ISO 2768 n 3 DIMENSIONS MILLIMETERS B 4 BEND RADIUS MIN INSIDE ALL FOLDING RADII R 1 5MM 5 N WISE NI DIN 6930 F Based on Prepored JHURELLI Title BACK GUIDE Doc des ffon leg sis Customer 16 Nov 03 Appr M 16 Nov 03 MODULE 1 1 4 EI Project 09 Jul 03 CC AM BEEMLOBBAWING EIX Rev 0 EN 55 Doc No Doc Sheet 1 ker No Drives E 34 4 45 6 7 8 i 8 3 2 i i t 9 E B H i Cet ub 82 N e o 2 2 gt o B NS E lt Ce lt eae Bosed on Prepored J H RELL 1 Title BACK GUIDE Doc des Scole Form z z Custoner 16 Nov 03 Appr JM 16 Nov 03 M
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14. OESA00D2PL 1 2 4 es es 1320 dL 136 0 5 98 0 1420 45 0 40 0 5 0 145 0 OZXK2 auxiliary contacts LI p E3 E3 2 07 2 29 46 45 203 OESL 630 32002
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17. 230V 115 V ED F EDID ASFC 01C SWITCH FUSE CONTROLLER BARCODE LABEL SSS 207 11 21 charging control unit 157 5 FUSE T 315 mA TO FUSE SWITCH FROM CHARGING SOLENOID RESISTOR 208 Diverse Output du dt filters 9 D mm 2 ys 47 gt 181010 imm Nm mm Nm NOCHO016 60 140 195 120 85 115 83 24 5 4 0 2 10 1 5 NOCHO030 60 165 215 145 108 130 95 47 M5 4 0 5 16 1 5 NOCHO070 60 180 261 170 125 150 120 9 5 6 10 35 2 5 NOCHO120 60 154 106 100 75 200 160 9 7 8 20 NOCHO260 60 185 111 124 82 383 368 13 12 M10 30 NOCHO400 60 18
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21. uappiqsoy 1 91 S s 24 jnouy 21209 Puy oj esn uonounoju puo juaujn2op SIU 0 M uonowoyny gay 139 Example Prevention of unexpected start J ON jeu g v PAS 08 0 1879 FAVE ON 900 r ON 200 1572 Nj w dsey 53100000 00852 Sejnpow QN 1551029 26010 10330 1 15 dX3N 30 NOILN3A33d panoiddy 901519 Sep sep 200 JIdWvX3 ONIMIM 5000 111720 L paiodaig 68665679 uo E E 5 18 2 i 3 o ue 252 8 124 72 X vI er 8 21 N i8 3d 3d 12018 env 025 uonosiep 55042 uonoejsp ON fy LS eas eee 7757 se6saa 25 cw LU P 23 ZN Za 9 9 999581029 119212205 lo o 2160 4 M LE ves ces 225
22. 202 OESE 630 32D02 T ace risate di ee HR CL peto e m qct 203 OESE630 32D04 lp UR RE ERU NA Ede 204 5 630 32006 inim yum Veet EU hak Boh ae vH us 205 ASFC 21C switch fuse controller 206 NCHM 11 21 charging control unit 2 2 207 DIVGESO es Sot ee bap beu Gel RC t Le PA DE he tle 208 Miers Ode esas pete 208 Common mode filter toroids 208 Table of contents 11 Introduction to this manual What this chapter contains This chapter gives the basic information on the manual Compatibility The manual is compatible with the ACS800 104 inverter modules intended for user defined cabinet installations Safety instructions Follow all safety instructions delivered with the drive Intended audience The reader of the manual is expected to know the standard electrical wiring practices electronic components and electrical schematic symbols Contents Hardware description Cabinet construction Electrical installation External 24 V power supply for the RMIO board Installation checklist Motor control and I O board RMIO Maintenance e ACS800 104 ordering information Technical data Circuit diagrams Dimensional drawings Introduction to this manual 12 Related publicati
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26. Hot area Mounting plates Air baffle Hardware description 18 Frames R6i and 7 Frame R6i and R7i modules have the DC input connection at the top of the module while the AC connection is at the bottom The DC voltage is connected to the input busbars either through fuses only or through a switch fuse with charging control circuitry The drive control unit type RDCU containing the RMIO board is to be installed separately The modules require an external cooling fan that has to be supplied from 230 V or 115 V AC auxiliary voltage For attaching the fan to the module mounting plate 64138375 is recommended alternatively a combined mounting plate air baffle can be constructed Module layout e Item Explanation 1 DC input connections 2 Motor output connection 3 Cooling fan e Qj 9 0 2 ell 3 Cabinet layout See the chapter Cabinet construction Hardware description 19 Frame R8i and multiples Frame R8i modules are used to achieve output powers from approximately 200 kW upwards in single or parallel configurations R8i modules run on wheels and can easily be removed from the cubicle for cable installation or service The DC input is located on the top front p
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29. 2 289 6652289 Three modules a Rittal TS 8 cabinet MODULE CABINET MOUNTING EXAMPLE to mount 3xR8i combine TS8 w eren Reproduction use disclosure 10 reserve nights m this document and m the Information Contained third parties without expre ABB authority Is strictly Forbidden 68259886 68259886 lt m o a ka st SEE px 215 ms 2 10 gt 44206 5 378 7 TA 21 59 SD gt LJ Lu Ld lt c eo 2 9 gt zl 218 o T 22189 2 3 22 zb i gt c Gd 1 5 7100 7100 MODULES WITH FUSE BASES Titte 3xR8i 758 RITTAL ASSEMBLY DRAVING MD CM ABB Drives Prepared MEKROOS 09 Sep 03 Check Appr Project nome Based on Customer Cust Doc No ABB Ref No
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34. ESSE 11758289 8 2 S v 2 E 194 19 01 ON 7994 dav 8289 JIVE SIAR SEELEY 98uv1 5 7395 4523 008529 awou 134034 NIVCHONVWII 2999 __ 92245 1 wj 1925 sep 204 31914 MOV aL 50 220 80 paaodaug uo pasg d 3 ceu 0000 0 058069 o 5 S 8 8 o o 3 4 40 1988289 wappmuos s ssaudxa 50 paur Oy Jo asn uononpougay 42229 gt aui U PUD SM 5 1988289 8 L 5 v T 195 Module extraction insertion ramp This example design of a module extraction insertion ramp is for a lifting height of 50 mm and should be redesigned for other heights
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36. 56 Installation of common mode filters 57 Power connections Frame R8i and multiples 58 Witlpgdlagramr sure x RE VIRO REOR OUR Pee 58 DC 2 58 Charglng cireult eun e 59 Motorconnection leas EA EUR ERE EU E ti dee 59 Direct motor cabling cuoio BO OE gc Gc EPA ungue 60 Common motor terminal cubicle 62 5 5 canis ca EIE Rura ege AU amp Sah 63 Frame R2I to 5 csse MER Pire UNE aS 63 Frame R21 to R4i R3i pictured 63 Frame RSi oe c acer Id uide ER pP ope x dedo dre 64 External 24 V power supply for the RMIO board 64 Frame R6i R8i and multiples 65 R6ei RTI connectors Nd eR RR Nu RU 66 ROECORDOSCIOFS aii Nard Eo e Et Fb olent dob C de ee d es e re 67 360 degrees grounding of cables 68 When the outer surface of the shield is covered with non condu
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39. 1 64089660 0050 3 0060 5 006073 00 00 2 170 2000 10003539 1 261288 58065749 1 64089650 0100 5 2 170 2000 10003539 1 261238 58065749 1 64089561 15 00 2 are eov 10285821 4 160 0170 3 0210 5 075 2 25 64786423 2 2 35009841 1 64808796 0320 3 0400 5 0390 3 0460 5 2 64786512 2 2 35009841 1 64808796 0510 3 0610 5 2 5 2 64673734 2 5 35009841 1 64808796 0770 3 0910 5 4 e 2 64786512 4 35009841 1 64808800 1030 3 1210 5 4 2 64673734 4 35009841 1 64808800 1540 3 1820 5 6 2 2 64673734 6 2 35009841 1 64808826 2050 3 2430 5 8 Seen 2 64673734 35009841 2 64808800 0011 7 2 OM 25A 10032041 1 ORAX 88088748 1 64089650 2 10033250 1 PTAA 64089650 10527135 IOM 10029791 1 64089650 004071 2 IOM 80 10029805 1 22125 58065749 1 64089650 5800 104 ordering information 97 DC fuses and fuse bases Switch fuse kits for inverter modules Module type DC fuse DC fuse base ACS800 104 Qty Type Info 25 Type Info e Qty Order code 0060 7 3 ZOM 10029813 1 58065749 1 64089650 0070 7 a
40. 2 68239427 68239435 68260744 5800 104 ordering information DC busbar kits 101 These kits contain the parts needed to connect the DC busbars of the inverter module and the DC switch fuse or DC fuses The common mode filters optionally available are to be installed on the DC busbars DC busbar kits for R8i modules Kit For Contents of 1 kit Order code 4 pcs Busbar Connecting 2 pcs Holder for busbars from Single R8i common mode filters fuse bases to DC module 5 pcs Support insulator input of module 1 pc Mounting plate for fuse bases Connecting busbars from Single R8i s al Pes aon switch fuse module 2 pole mode filters 68256747 OESL to DC Switch fuse 5 pcs Support insulator input of module ACS800 104 ordering information 102 DC busbar kits for R8i modules Kit For Contents of 1 kit Order code Two 8 8 pcs Busbar modules side by 4 pcs Holder for 68256771 side 4 pole common mode filters Switch fuse 8 pcs Support insulator Connecting busbars from switch fuse Three R8i Bios Ma 49550 to DE modules side by common mode filters 68256780 input of module side 6 pole 15 pcs Support Switch fuse insulator 12 pcs Busbar modules in di t Rittal 6 pcs Holder for adjacent Nita common mode filters 68260752 TS 8 cubicles 15 pcs Support 6 pole switch 5 insulator fuse
41. 10819289 v 36 MOUNTING EXAMPLE MODULE CABINE T here Reproduction use or disclosure to tion contained 8 22 5 68241871 68241871 Connecting busbors to module tch fuse DESL to module Connecti DESL prt ne 6480 8796 BUSBAR SET ing swi ABB prtllst 6480 6823 COMBI M8 6 COMBI 6 4pcs DESL BUSBAR SET ABB prt lst 6825 6747 MODULE CABINET ASSEMBLY WITH SWITCH FUSE MODULE CABINET ASSEMBLY WITH FUSE BASES c TE Form EN Long Sheet Total 4 5 Scole 100 9 Rev ind 0 Doc des ASSEMBLY DRAWING EIX 3AFE 6824 1871 Resp dept Doc MOUNTING INSTRUCTION RITTAL TS8 400 RBi MD CM ABB Titte Appr Prepored 09 Sep 03 E E 5 PE So ola zs amp 6 55 gle 2 81 95 2 23 5 ae de 37
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43. e Q 2 N e e e 3 L 95 265 V AC Voltage must be ON o O lo for the inverter to start o o o e Cr 93e 9 9 67 connectors The fibre optic connectors for connections to both the RDCU and the ASFC boards on the AINT board of the inverter module are accessible through an opening on the front routing Optical cable Access to fibre 21 optic connectors of AINT board Ix If the inverter module is equipped with the Prevention of unexpected start option Q950 or not equipped with a speed controlled fan option C126 the necessary connections are made via a detachable terminal block X50 The counterpart included in the delivery can be installed near the top of the module In the picture below the terminal block is installed on the mounting plate on the upper guide of the module DC busbars 1 See Terminal block X50 DODO UU 122211111 360 degrees grounding of I O cables Insulation Double shielded cable Single shielded cable When the outer surface of the shield is covered with non conductive material Strip the cable carefully do not cut the grounding wire and the shield Turn the shield inside out to expose the conductive surface Wrap the grounding wire around the conductive surface Slide a conductive clamp onto the conductive part Fasten
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46. 180 Front crossmember modules side by side included in kit 268259541 184 Rear crossmember 3 modules side by side included in kit 68259541 186 Fuse Fuse switch mounting plates 187 Mounting plate single R8i mod in a Rittal TS 8 cubicle included in kit 268283027 187 Mounting plate two modules in a Rittal TS 8 cubicle included in kit 268283035 189 eee REOR RR CS p E LEGO T XC CO e uas 191 Air baffle single R8i module in a Rittal TS 8 cubicle included in kit 268283027 191 Air baffle two R8i modules in a Rittal TS 8 cubicle included in kit 268283035 193 Module extraction insertion ramp 195 Control electronics 197 FRDGU QZ C si aa a i e gc E 197 NPBU 42C branching unit 198 APBU 44C branching unit 199 Fuse Ddses 200 iis hw Weg c ER Na me e RR VR eda oe We qx ted 200 ORASAS hy dsm ad tg 201 Switch fuses charging control 6 202 OESAO00D2BE MORE T eid Mes 202 OZXK2 auxiliary contacts
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48. ACS800 104 ordering information Upper and lower guides 103 These parts guide the top and bottom of the module when it is being inserted into the cubicle Guiding parts kits for R8i modules For Contents of 1 kit Order code 1 pc Lower guide Single R8i 1 pc Upper guide 68256836 module 1 pc Upper guide rear 2 pcs Crossmember Kit 468256836 and 1 pc Floor plate Single R8i 1 pc Mounting plate module in Rittal 2 pcs Air baffle 68283027 TS 8 cubicle 1 pcs EMC sealing conductive comes in 2 pieces 22006 modules side py lt PCS 68259517 2 pcs Upper guide rear side 2 pcs Crossmember ACS800 104 ordering information 104 Guiding parts kits for R8i modules For Contents of 1 kit Order code Kit 868259517 and Two R8i 2 pcs Floor plate modules in 1 pc Mounting plate d 2 pcs Air baffle 68283035 Rittal TS 8 1 pcs EMC sealing cubicle conductive comes in 3 pieces 3 pcs Lower guide Three R8i 3 pcs Upper guide modules side by 3 pcs Upper guide rear 68259541 side 1 pcs Crossmember front 1 pcs Crossmember rear 1 2 88 modules i 66585027 68283035 68260833 adjacent Rittal TS 8 cubicles ACS800 104 ordering information Cabinet ventilation kits These kits contain air inlet gratings and filters for different degrees of protection 105 Cabinet ventilation kits for R8i modules
49. INZ 6 88 62 218 INZ 66 0 88 395 EEGNIT A3XOS 2 6 07 LENI mr 9 00 07 113105 OON 301330803144 0 21 00 0 2 2 9562 153 9619 NIC WWEXEI 62 9 84 dh ZIW 961981 9445 6 00 1 1 14 1 72 88 CE6NIC 2 8 18 22 19332518803 ZIXBN 5 1860 9 6 00 0 23 11026999 88 SOLIANNOD 1593 10986999 1 t 00 0 4 2 22 11062999 80123NN02 1593 064 1804405 062999 8 1 00 2 8 22 7651959 NOI123NND2 31892 398508 17601909 6 6 20 4 8 OEH OEC 6 6 1579 21sMa 060 uopuor 6020 4030150 020 Wop4or 5080 866 69 01 6 3 196221 ELS E 821 90 X 1611 09 jg TN ro e S82 EL gi ee oee ls 18941 89118921 89 18921 89118921 89 8921 89 89 89 ITE 6 E 8T 18 olo flo A A A AN i 9 _ o Io 4 2 AN CTE 918 fo eue 525 SpA 8 e 3 cor 1 e 8601 62 16901 61 16191 201 126601 992 3 8 9 V 24 7131 XS f 1628 7289 117 ISITI 19 8 HOU 558 0 51964289 40 asn wonanposday UORRLOJU PUO 10 ON 51964289 8 1 9 6 175 i rts iding pa Upp
50. eues UN Oud Jul A PUD SMF SHER NO 27758289 8 L 9 S v T 190 19101 ON 88V 2 8996 8289 JIE SIAR ALI ig PUTAN 4584 10 08 awou 044 ST 9 119134 791119 745942 PT 2105 2oq 31914 21311 0 331 80 _ 50089 p330da3g uo pasdg vu cO 0000 0 o s Lor o 9 ber gt 186 8 9 EN o 8 e ES 40 gay O 728289 uopppuo Anis s ssaucxo ino 591 59 2unsonsip Jo ash uonnpoudes ueJaus paumiuO2 ou UI Pu SIUI ND 33524 IA 27758289 8 2 9 5 v 2 191 Air baffles Air baffle single R8i module a Rittal TS 8 cubicle included in kit 68283027 2 1935
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53. vol 95 22 49j49 u XX WHON tex IZY iz 8102000 uappiquoy S S 929 21209 oj esn uononpojdey peuibjuoo BY PUD jueunoop Sjubu 0 M i9owuoiny ggv do 129 Frame R8i and multiples R8i Internal diagram controlled fan The diagram depicts an R8i module with optional speed 8 SA B H IL 18070179 339 Seng 887 88 19945 2 mw buo1 4dep dsej OSA 2 4 a 3 2533 4 0860 0620 lt 002 600 Jouioysng sep uei wos6o1g A069 8 01 00852 002 80 vZ Pedeid ON 500 188
54. 20g ATA W N Pu ey dsay f S 3 uem 21055 Ajquessy sop 7200 W5 ON IBYXE NOWONALSNI ONUNAOW enu INVYYNOGIY ON 88V ON 200 1812 72942 29401519 007 3 0 uo pesog 86 10600 Sore 059 et 9130 9152 6661 C69 rosi 182 9105 109 0 509289 1404 4eidopo uo sejou 809 ont 9130 087 gav Anas 51 jnouym 91 59 Pay aunsojosip Jo asn uononpoude peurojuoo uonounoju 24 ur SIY 5140 0 e JesaJ 48 49 Electrical installation What this chapter contains General This chapter describes the electrical installation procedure of ACS800 104 inverter modules The wiring diagrams in this chapter are simplified presentations See the chapter Circuit diagrams for details WARNING Make sure that the drive system is disconnect
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56. 9 ANIE 119 v SASLANITIW SNUISN3WIG 4 89 2 051 2345 3101 Y3d 2 80229 TWNOISN3WIG 2 1 4 4001 V9 rl YO 02 13315 431902 2 12 dI 10H QUNG 22 S GE 051 NDILVOLIIO3dS 834 1 13319 i S310N V 3 81568289 Oy aunsojasp ash uononpoudaw UIUI IU uj PUD JUdUND0P 33524 81758289 8 L 9 S v 2 T 188 10401 2 ON 324 H V pe SINS 1 UE ydap 4525 Wo OW awou 2 a m OOTZT ONIAVAT 119130 MALIS 8AXT E 4ddy 713805 49404519 1 21025 31914 21911 0 220 S0 SDUWXJW paaodaug 00 pasog w o 8 2 q 00155 gt 00000 L e 9 62199601 2 4 81868687 03 215012510 YO ash uoanpoudaw pauriuo UI PUD Siu 5348 ND 8 42584 M 81758289 8 2 2 5 v 189 Mounting plate two R8i modules a Rittal TS 8 cubicle included kit 68283035
57. A 170 xa 2 1 7f Module top fixing DC connection an points 2 8 AT 2 Drive control unit S 1 4 Module bottom fixing AG connection points 4 6 1 12 180 I Le Combined mounting plate air baffle See 1 Dimensional 11 Cooling fan fixed to drawings Air in 450 32 Frame R8i and multiples General See the chapter Technical data for module specific cooling requirements Cooling In a typical cabinet construction the air inlet is at the bottom of the cabinet while the outlet is at the top ideally on the roof The inlet may be filtered Note Do not install a filter in the air outlet Circulation of air within the cabinet must be prevented With R8i inverter modules lateral airflow should be blocked with a collar type air baffle at the top of each module Special attention must be paid to covering the gap between the guide at the top of the module and the side wall of the cubicle Module extraction insertion ramp The inverter module is to be inserted into and extracted from the cabinet along a suitable ramp An example design is shown in Dimensional drawings Mounting examples The following pages contain examples of 1 2 and 3 R8i modules installed into Rittal TS 8 cabinet frame In addition there is an example of 3 R8i modules installed side by side 33 ON 398 88V
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61. Module d 19401 ON 394 88V 9 09 39 sl seq 3597 5907 0 XI3 4554 7012008520 32afoug 184355 0041 3 0 544849 75245 2940157 SL wo 4 2155 sap Bujmoup 1 5 0 AON GI paaodaag uo pasvg d SN ou 060 o gt zx 11000000 1 2 Is ci 1 22001 22 3 E Ege 2 N E hrr a ea bie 00 o o ES o m 2 1 gt Ege a EL s ed a ae Qj 5708 22 09 26 v 1 9601 92 3 5 8 en CA E sit EM a z ol 1HDIN vO Ol 1431 390000060088 29 0 1 01108 28 02 401 u SINSNS3YINOIY 32948 3384 489160 2 1 6229099 WNDLSNAL 03 24501256 40 asn uononpoudas gt BUI PUD 5346 WO aA 6 229 9 WNDISN3AI 8 2 9 v 2 T Frame R3i 148 Mounting plate vertical 1009 9845 OLCCOLV9 FAVE ON 200 S3AINQ
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63. UDC 1 360 degrees grounding 2 Use a separate grounding cable if the conductivity of the cable shield is less than 50 of the conductivity of the phase conductor in a cable with no symmetrically constructed grounding conductor see the document ACS 800 MultiDrive Planning the Electrical Installation 64783742 English Note If there is a symmetrically constructed grounding conductor in the motor cable in addition to the conductive shield connect the grounding conductor to the grounding terminal at the drive and motor ends Do not use an asymmetrically constructed motor cable Connecting its fourth conductor at the motor end increases bearing currents and causes extra wear Grounding of the motor cable shield at the motor end For minimum radio frequency interference ground the cable shield 360 degrees at the lead through of the motor terminal box 360 degrees grounding Conductive gaskets or ground the cable by twisting the shield as follows flattened width gt 1 5 x length b gt 1 5xa 52 Conductor stripping lengths Strip the conductor ends as follows to fit them inside the power cable connection terminals Stripping length Frame size mm in R2i R3i 10 0 39 R5i 16 0 63 Connection box kit The inverter module is supplied with a connection box kit containing the following items back plate cover
64. du dt filter Inverter modules Motor cable entries This drawing is side view of three R3i modules in 400 mm wide cubicle ii DC bus i 2 LJ DC fuse bases JL NM i a Airflow guides Lee rt d nm didi nverter modules BE jt bs Uu Em 3 zm 4e 4 Heer 4 m 4 m H 4 h H E H E 4 Motor cable entries ne jt EEEE 30 Frames 6 and The module can be installed the cabinet using the optional mounting plate code 64138375 and a separate air baffle Alternatively a combined mounting plate air baffle can be constructed The fixing points are shown in the cabinet layout examples below Several R6i or R7i modules can be installed in one cubicle providing the minimum clearances indicated in the dimensional drawings are followed Installation using mounting plate 64138375 The module is fastened by the two fixing points at the top to the rear wall of the cabinet using two M8 screws The mounting plate which connects the module and its cooling f
65. 1 Contact OZXK 2 including 2 NC contact 2 NO contact 2 Resistor ZRF 30x167 5 1 Charging Monitoring Unit NCHM 21C 1 Wire Set OESA control wiring 64349627 1 Switch Fuse OESA250DR2PL X including locking device charging contacts 1 contact 1 NO contact 1 Aux Contact OZXK 2 including 2 NC contact 2 NO contact 2 Resistor ZRF 30x167 5 1 Charging Monitoring Unit NCHM 11C 1 Wire Set OESA control wiring 64349643 1 Switch Fuse OESA250DR2PL 21 1 including locking device charging contacts 1 contact 1 NO contact 1 Contact OZXK 2 including 2 NC contact 2 NO contact 2 Resistor ZRF 30x165 1 Charging Monitoring Unit NCHM 21C 1 Wire Set OESA control wiring 64349651 1 Switch Fuse OESA250DR2PL X including locking device charging contacts 1 contact 1 NO contact 1 Aux Contact OZXK 2 including 2 NC contact 2 NO contact 2 Resistor ZRF 30x165 1 Charging Monitoring Unit NCHM 11C 1 Wire Set OESA control wiring 64808796 1 Switch Fuse OESL630 32D02 2 Resistor ZRF 30x167 5 1 Switch fuse controller ASFC 01C 64808800 64808826 1 Switch Fuse OESL630 32D04 4 Resistor ZRF 30x167 5 1 Switch fuse controller ASFC 01C 1 Switch Fuse OESL630 32D06 6 Resistor ZRF 30x167 5 1 Switch fuse controller ASFC 01C 64808842 1 Switch Fuse OESL630 32D02 2 Resistor ZRF
66. 5800 104 0020 5 350 1200 69 41 200 31 400 62 320 50 640 99 12 5800 104 0025 5 420 1440 69 41 200 31 400 62 320 50 640 99 12 5800 104 0030 5 490 1680 103 61 300 47 600 93 480 74 960 149 12 5800 104 0040 5 650 2220 103 61 300 47 600 93 480 74 960 149 12 5800 104 0050 5 R5i 790 2700 168 99 400 62 800 124 640 99 1280 198 17 5800 104 0060 5 R5i 950 3250 168 99 400 62 800 124 640 99 1280 198 17 5800 104 0070 5 R5i 1150 3930 168 99 400 62 800 124 640 99 1280 198 17 5800 104 0100 5 Rei 1500 5120 480 283 325 50 650 101 520 81 1040 161 67 5800 104 0120 5 R7i 1800 6150 480 283 325 50 650 101 520 81 1040 161 67 5800 104 0140 5 R7i 2100 7170 480 283 325 50 650 101 520 81 1040 161 67 5800 104 0210 5 1xR8i 2500 8540 1280 750 575 90 1150 180 920 140 1840 290 150 Technical data 115 Minimum effective area Minimum effective area Max pressure of air inlet of air outlet drop of Nominal air 5 Inverter module Frame Power loss flow with with cabinet at unit type size unfiltered Luftfilter unfiltered Luftfilter nominal air
67. Guiding the cooling air flow The hot air from an inverter module must not be allowed to enter another module In a cubicle with multiple modules a practical way of achieving this is to install a mounting plate to separate the cool area at the front part of the cubicle from the hot area back part The mounting plate can be fastened to two vertical pillars on both left and right Since the air outlet at the top of the modules points directly upwards the air must be guided to the hot area See the example below SIDE VIEW 600 23 6271 Cool area Hot area Inverter modules Airflow guides Mounting plates 27 To save vertical space the inverter modules can be mounted by their flanges an inclined position as exemplified below 600 23 62 SIDE VIEW Inverter modules Mounting plates Air baffle The chapter Dimensional drawings presents mounting plates for vertical and inclined mounting positions The airflow guides needed in vertical mounting are also presented The mounting plates are directly mountable in a 400 mm wide Rittal TS 8 cabinet system the outer dimensions and fastening holes can easily be adapted for another system 28 Layout examples The drawing below is a front view of a cubicle with three R2i modules installed on top of each other 400 115 75 DC switch fuse DC fuses
68. Li Y 5 Sz te Sel 5 i Y m 0 0 ON 2i IND 315592 NUISNJANUJ 304705019 ONY 5349 03009 lt 711 2 a ib Si Uns es ROS 8 L 9 5 v 2 179 2 19301 ON 7384 889 m Gn N3 5097 dep dsay 12 23 d f Oad Ee eT 9 149840 19130 INNON 0 AON 1 012999 0 ON E 342592 42403519 woj 21955 sep 200 30109 ND1108 21311 0 Mr 00 ITI3MUHT 5 x Or 9 0 QU ug 6082 80 21 d3INNV2 NUISNJANUJ 39 4 0930109 CNY 524 N 03009 S310H 2 19821999 E Ee 1821979 8 L 9 6 v 5 2 180 Crossmembers Rittal TS 8 400 mm included in kit 68256836 rL ON 928 889 EE pU SAN MORE 5991 12 08 044 Sr SNIAVS
69. OMG Ajddns samog 909 069 24159 911 SdoV NOLdO noo 062 SELER ENG SEU 31000N NOU dO EHA 006 062 210 01 p X 4 13 2 01 00850 5431 SALVIS 6vv jJ M3LS3ANI I 1 9 gt lt m 10 02 20 0118 1391 JO OVAO Z SII uappiquoy gt 1 ssasdxa 591209 JO 5 uononpojdeay UO DULOJU au PUD SIU 34612 0 2409 uonouojny gay 125 Example Three frame R2i to R5i inverter units 3909 10 11 86 101 33 5910 gav 862101 ON jeu 19945 ON 200 ON 200 180 1 Vu wey 713 dep 1 100 2 4 200 101 008527 UDJbDIp 101 008vV2V 1940119 500 SIAYA enu 007 9010 ueucloDg pouodeug pasog t T 1 701 00852 5an oan 30N 90N 30N E53
70. oM 151 Mounting plate inclined yuo 325 88V eus 16 79 JAVE 200 887 ON 200 3579 28801 001 dep dsay amp 21018 ddy 40949 Ee uuoj 21055 sep 200 008 S Y 002 20 12 MDIDASS 11494 uo posog g weer os amp 8S as P 4 42224016 0 29 01 0 133HS 13315 934909 40 10 1VIJ31VN gt 5 W CRX TE 80776308 1 m 8 Sa 9 gt 4 o o ES 04 806 me DAS D res M o GO E L zg 5 M 1 jo gt 116 01 9 lt 56 9 896 5 sup 8 2 i sod 200 gt 81 i lt 9 N be Sh Sesh 991 vio 988 ot 96 1 Bea umop 9W 161 892 E o 9 661 oie 9 06 2 de MER 24 9612 25 E 9 607 8 1 9 9992 o 91 9652 o m E 52 5 SI gs o e o 5 i
71. 232 9 13 12 26 62 820 ACS800 104 0025 5 R3i 466 18 35 173 6 81 232 9 13 12 26 62 820 ACS800 104 0030 5 R4i 525 20 67 240 9 45 252 9 92 15 33 62 1000 ACS800 104 0040 5 R4i 525 20 67 240 9 45 252 9 92 15 33 62 1000 ACS800 104 0050 5 R5i 673 26 50 265 10 43 276 10 87 23 51 65 2000 ACS800 104 0060 5 R5i 673 26 50 265 10 43 276 10 87 23 51 65 2000 ACS800 104 0070 5 R5i 673 26 50 265 10 43 276 10 87 23 51 65 2400 ACS800 104 0100 5 R6i 744 29 29 228 8 98 367 14 45 37 82 64 2270 ACS800 104 0120 5 744 29 29 228 8 98 367 14 45 37 82 64 4530 ACS800 104 0140 5 744 29 29 228 8 98 367 14 45 37 82 64 4530 ACS800 104 0210 5 1xR8i 1397 55 00 245 9 65 596 23 46 150 330 72 8200 ACS800 104 0260 5 1xR8i 1397 55 00 245 9 65 596 23 46 150 330 72 8200 ACS800 104 0320 5 1xR8i 1397 55 00 245 9 65 596 23 46 150 330 72 8200 ACS800 104 0400 5 1xR8i 1397 55 00 245 9 65 596 23 46 150 330 72 10250 ACS800 104 0460 5 1xR8i 1397 55 00 245 9 65 596 23 46 150 330 72 12300 Technical data 113 Inverter module unit Frame _ Height Width Depth weight capacitance type size 4 kg Ibs dBA ACS800 104 0610 5 1xR8i 1397 55 00 245 9 65 5
72. 3 clamps lug terminals frame sizes R2i and R3i only Screws The kit also contains a shroud for covering the relay outputs of the RMIO board Cable connection procedure Refer to the diagram below 1 Insert the hooks of the connection box back plate to the two corresponding slots in the bottom plate of the inverter module 2 Fasten the back plate to the module frame with two screws 3 Strip off the plastic sheaths of the input DC cable if of shielded type and motor cables under the cable clamps Fasten the clamps onto the stripped part of the cable Frame sizes R2i and R3i Crimp lug terminal supplied in the connection box kit onto the twisted shields of the cables All frame sizes Connect the shields to the grounding terminals Connect the conductors of the input DC cable to the UDC and UDC terminals and the phase conductors of the motor cable to the U2 V2 and W2 terminals 6 Secure the cables outside the unit mechanically 7 Connect the control cables as described in section Control connections Fasten the cover to the back plate with two screws 53 Frame R2i to R4i power connections Frame R3i pictured Item No Information a A d 1 Connect to PE busbar of cabinet 2 4 Prevention of unexpected start optional See also the chapter Circuit diagrams 2 L 95 265 V AC Voltage must be ON for the inverter
73. 591 55 28 m 9 5 32 CEN 9 ae gt 8 2 E Se 8 0 b 8 a s d y PE 80 co o 24 88 2 Co S Gve Ir 2 ino you _ 5 Que gs SOLE gt ae 1 P _ 558 ge poaiyy 9w f G Sec 9 168 iy uoo g 3 91 8 19 7025 or 02 8 o 9 O v 0 2 gep 051 5 5 7 5 UN 4 4 8 o ns k o 867 5 4 G G6y 8 4 77 805 7 gt ize 8 905 E M SN 10 29 8 89 a A d Sle 5 B v ista Vd RI xS 5 N S 2 5 27165 2 8 5 809 i 52 6209 5 919 5 e SNIOQN3d LN3LVd 3 Y a 5 2 6 47 44016 0 27101 WwG 133HS 13315 9349 09 2 0 10 8 L 9 5 y ni 164 Frames 6 and Module dimensions excluding fan
74. 68263751 68261040 1 0210 5 0260 5 1 68263565 68260990 68263697 68263620 68261031 68261015 68263760 68261066 1 0260 5 0320 5 1 68263581 68259258 68263719 68263638 68259703 68259738 68263816 68259720 1 0320 5 0400 5 1 68263590 64766252 68263727 68263646 64766244 64766236 68263824 64766201 1 0400 5 0460 5 1 64694197 64794124 64650289 64694189 64794159 64794183 64650297 64794167 1 0460 5 0610 5 1 64694162 64794191 64650301 64694154 64794205 64794221 64650319 64794213 1 0610 5 0910 5 1 68260116 68260132 2 0460 5 1210 5 1 68260574 68260591 2 0610 5 1820 5 1 68260612 68260647 3 0610 5 2430 5 1 68260655 68260671 4 0610 5 Uy 690 V 0210 7 1 68263841 68261074 68263921 68261091 1 0210 7 0260 7 1 68263859 68259665 68263930 68259681 1 0260 7 0320 7 1 68263875 68261082 68263956 68261104 1 0320 7 0400 7 1 68263883 64766406 68263972 64766309 1 0400 7 0440 7 1 64650327 64793918 64650335 64793926 1 0440 7 0580 7 1 64650343 64792571 64650351 64794086 1 0580 7 0870 7 1 68260728 68261155 2 0440 7 1160 7 1 68261163 68261198 2 0580 7 1740 7 1 68261201 68261210 3 0580 7 2320 7 1 68261228 68261236 4 0580 7 5800 104 ordering information 9
75. 8 E EL H CNTL2 275 OR DDCS PC ol TRIGGER i DDCS NODE ADDR APEB 4C RBs PWR V11 TEST 1 TEST2 MODE 1 APBU 44C PPCS BRANCHING p RXD 69 60 TXD amp DATALOGGER o lo 8 G9 PWR UNIT 4 8 CH oa 8 24 VA Er Pow BD ED 24 VB IN FAD T 6468 8391 199 200 Fuse bases OFAX series S00312A 2 2 c 10 E M 2 k L OFAX 00_ 38 74 109 42 77 112 128 145 148 100 8 25 0 35 70 17 5 35 255 2 95 1111 OFAX 1_ 59 5 114 5 169 5 64 119 174 225 240 250 175 25 30 85 140 10 5 55 41 5 1097 11232 2_ 69 5 134 5 199 5 84 149 214 225 240 250 175528 25 95 160 105 65 41 5 119 1133 OFAX 3_ 60 141 5 223 84 164 246 241 270 265 210 25 30 82 164 10 5 81 5 38 3 1142 5 OFAX 18 119 2 OFAX 1S 133 045 045 S UN 6 6 x 10 6 9x13 4 QQ 1 L 1 1 11 23 5 iL J 11x 23 5 5 E 115 20 25 OFAX 00_ 00 OFAX 1_ OFAX 2_ OFAX 3_ 201 OFASA3 250 02 005 202 Switch fuses charging control units
76. 88 HeatsinkS xA mI UE E M CREE utr A necs 88 ESPERE RE Le Pad dhe 89 Fan replacement R21 ER RUE er EE RI Li utut qs 89 uo rx Mat 8 89 Fan replacement eo aa e Pace 90 Additional Tan eee eR Ue D e eae sed 90 Replacementi R2iy RG t Sd SEE 90 Replacement R4 REV EP aV 90 Fan S PRO RIP en ela cre oon 91 Power connections R81 92 Capacitors x uos ako b Ree de ba ie etd ec Der cae eee cu et eie Ree a De es 92 Table of contents ACS800 104 ordering information What this chapter contains 93 1 144 1210 01510 d s es 93 51265 2110 8 1 2 az wee ae bcd CR C it 93 Frame size R8i and multiples 95 DC fuses and fuse bases DC switch fuses 96 Inclined mounting plates for 2 to R5i modules 99 Cooling fans for and R7i modules 99 Common
77. AWG 14 double insulated NCHM to ground 2 5 mm AWG 14 From fuses NCHM to charging resistors 1 5 mm AWG 14 Switch fuse auxiliary contact solenoid wiring auxiliary voltage supply to NCHM 0 75 mm AWG 18 57 Installation of common mode filters The following diagram shows how the common mode filter consisting of three toroidal cores is installed on the output cable Tie conductors tightly together using In order to provide thermal insulation for conductors non conductive electrical tape plus wrap cables inside toroid rings with silicon rubber tape non metallic cable tie to prevent included Each turn of tape should overlap half of damage to insulation due to rubbing previous turn Approximately 1 5 metres of tape is against toroid ring edge needed per cable Type of tape LW 50125 R12 PO 32 x 1 25 mm o Loj m Bind toroid rings together and to cable using heat resistant non metallic cable ties MIN 20MM SS 270 2108 Concentric PE shield of motor cabl PDM 58368 B 58 Power connections Frame R8i and multi iples See also the document ACS800 MultiDrive Planning the Electrical Install
78. OM 10029813 1 OREX agg 58065749 1 64089684 a eS won SSR 0210 7 1 an 10001773 2 OFASA 35009841 1 64808796 0400 7 0440 7 2 e 10029881 2 Rd 35009841 1 64808842 0580 7 2 pei 64673769 2 35009841 1 64808842 0870 7 4 d 2 10029881 4 dnm 35009841 1 64808851 1160 7 4 E 64673769 4 35009841 1 64808851 1740 7 6 burg 64673769 35009841 1 64808877 2320 7 8 64673769 522 35009841 2 64808851 Switch fuse contents Order code Kit contents 64089561 1 Switch Fuse OESA00 160D2PL 1 Mounting Frame for 4 aux contacts 4 Contact 2 NO 1 NO gold plated 1 1 Resistor ZRF 30x167 5 1 Contactor LP 1 D501124 1 Relay 11 pole 1 Socket 64089650 1 Switch Fuse OESA00 160D2PL 1 Mounting Frame for 4 aux contacts 4 Contact 2 NO 1 gold plated 1 64089684 1 Switch Fuse OESAO0D2PL 1 Mounting Frame for 4 aux contacts 4 Contact 2 1 NO gold plated 1 2 Resistor ZRF 30x165 1 BC 25 30 10 24 1 Relay 11 pole 1 Relay Socket 64349619 1 Switch Fuse OESA250DR2PL 21 1 including locking device charging contacts 1 contact 1 NO contact
79. 0 08 21 230 50 10 20 NCHM 22 E 45 60 20 4 0 230 50 60 0 16 6 0 1 2 cycle NGPS 01 115 60 0 32 6 0 1 2 cycle NPBU 42 24 02 0 235 RDCU 02 24 0 25 12 Cooling fans Frame U In lstart size V AC Hz A A 50 0 7 14 2 140 151 09 230 R7i 60 0 9 1 8 G2E140 AI32 ABB 115 60 18 3 6 400 50 13 R8i D2D160 BE02 11 320 60 13 119 Technical data 120 Technical data 121 Circuit diagrams What this chapter contains This chapter contains the block diagrams of the ACS800 104 inverter modules as well as example connection diagrams for the whole inverter unit Circuit diagrams 122 Frame R2i to R5i R2i R3i Block diagram 9 1 9409 6979 34 5 4 sedg 88 3dep dsajy 40260 1049499 irr u uol ood 154 164 01 00852 ON 88v 2002 0 0 224101519 ON 200 38ND jp lt 31000N v are 3 rd dt z 310000 NOU dO i EKAA x eng pee 1 pd 4 23 doo E 412010 Ma a d pei fel ERE OST pup 8 a ri pt 1 5
80. 081 888 81 5 328 194 2 902 4 54 5 N soz Elg 8 oo 1 572 23 60 0 2 re ie lt lt 62 List se 2 53 o e 80 ooo a8 soz L 28 9 mE 6576 N ER 82 dn poeiuy gw RI Lseec 87026 ES gt 35 198 3 566 e 2H 965 919 2 y 02 F 8 gt jno 20ux 726 44 8 8 Sosy E amp EE Ley D z D 5 o o o o o o 5 S Sur o 66v sev 19 66v o 1909 6 lt lt 6 2 5 lt 125 8 a 2 9 5 5 2166 906 sis SS 8 809 R 2 5809 805 9 9 99 200 Sal GEY oT 1317 50670 _ ___ Wes 329024 FRISS 0081 1 82 592099 5094 wavoisng 21025 sop 500 youojsuauip axi E Kon 89 ACT 252521 2568 Module dimensions e F f 2 201
81. 2700 9220 1280 750 575 90 1150 180 920 140 1840 290 150 5800 104 0260 3 1xR8i 3700 12700 1280 750 575 90 1150 180 920 140 1840 290 150 5800 104 0320 3 1xR8i 4500 15400 1280 750 575 90 1150 180 920 140 1840 290 150 5800 104 0390 3 1xR8i 5800 19800 1280 750 575 90 1150 180 920 140 1840 290 150 5800 104 0510 3 1xR8i 7900 27000 1280 750 575 90 1150 180 920 140 1840 290 150 ACS800 104 0770 3 2xR8i 11400 38900 2560 1510 960 150 1920 295 1536 240 3072 475 180 ACS800 104 1030 3 2xR8i 15300 52300 2560 1510 960 150 1920 295 1536 240 3072 475 180 5800 104 1540 3 3xR8i 22500 76900 3840 2260 1440 225 2880 445 2304 355 4608 715 180 5800 104 2050 3 4xR8i 29500 101000 5120 3010 1920 295 3840 595 3072 475 6144 950 180 500 V ACS800 104 0004 5 R2i 100 340 35 21 100 16 200 31 160 25 320 50 12 5800 104 0005 5 R2i 110 380 35 21 100 16 200 31 160 25 320 50 12 5800 104 0006 5 R2i 130 450 35 21 100 16 200 31 160 25 320 50 12 ACS800 104 0009 5 R2i 160 550 35 21 100 16 200 31 160 25 320 50 12 ACS800 104 0011 5 R2i 200 680 35 21 100 16 200 31 160 25 320 50 12 5800 104 0016 5 270 920 69 41 200 31 400 62 320 50 640 99 12
82. 3 Motor control and I O board RMIO 84 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 Rin 100 ohm and one programmable differential voltage input 10 V 0 V72 V 10 V Rin gt 200 kohm The analogue inputs are galvanically isolated as a group 500 VAC 1 min 15 VDC gt 60 dB at 50 Hz 0 025 96 12 bit for the 10 10 V input 0 5 11 bit for the 0 10 0 20 mA inputs 0 5 96 Full Scale Range at 25 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 77 F Temperature coefficient 100 ppm C 56 ppm F max 10 mA 1 kohm to 10 kohm Voltage Current consumption Analogue outputs 24 VDC 10 short circuit proof 250 mA without any optional modules inserted onto slots 1 and 2 1 2 A max Resolution Inaccuracy Digital inputs Two programmable current outputs 0 4 to 20 mA lt 700 ohm 0 1 10 bit 1 Full Scale Range at 25 77 F Temperature coefficient 200 ppm C 111 ppm F max
83. 9 S Y 2 L PAY 0 BY puo SIY 161 1009 4 jeeus 4666 79 Jive ON 200 53490 88V pu Aay 001 13 4584 1 25 sap 200 ay ON 88V ON 200 1509 ydaloig addy 094 94101519 40069086 5 neg posodaig Uo pasog 192 021 Ajos si Ajuoujno 52158 PAU 0 eunsopsip Jo esn uononpojdey Y puo SIU SjuDU ASII oM 162 Mounting plate inclined 1005 seus 660695179 SAVE ON 0Q 0 99 8 N3 pu nay 001 dep dsay vv 64 2055 sap 200 Aod ON jeu 88V ON 200 1500 2 019 bununoy addy 7224 15 008 59
84. Ing circuli R6i Charg A 6v v 09 44 6 ON 209 D sep 2543 woog yold 19 n1 Buibsoyo Uu8uDS X0 2002 LL ZZ Pe ouddy 008 62 enu 010 SOOT LILLE ON 88V ON 3579 AQ69 2 pasn si Zy 101002 XX MOdN ON 1 391 1 1 SLOP 0109 336 JOHLNOO 3 ONIIOOD 803 12161 28102000 ueppiquo AOS S AqOUIND ssoJdxe SonJod PIU 9JnsOposip JO UOnbuLOJU PUO SIY U 53462 0 9 J9S9J 9M 2409 uonouojnv 88 128 Ing Circul Charg 8 1 S A A 19945 S 99v 0179 33 204 2543 143 40 uSuDS 0 sep ue 464601 e upninw 008 52 enu 40 010 n 22 929 00211 2 SOOT LLL pasodesg ON 88V 48u015n2 ON 2 011 0 2 SL9v 0179 JAVE 3 9 1002 303
85. Kit For Contents of 1 kit Order code 20 air inlet kit unfiltered 400 mm wide cubicle Aperture size 274 x 526 mm 10 8 x 20 7 1 pc Grille metallic 68239478 600 mm wide cubicle Aperture size 471 x 504 mm 18 54 x 19 84 1 pc Grille metallic 68239460 800 mm wide cubicle Aperture size 671 x 522mm 26 42 x 20 54 1 pc Grille metallic 68259827 400 600 mm 68239478 68239460 wide cubicles 68260817 ACS800 104 ordering information 106 Cabinet ventilation kits for R8i modules wide cubicles Kit For Contents of 1 kit Order code 1 pc Grille inner 400 mm wide metallic cubicle 1 pc Filter mat Luftfilter Aperture size airTex G150 68239443 274 526 mm 1 pc Grille outer 10 8 20 7 plastic 1 pc Fastener 1 pc Grille inner 600 mm wide metallic cubicle 1 pc Filter mat Luftfilter Aperture size airTex G150 68239451 42 airinlet 474 504 mm 1 pc Grille outer kit filtered 18 54 x 19 84 plastic 1 pc Fastener 1 pc Grille inner 800 mm wide metallic f ji n cubicle 1 pc Filter mat Luftfilter li n y Aperture size 6150 t 68259797 671 522 1 pc Grille
86. Planning the Electrical Installation 64783742 English Inverter modules R2i to 71 ACS800 104 type Frame size Order code kW no options Q950 400 V 380 400 415 V ACS800 104 0003 3 R2i 1 5 64685724 64741730 ACS800 104 0004 3 R2i 2 2 64704338 64751972 ACS800 104 0005 3 R2i 3 64704346 64751999 ACS800 104 0006 3 R2i 4 64704354 64752162 ACS800 104 0009 3 R2i 5 5 64704362 64752243 ACS800 104 0011 3 R3i 7 5 64702262 64752464 ACS800 104 0016 3 R3i 11 64704478 64752529 ACS800 104 0020 3 R3i 15 64704486 64752723 ACS800 104 0025 3 R4i 22 64702271 64752812 ACS800 104 0030 3 R4i 30 64704524 64752855 ACS800 104 0040 3 R5i 37 64702246 64759833 ACS800 104 0050 3 R5i 45 64702254 64759922 ACS800 104 0060 3 R5i 55 64704320 64759965 ACS800 104 0100 3 75 68253390 68260400 5800 104 0120 3 90 68253411 68260418 Un 500 V 380 400 415 440 460 480 500 V ACS800 104 0004 5 R2i 2 2 64704419 64752065 ACS800 104 ordering information 94 Inverter modules R2i to 71 ACS800 104type Frame size Pcont max Order code kW no options Q950 ACS800 104 0005 5 R2i 3 64704427 64752111 ACS800 104 0006 5 R2i 4 64704435 64752146 ACS800 104 0009 5 R2i 5 5 64704443 64752201 800 104 0011 5 R2i 7 5 64704451 64752278 ACS800 104 0016 5 R3
87. SN 590 35 5401 puray 4584 W2 UN awu 122044 Sra ev 0015 51883559 WILLIS 30123NNO2 1573 EDEN TTZ 50942 4840350 YT sap 300 120815 1 SDDSXH 62200529 pasog 4 Di A38 X 17007900 300 27 JUL 80140831 14182530 ON lad 00 0 9266 292 BELE 535 2 ZIN BELENIT 9 00 v INZ 6NIC 88 LANNY INZ 666110 88 3805 EON ARIS 9 0 LINE TS 9M 8 00 0 AGNOS OCX9N 401234021593 8 00 0 Xelv62rf dA 2 2 9562 153 9679 NIC 21W 6 9 84 403 ZIN 96 9410 74845 ANI 9 00 I e 83 X21X84nSH14 NZ 1 77 88 CC6NIG 18 03 342518402 21 8 AOS 18002 9 9 00 07 2 20 1918 289 524 2 MU123NN02 1594 184405 19186289 1 00 ov 22 1026999 83 SCLOSNNGD 1594 1086999 8 2 00 2 W8 20 17651979 314 2 394518 1969199 6 9 20 4 OEH 050 5766 1599 91549 0 6 099 vovoinsul DET 40040 64089 860 809 01 9 3 N nA Y 3 m amp IET 666 ES D 5 Fh pe 3 205 E 5 8 d amp 5 1512 09 684162 5 8921 89 18921 89 18921 89 18921 89 16661 68 a 5501 v 7 5 m gt co n 2
88. eee ete Ere duc 18 Cabinet layout oS Ne ee wetted el hee a Shas 18 Frame R8i and multiples i ssi orem RE e ee ae 19 Module layout i Bek ae ele 20 CabinetlayoUt iui wr ERR ede oe kale 21 Controblinterfaces x feces dti Base RT Saline Sat ene 22 Type Gde Er 23 BASIC COGS EE EA AA A E ME 23 ODptlon Codes 2 2 RM Be Died 23 Cabinet construction Whatthis chapter contalns eee RAE ER 25 Frame R2Ito RbI cua ER EM RUE E E 26 Guiding the cooling air flow 26 Layoutexamples i i 9 ea eg Pee eee 28 Frames R6 and RI esos Le ecient EP and wie ete 30 Installation using mounting plate 64138375 30 Installation without mounting plate 64138375 31 Frame 8 and multiples 32 General i eO PUR IS deat sei dpt oed c ied dat 32 ERE 32 Module extraction insertion 32 Table of contents Mourting exampl s sess tages nan Bel esos Sade we cree
89. lt 700 ohm X22 E DI Stop Start 2 012 Forward Reverse 1 3 DI3 Not in use lt 4 014 Acceleration amp deceleration select 2 5 015 Constant speed select 3 6 016 Constant speed select 3 7 24VD 24 VDC max 100 mA 8 24VD 9 DGND 1 Digital ground 10 DGND2 Digital ground 11 Start interlock 0 stop 7 X23 r 34 1 24 Auxiliary voltage output non isolated 2 GND 24 VDC 250 mA X25 1 RO1 Relay output 1 ready 12 RO1 3 __ ROW X26 1 RO2 Relay output 2 running 2 RO2 E LS RO H X27 1 RO3 Relay output 3 fault 1 Fi 2 RO3 um 3 RO3 Motor control and I O board RMIO 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 Terminal block size cables 0 3 to 3 3 mm 22 to 12 AWG Tightening torque 0 2 to 0 4 Nm 0 2 to 0 3 Ibf ft 1 Only effective if par 10 03 is set to REQUEST by the user 20 open 1 closed Ramp times according to 0 parameters 22 02 22 03 1 parameters 22 04 and 22 05 3 See par group 12 CONSTANT SPEEDS 015 DI6 Operation 0 0 Set speed through 1 0 speed 1 0 1 Constant speed 2 1 1 Const
90. 11 13 7 5 ACS800 104 0020 5 R3i 25 32 15 23 15 18 11 ACS800 104 0025 5 R3i 34 46 18 5 31 18 5 23 15 ACS800 104 0030 5 R4i 42 62 22 39 22 32 18 5 ACS800 104 0040 5 R4i 48 72 30 44 30 36 22 ACS800 104 0050 5 R5i 65 86 37 61 37 50 30 ACS800 104 0060 5 R5i 79 112 45 75 45 60 37 ACS800 104 0070 5 R5i 96 138 55 88 55 69 45 ACS800 104 0100 5 R6i 112 168 75 108 75 84 55 ACS800 104 0120 5 135 224 90 130 90 112 75 5800 104 0140 5 164 270 110 157 110 135 90 690 V ACS800 104 0011 7 R4i 13 14 11 11 5 7 5 8 5 5 5 Technical data 110 Nominal ratings No overload use Light overload use Heavy duty use Inverter module type pi leontmax Imax bon PN Ind Pha A A kW A kW A kW ACS800 104 0016 7 R4i 17 19 15 15 11 11 7 5 ACS800 104 0020 7 R4i 22 28 18 5 20 15 15 11 ACS800 104 0025 7 R4i 25 38 22 23 18 5 19 15 ACS800 104 0030 7 R4i 33 44 30 30 22 22 18 5 ACS800 104 0040 7 R4i 36 54 30 34 30 27 22 ACS800 104 0050 7 51 68 45 46 37 34 30 ACS800 104 0060 7 R5i 57 84 55 52 45 42 37 ACS800 104 0070 7 R6i 65 104 55 62 55 52 45 ACS800 104 0100 7 88 130 75 84 75 65 55 ACS800 104 0120 7 105 176 90 101 90 88 75 Frame R8i and multiples No overload Light overload Nominal ratings Heavy duty use Inverter unit type Frame Inverter mod
91. 2 12015 28dxoun 01 J3M JO 02 f 23 SA TOMLNOD z U 218412 day d N 2HO9 ZHOS AGLI OSZ ES oe 22 2 3 Fat gt Zcun PFun SNS gt 02 TEx 212 112 gt 339 2 1075 88 1075 8e 0 DMN vct OZLA 1X3 IZLA ZO OINY 0 1 1OMINOO 2 LINN SNIHONWYS 5344 SV uonounoju 54 PUO Siu 5140 0 M uappiquoj Anouis ssejdxo sanjod oi eansopssip JO osn uononpojday 7805 uonouoinv 88v 135 Cooling fan control inverter modules without optional speed controlled fan Auxiliary voltage distribution
92. 2 5 N Gilt ee N Sa lo 00 x i5 I CN H S 103 64152955 72 Wiring Control panel with monitoring display X3 Monitoring Display NLMD 01 X4 312R X1 X4 X1 X3 Panel Interface ADPI 01 RMIO X2 H x39 Monitoring display only RMIO X39 NLMD 01 X4 Fa 73 Earthing Each 01 board is to be individually earthed The earthing wires are included in the control panel platform and LED display kits NLMD 01 DIN 7981 F 3 5x6 5 TORX St Zn NLMD 01 NLMD 01 74 75 External 24 V power supply for the RMIO board What this chapter contains This chapter describes how to connect external 24 V power supply for the RMIO board When to use External 24 V power supply for the RMIO board is recommended if the application requires fast start after connecting the input power supply fieldbus communication is required when the input power supply is disconnected For current consumption of the RMIO board see chapter Motor Control and Board RMIO Paramet
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94. 32 Single R8i module a Rittal TS 8 cubicle 33 Two R8i modules in a Rittal TS 8 cubicle 38 Three R8i modules in a Rittal TS 8 cabinet 43 Three modules side by side 46 Electrical installation What this chapter contains eris easten eoi te ee eee a 49 eu ERE RENS sete ee rid SLM 49 Notes on Optical Components 49 Checking the insulation of the assembly 50 Power connections Frame R2i to 51 Diagrama 2 icm ea ae wha week he Data ie des 51 Conductor stripping lengths 52 Connection box 52 Cable connection procedure 52 Frame R2i to R4i power connections 53 Frame R5i power connections 54 Power connections Frames and 55 Diagram c Res XR Cie RI Ra Pet 55 DGC and motor connections vu E Pee 56 Charging Circuit asd nck sre I eR
95. 4 il L NOT Lad Ug vers vaduT ME JOULNOD 20 D 1 1 1 1 D m 15 S S S N gt Sindino ZM zn 2 2010 y 510400 1015 SINdNI 3090 1VNV 1 1 gt SINANI 1 1910 3 3 20584 d jme eine n liy merce A K 3 2 1075 gt 10 1 l NJ 1075 Gea eae kones 2571 Kiddns TOHLNOS 3091 39V JH31NI YOLOW LINDYID 10 OINM onv 0 1 1 211 549 NOLdO 21166 911 28 18 NIV f Icev 141 Pez gt 01 00852 L 5091 511 157 69 LINA XILINI 1391 30 OVAO Z SIL 89 01 002 v0 9l OMASI VIG ION 58 uappiq oy si 5552659 521259 O JO sen uononpoudeg UONOULOJU By U PUO SIY U 514612 10 9AJ9S9J 2809 88 123 R4i Block diagram
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99. Is 242 1 s wer 43447741 1 2 8 1 1 1 1 1 i H 1 1 1 1 si 58 aa 33 3d 3d ES Eg 1 3 Ei 8 L 9 5 Y 126 Frame R6i and R7i ion diagram Connect A 49 0198 335 ON 20g Pursy ydap dsay 2543 sop ue woog 008 52 enu 0 010 ION yoefoag UGuDSxO 002 11 00 11 ON eH 887 294101519 7200 1880 318VN3 01 80333 210 Yndui ajqoua uns 40 pasn amp ZLY 203201009 PUD ZGA 40 98UUO gt OINY vv 91 12045 2edxeun jo VASLI OSZ 10 696 0199 JAVE 0199 3395 10 550 YAMS jo 1201402 2140 gt ando 22413 2 1 21 549 26102000 Ueppiquo Apowys 5 iuouino ssejdxe 591209 puru 20 Sn uofonpoudeg PUO Siu Ul 53460 2059 M 2902 uonouo ny ggv 127
100. PUN x3 4584 1 23 35a oug ev 00758 719130 INON 304 0 d3S GI 4489 60 435 1 4 12942 woy 21925 204 0 1904415 1043 21411 0 TITI3NDHT 4945 4 uo 8594 6858 o o o o o O Q O O 268 40 88 0 26920979 26920999 8 2 9 5 v 2 186 Rear crossmember 3 modules side by side included kit 68259541 3009 SIAING ON 88V S 55 00505 0979 JAYE 200 ON 7200 1590 3 Nj Pu ray dep 2 223 g Aral 40 10190 NAON 7002 19011 389 7002 12001 99940 Juosn 5 Yt woy 2056 200 05 1404405 OWE 2002 ON IL STA N3NOMlld pe odeid uo pasog 2 ONIGIOS Tiv E229 SNINV31O 9SNISV3393G 0269 3ONVH31Ol LNOHLIM NOISN3NWIG 54 691 1H9I3M 2 6 lt 7 02 40 15 0 2 101 N3 ww 33HS 13315 93409 ONIZ 1 doa ied 5 g d vum 8 55 3 8 0 ces 0 E 1 1 1 pir f El 258 v9 553 EB Es de sod 01 23
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102. b 3 Bs A ros 5 i d 07006 22 g N 8162 7 2 60 2 60 12007 8 N o 5 8 5 7 N 2 5 5 2 1 yno 11729 N o 88952 sod 2 6 667 7 5 8 umop 85226 LEG 0 uc 466 3 sod z 22 04 LvG QvvG H clo N 17855 EM 5 200 1 AE sod g 8 2 4 ES p 59 3 8 5 2 0 4 2 ES 3 152 Frame 41 Imensions Module d I wri ON 398 889 62009299 JAEN sal nd N3 5997 0 yPwr ss XIJ 1d8p v01 008S2V auvu S 31813559 0041 v3 80 08 12 544989 712305 5 2 OT 2155 sap 2o youo suawip 0 AoW I2 APSVH paaodaug pasvg 200 SN
103. below For external control connections of other application macros and programs see the appropriate Firmware Manual Terminal block size cables 0 3 to 3 3 mm 22 to 12 AWG Tightening torque 0 2 to 0 4 Nm 0 2 to 0 3 Ibf ft 1 Only effective if par 10 03 is set to REQUEST by the user 2 0 open 1 closed Ramp times according to 0 parameters 22 02 22 03 1 parameters 22 04 and 22 05 3 See par group 12 CONSTANT SPEEDS DI5 DI6 Operation 0 0 Set speed through 1 0 Constant speed 1 0 1 Constant speed 2 1 1 Constant speed 3 4 See parameter 21 09 START INTRL FUNC X20 1 VREF Reference voltage 10 VDC 1 lt lt 2 AGND 10 kohm X21 r1 1 VREF Reference voltage 10 VDC 1 kohm lt lt 2 AGND 10 kohm 3 Speed reference 0 2 10 V gt 1l 4 1 200 kohm 15 Al2 By default not in use 0 4 20 mA Rin 6 Al2 100 ohm 7 AI3 By default not in use 0 4 20 mA Rin 8 13 100 9 1 Motor speed 0 4 20 mA 0 motor nom 10 1 speed lt 700 ohm 11 2 Output current 0 4 20 mA 0 motor 12 2 nom current
104. cm in Pa Un 400 V ACS800 104 0003 3 R2i 80 280 35 21 100 16 200 31 160 25 320 50 12 ACS800 104 0004 3 R2i 100 340 35 21 100 16 200 31 160 25 320 50 12 5800 104 0005 3 R2i 110 380 35 21 100 16 200 31 160 25 320 50 12 ACS800 104 0006 3 R2i 130 450 35 21 100 16 200 31 160 25 320 50 12 ACS800 104 0009 3 R2i 160 550 35 21 100 16 200 31 160 25 320 50 12 ACS800 104 0011 3 R3i 200 680 69 41 200 31 400 62 320 50 640 99 12 ACS800 104 0016 3 270 920 69 41 200 31 400 62 320 50 640 99 12 ACS800 104 0020 3 350 1200 69 41 200 31 400 62 320 50 640 99 12 ACS800 104 0025 3 Rdi 420 1440 103 61 300 47 600 93 480 74 960 149 12 ACS800 104 0030 3 Rdi 490 1680 103 61 300 47 600 93 480 74 960 149 12 ACS800 104 0040 3 R5i 650 2220 168 99 400 62 800 124 640 99 1280 198 17 ACS800 104 0050 3 R5i 790 2700 168 99 400 62 800 124 640 99 1280 198 17 ACS800 104 0060 3 R5i 950 3250 168 99 400 62 800 124 640 99 1280 198 17 5800 104 0100 3 R7i 1500 5120 480 283 325 50 650 101 520 81 1040 161 67 5800 104 0120 3 R7i 1800 6150 480 283 325 50 650 101 520 81 1040 161 67 5800 104 0170 3 1xR8i 2200 7510 1280 750 575 90 1150 180 920 140 1840 290 150 5800 104 0210 3 1xR8i
105. fibre optic link See this chapter under Control connections Motor connection The motor connection of frame R8i inverter modules is located at the back of the module so that a quick connector can be used enabling easy extraction of the module from the cabinet for maintenance The chassis socket available separately with different mounting parts is attached to the rear part of the cubicle see the examples in the chapter Cabinet construction The picture below shows a cabling example Chassis socket with Er di mounting plate Gland plate Lower module guide 60 Direct motor cabling The diagram below shows the connection of the motor when the inverter unit consists of one inverter module only 1 a U2 lg 2 v2 TE CONSE GS eo 1 Inverter unit cubicle If a common motor terminal cubicle is not used all the inverter modules in a parallel configuration 2xR8i 3xR8i etc are to be cabled separately to the motor as shown in the diagram below U2 w2 T 02 eer s e Ex Inverter unit cubicle 61 WARNING The cabling from all inverter modules to the motor must be physically identical considering cable type cross sectional area and leng
106. fune esaucxo noun son id Drs 89166283 03 01051 JO uononpouda uppuaui UI Duo Ska 5140 WO anuasau 89165289 8 2 9 y 2 I 183 eol ON 7994 88V 3995 200 SAAS 4147 ON 501 3575 N3 8uv1 WI3 dsay S3d awou 32a 0ug tv ST 119131 2 43934915 543592 224051 D L sap 504 1350958 70 45 22 SUDSX3W pauodaag Uo pasog 18 O O OO OO R 2 11914 89162 289 2 20 UI SH UJ 53402 WO 2 22522 89165289 8 4 v 184 Front crossmember 3 modules side by side included kit 68259541 2 10391 388 88V 2845 moy 200 ee Y 200 3592 Nj 5401 554
107. is completed See Electrical installation Installation checklist 80 Installation checklist 81 Motor control and 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 ACS800 units which employ the RMIO board Note for the ACS800 02 with the enclosure extension and the ACS800 07 The terminals of the RMIO board are wired to optional terminal block X2 if present The connections shown below apply also to terminal block X2 the markings are equal to the ones on the RMIO board Terminals of X2 accept cables from 0 5 to 4 0 mm 22 to 12 AWG Tightening torque 0 4 to 0 8 Nm 0 3 to 0 6 Ibf ft Note for external power supply 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 WARNING If the RMIO board is supplied from an external power source the loose Motor control and I O board RMIO 82 External control connections non US External control cable connections to the RMIO board for the ACS 800 Standard Application Program Factory Macro are shown
108. is suspected Replacements are available from ABB Do not use other than ABB specified spare parts Capacitor reforming Reform re age spare part capacitors once a year according to ACS 600 800 Capacitor Reforming Guide code 64059629 LEDs This table describes LEDs of the drive Where LED When the LED is lit RMIO board Red Drive in fault state Green The power supply on the board is OK Control panel mounting platform Red Drive in fault state Green The main 24 V power supply for the control panel and the RMIO board is OK the LEDs are not visible in frame sizes R2i to R5i Maintenance 93 ACS800 104 ordering information What this chapter contains This chapter lists the components and accessories specific to the ACS800 104 inverter module range See the ACS800 Product Reference 3AFE 64813340 English for generic equipment for the ACS 800 product family such as control panels I O options application programs and PC tools Inverter modules The following tables list the ACS800 104 inverter modules available Notes The application program for the modules must be specified when ordering Control panel CDP 312R is not included Frame R6i and R7i modules require an external fan The modules have coated circuit boards as standard equipment Frame sizes R2i to Option key Q950 Prevention of unexpected start for more information see the document ACS 800 MultiDrive
109. m s 23 1 82 13 2 to 100 Hz sinusoidal Max 1 mm 0 04 in 5 to 13 2 Hz max 7 m s 23 ft s 13 2 to 100 Hz sinusoidal Max 3 5 mm 0 14 in 2 to 9 Hz max 15 m s 49 ft s 9 to 200 Hz sinusoidal Shock IEC 60068 2 29 Not allowed 100 m s 330 ft s 11 ms 100 m s 330 ft s 11 ms Free fall Not allowed 250 mm 10 in for weight under 100 kg 220 Ib 100 mm 4 in for weight over 100 kg 220 Ib 250 mm 10 in for weight under 100 kg 220 Ib 100 mm 4 in for weight over 100 kg 220 Ib Technical data 118 Materials Module PC ABS 2 5 mm colour NCS 1502 Y RAL 90021 PMS 420 C hot dip zinc coated steel sheet 1 5 to 2 mm thickness of coating 100 micrometres cast aluminium AISi R2i and R3i extruded aluminium AISi R4i and R5i Packaging Corrugated cardboard frames R2i to R5i and option modules expanded polystyrene Plastic covering of the package PE LD bands PP or steel Disposal The drive contains raw materials that should be recycled to preserve energy and natural resources The package materials 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 Most recyclable parts are marked with recycling marks If recycling is not feasible all parts excluding electrolytic capac
110. o z jou 4 D 9 en 5 nouo iB AOL 2 0 lt 1 v ainpow 92u849j94 45 m D vuoz v o zov oy _______ awa ML 2H09 aozs a NOLLVNOIS3Q 104100 6 IN Fs e EE ES de UU vuoz v xw 1 2802 54 cod OL 701 AO17 Z 0 NOLLWNOISSG LAGNI gt GioH TOMLNOD 3 L N 01 J3MA mon 4 8 RS sno bJ 6 1 13 4 777 9 0 joadxaun JO A 89A C CYN 23 3 JE UNS 900 1 47 at P8 yamOd Pun 2 1015 gc PT 128 e Viz 1108 a 5 01 J3MA LX 0 6 SQA 02 2 1X3 1 20 01 LINN 0 1 ONY J1OMINOO 3OLON sng 20 y 8 L 9 s V 2 usppiquoj Knows si sseJdxe 591258 pau eJnsoposip Jo osn uonbunoju By SIY M 72809 uonouojnvy 887 2xR8i 134 g L S A L 2009 52 20 88v jeu 88v ies PEY Bun 2001100 223 710 107 sap way uiDJboIQ 241
111. outer hA 26 42 x 20 54 plastic 2 pcs Fastener 400 800 mm 66239445 68239451 68260795 ACS800 104 ordering information branching units for 8 inverter units 107 Inverter units consisting of parallel connected frame R8i inverter modules require PPCS branching units for distribution of control signals to the modules One branching unit can control up to four inverter modules There are two types available the NPBU 42C is the basic unit the APBU 44C also incorporates a datalogger and supports redundancy enabling in case of removal of one inverter module continued operation using the remaining modules PPCS branching unit Multiples of frame R8i Inverter unit type ACS800 104 Quantity Contents of 1 kit Order code 0770 3 1030 3 0910 5 1210 5 0870 7 1 pc APBU 44C branching unit amp datalogger 1 2 pcs 2000 mm fibre optic cables 2 pcs 3000 mm fibre optic cables 68242355 1160 7 1 pc NPBU 42C branching unit 1 2 pcs 2000 mm fibre optic cables 2 pcs 3000 mm fibre optic cables 64349091 1540 3 2050 3 1820 5 2430 5 1740 7 1 4 pcs 4 pcs 1 pc APBU 44C branching unit amp datalogger 3000 mm fibre optic cables 5000 mm fibre optic cables 68242371 2320 7 1 pcs 1 4 pcs 4 pcs NPBU 42C branching unit 3000 mm fibre optic cables 5000 mm fibre optic cables 64349139 Check a
112. series followed by descriptive digits The option codes are separated by plus signs The main selections are described below Not all options are necessarily available for all types For more information contact your local ABB representative Basic code Digit no Name Description Alternatives Description 1 6 Product series 5800 8 10 Construction 104 Inverter module 12 14 Size 0003 and up 3 kVA and up 16 Voltage rating 3 380 400 415 V Nominal voltage 400 V 5 380 400 415 440 460 480 500 V Nominal voltage 500 V 525 575 600 660 690 V Nominal voltage 690 V Option codes Ident Name Description Alternatives Description letter C126 Speed controlled cooling fan supplied from the DC bus Frame 8 only E Filters E205 Internal output du dt filters Frame R8i only P Protection class P901 Coated circuit boards This feature is standard Q Safety features Q950 Prevention of unexpected start built in AGPS board Hardware description 24 Hardware description 25 Cabinet construction What this chapter contains This chapter contains instructions for constructing the cabinet for ACS800 104 inverter units Also refer to the document ACS800 MultiDrive Modules Planning the Cabinet Installation 64783572 English Cabinet construction 26 Frame R2i to R5i
113. the clamp to the grounding plate with a screw as close as possible to the terminals where the wires are about to be connected Connecting the shield wires Single shielded cables Twist the grounding wires of the outer shield and connect them through the shortest possible route to the nearest grounding hole with a cable lug and a screw Double shielded cables Connect each pair cable shield twisted grounding wires with other pair cable shields of the same cable to the nearest grounding hole with a cable lug and a screw Do not connect shields of different cables to the same cable lug and grounding screw Leave the other end of the shield unconnected or ground it indirectly via a few nanofarads high frequency capacitor e g 3 3 nF 630 V The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points Keep the signal wire pairs twisted as close to the terminals as possible Twisting the wire with its return wire reduces disturbances caused by inductive coupling 1 69 Cabling of I O and fieldbus modules Module Keep as short as possible Shield 000 000 2 Note The RDIO module does not e include a terminal for cable shield grounding Ground the pair cable shields here Pulse encoder module cabling ES 9 short as possible 5 Note 1 If the encoder is of u
114. w 888 09 1584 sog Se hpojN 198 Qaway od am ty ayjog ayojd baby V L 08055 4015 494 ssa 40d Pmumdmeg Qdimapaiseg 0269 SJONVYSIOL LAOHLIM NOISN3AIG 4120224014 0 0297101 N3 113 5 13315 93409 ONIZ dIG LOH SNOISN3IAIG WOWININ bunim 7 6 2 21905 X X 04193 _ amp nue 2 809 028 5 9 ORE 511 y 24 amp 58 g 2 Ei e 524 91 x 8 e Bp pU 268 8 h 8 1 Y 1 081 B 697 m 3697 NOILOJS EN S Hi ic 1 L 261 001 88 i 1 E iE M C H LL 3 4 diy ajoH Le 55 B 892 i H 8 9 5 Y 2 170 Frame 81 Imensions Module d 15391 ON 388 447 1555 DO SJAA ON DOT 4587
115. 0 e x 5 ZIA EE 9 9X AGLI P v 9X AGLI d xa 221 Tex 9 0 m lt lt 52 EZX l 5 so 2 a c J Ke 2 7 BD 2 3 AES 205 8x S 2 010 543 mA 9 o 1 lt 5 L 9 8 eus Jg 210 NI3V Z vv I LIND 1773 6 5 WA e 42 2 osx 5 lor ex ONo O8dNAL S giyx 109 45 ZA Liyx 28145 rv gx 1089 aa 11904 76 2 G pX 2802 2 201 AE 5 pyx 100 84 cos 2 INZ pux AS Met ONPC 2 INZ yirx ZENAZ p NN PERLES APE u3gossNvat 2 LN3XYNI 3 8 SONS NOS 192 71 2 25 a n 11 9 02 oe 75 NO 309v 4 31v9 1 07 xX 15428 9 0 gt ZONO zx vX mI zzi sng 20 Ta ex 209 9 ZX 8 8 ae ol lol 1 8 CALLE vad l vrz gx Mt N09 FGX EZX AVES g 2 09 2 05 lt ano 100 70 3 ASLL OEZ 2 8 25 _ x6 8 1 8 11254 VZX 06 X E d 11 M sna 20 mA Mit Tox
116. 0 104 0120 3 744 29 29 228 8 98 367 14 45 37 82 64 4700 5800 104 0170 3 1xR8i 1397 55 00 245 9 65 596 23 46 150 330 72 8200 5800 104 0210 3 1xR8i 1397 55 00 245 9 65 596 23 46 150 330 72 8200 5800 104 0260 3 1xR8i 1397 55 00 245 9 65 596 23 46 150 330 72 8200 5800 104 0320 3 1xR8i 1397 55 00 245 9 65 596 23 46 150 330 72 10250 5800 104 0390 3 1xR8i 1397 55 00 245 9 65 596 23 46 150 330 72 12300 5800 104 0510 3 1xR8i 1397 55 00 245 9 65 596 23 46 150 330 72 14350 ACS800 104 0770 3 2xR8i 1397 55 00 245 9 65 596 23 46 150 330 74 24600 ACS800 104 1030 3 2xR8i 1397 55 00 245 9 65 596 23 46 150 330 74 28700 ACS800 104 1540 3 3xR8i 1397 55 00 245 9 65 596 23 46 150 330 76 43050 ACS800 104 2050 3 4xR8i 1397 55 00 245 9 65 596 23 46 150 330 76 57400 Un 500 V ACS800 104 0004 5 R2i 401 15 79 165 6 50 193 7 60 9 20 62 350 ACS800 104 0005 5 R2i 401 15 79 165 6 50 193 7 60 9 20 62 350 ACS800 104 0006 5 R2i 401 15 79 165 6 50 193 7 60 9 20 62 350 ACS800 104 0009 5 R2i 401 15 79 165 6 50 193 7 60 9 20 62 350 ACS800 104 0011 5 R2i 401 15 79 165 6 50 193 7 60 9 20 62 350 ACS800 104 0016 5 R3i 466 18 35 173 6 81 232 9 13 12 26 62 820 ACS800 104 0020 5 R3i 466 18 35 173 6 81
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118. 02 a 2 249 4 5 5 2 gs 5 a 1 864 044 908 8 5242 2 GW 2 p 4 0601 870 00 g a 8 E 8 166 E T 5 2 5 27 015 0 0 101 NJ 3 133 5 13315 4931909 ONIZ dIG LOH VIXJLYN 8 9 S Y 4 1409 23 626479 JIVE on v0 53180 88V 4 88V ON 200 1500 Buo pul 001 dep dsay addy 75249 294101519 SZ ES wuoj 91025 200 opinb any 002 9087 MADS neg uo pesog Airflow guide for vertical mounting 119 509 965 Sev S S6c 5 59 SSEL 66 4 14 514 4 SI 81 ee so 70 B 10 96 1 1 1 1 1 021 2101 026 roez 80 994 1 4 065 9 8 49 0 70 0 ueppiqJoj jouis 51 91409 87085 795 gv 299 49 LBS 6956 15 2 gt 1 1H9I3M 8 2 6 lt 02 015 0 67101 N3 uL 143 5 13315 031 02 ONIZ 40 10 160 8
119. 04 0030 7 R4i 610 2080 103 61 300 47 600 93 480 74 960 149 12 5800 104 0040 7 690 2360 103 61 300 47 600 93 480 74 960 149 12 5800 104 0050 7 R5i 840 2870 168 99 400 62 800 124 640 99 1280 198 17 ACS800 104 0060 7 R5i 1010 3450 168 99 400 62 800 124 640 99 1280 198 17 ACS800 104 0070 7 R6i 1100 3760 480 283 325 50 650 101 520 81 1040 161 67 ACS800 104 0100 7 R7i 1500 5120 480 283 325 50 650 101 520 81 1040 161 67 ACS800 104 0120 7 R7i 1800 6150 480 283 325 50 650 101 520 81 1040 161 67 5800 104 0210 7 1xR8i 3300 11300 1280 750 575 90 1150 180 920 140 1840 290 150 5800 104 0260 7 1xR8i 4000 13700 1280 750 575 90 1150 180 920 140 1840 290 150 5800 104 0320 7 1xR8i 4600 15700 1280 750 575 90 1150 180 920 140 1840 290 150 5800 104 0400 7 1xR8i 5200 17800 1280 750 575 90 1150 180 920 140 1840 290 150 5800 104 0440 7 1xR8i 6800 23200 1280 750 575 90 1150 180 920 140 1840 290 150 ACS800 104 0580 7 1xR8i 7400 25300 1280 750 575 90 1150 180 920 140 1840 290 150 ACS800 104 0870 7 2xR8i 12900 44100 2560 1510 960 150 1920 295 1536 240 3072 475 180 5800 104 1160 7 2xR8i 14400 49200 2560 1510 960 150 1920 29
120. 1 81 9289 JAVE gen SUED 070 say W3 ON awou d f oud 021 ONIAVSC 4180355 BY 00 851 191113 ddy pau 48u05n 21925 sap gt 00 NOILOASLSNI ONLINDON 50 925 60 SDUNX3WP220daag uo pasdg Single R8i module in a Rittal TS 8 cubicle 0016 554 y Sex0IW I8NDO 000 Y 6E yOU3 4d 101518 529 2 13088 14044085 5 31914 18 04405 520 54 4504 104100 30109 a3A 01 5386 elX8W 1440 5546 19105 1 13404405 a 5540 V ASHSVA LAN 01 30110 s3ddn 0193 05 22100 OSX 0078 IVNIWS3L 31914 ONTLNNOW SS 4939 30110 434410 1935 438803 5348 51935 14 3IV 5240 43843455042 0922198 04424 103118 5242 1342 4 144405 31919 1409915 498506 009v8980w 48 104314 38944 3418012 3 AWOUF 2 51404 Oununou ejnpou jo 8uiu20340 J 34 14 3 ONILNDDN 13 1899 41100 A GO 11812289 vases s Kaur anoun san Jd aunscusp Jo ash uonanoeaday wen Du Sha A SIUH Ne 3002590 11817289 8 L 9 S e 1 34 19101
121. 1 ON Ju 88 39545 ONE DOC SANS ON 7590 9575 Nj 95 say W2 OR CV WILLIS 8NXI 2292 2240351 7 2 4403 9105 sap 504 31914 073 av 21411 80 20 01 SDOS3W paJodaug uo pasog E SO IDAR 8 ae X UO MES SEN o 2 5888 eer 0 0000 0 000992 0009 6 0009 87 0009 SS a 0009 SS 00001 0040 2 00092 000 4 M 524 8 TO 8 9 2 8 PNE g 8 g 3 5 8 5 gt 0310 3SIAN3HIU 5531 1 SS3NDOIHI 79133198 OL 7003 9 101014 3015 501093 N38 S8313AT11IA SNDISN3HIO 4 89 2 051 2345 32NVN3101 N3d 2 8022 TIWNDISNGWI 2 1 819001 V9 61 ND QI 13318 031V02 ONIZ dl 1DH s20NSL2Z S SE 051 1921312345 834 01 S310N 001121 v AQ 888 69758289 is sw Sen aod Ra EE 69968283 8 4 9 S v 121 2 T 192 2 19301 ON 328 484 39845 eot DOT Gey ON 500 3571 8uv1 G Pur as dap 4534 02 01 awou 044 Sra ev et WALLIS add 545502 15 woj 21925 sap 204 31914 073 JY FIL 0 120 001 004539 02200224 504 3 1 21
122. 160 Mounting plate inclined 162 Table of contents 10 Frames ROl and belle EE 164 Module dimensions excluding 164 Main dimensions and clearances of module including fan 165 Cooling fan dimensions 166 Mounting plate Kit 64138375 167 Combined mounting plate air baffle 169 Frame ee ecc SR d d tite E ale bu 170 Module dimensions 4 170 Quick connector chassis socket kits 172 6823942 a mST Phe 172 69239435 225 Wed eq dt Dc WERE Ba 173 Kit 468242231 eto CI eta det CP a De a OR 174 Module guiding 175 Upper Guide uet 175 Rear upper ba ee eben eb Ge DTE pP 177 L Wer gulde iis i MP 178 Crossmembets es bene re Soe ee id 180 Rittal TS 8 400 mm included in kit 68256836
123. 215 us av 1 3d ont 3199 OL YMOd ERES 13 1 1 1 4 lt 212 5997 Po Rae 544 665666048 ecu nates 1 228 aiz ou sdov 1 9 s i i 802 5 TINGOW 83 1 0 1 008 9 2 82 LIS Leid eid al dett a ee Bises tl caa dos st 8 88 23 z8 28 5 2092 33 ca 82 Ooty Z 2 52 Er Opv gt ES 2 3 amp 8 82 2 062 611 EL amp 5 8 4 9 5 Uu 2 140 141 Dimensional drawings What this chapter contains This chapter contains dimensional drawings of the ACS800 104 inverter modules as well as auxiliary components and mounting accessories Dimensional drawings 142 Frame 21 Imensions Module d 19351 ON 7394 88V 38 _ 1222 9 99 3 6 53 130 RES NJ 59075 XIJ dep 9525 01
124. 309 1593 184415 2186089 I 00 077 Wv 22 11026979 88 301534402 1593 10986979 8 N 00 W8 22 12661979 1123 802 37892 398504 1169199 6 M 20 v v 8 OH 060 Gv6C 1659 915143 060 64020 20897059 DEH 060 wepjor 54029 Ol amp a 48461 EET S red c fo 2 LST 0015821 61 9 e e 7 T 8921 891897 89 2 v 601 D B 960 71 Z Do 3 n 7 xy q gt 5 5 gt 00 c 05 en 5601 tI en c 7 16171 1276 289 1D4 LST Lavd 1 16969289 T 16969289 8 L 9 S y 2 1 173 Kit 68239435 19101 7398 99 806 289 3496 oy SAA
125. 30x165 1 Switch fuse controller ASFC 01C 64808851 64808877 1 Switch Fuse OESL630 32D04 4 Resistor ZRF 30x165 1 Switch fuse controller ASFC 01C 1 Switch Fuse OESL630 32D06 6 Resistor ZRF 30x165 1 Switch fuse controller ASFC 01C ACS800 104 ordering information 98 Charging circuit fuses for inverter modules Module type Fuse Fuse base ACS800 104 Qty Info code Qty Type Info cod 0100 3 0100 5 170M 50A OFAX 2x125A 0120 3 0120 5 2 4564 09838767 1 00521 58085749 0140 5 0170 3 0210 5 0070 7 0210 3 0260 5 0100 7 0260 3 0320 5 0120 7 0320 3 0400 5 0210 7 0260 7 0320 7 170M 10A OFAX 2x125A 0400 7 2 2690 1000 10032801 1 952 egoy 98065749 0440 7 0580 7 0870 7 1160 7 1740 7 0390 3 0460 5 0510 3 0610 5 170 50 OFAX 2x125A 0770 3 0910 5 2 09838767 1 58065749 1030 3 12105 1564 660V 00521 690V 1540 3 1820 5 2050 3 2430 5 170M 50A OFAX 2x125A 4 1564 egoy 09838767 2 00521 58065749 170M 10A OFAX 2x125A 2320 7 4 5699 1000 10032601 2 58065749 ACS800 104 ordering information 99 Inclined mounting plates for R2i to R5i modules Ready made mounting plates for inclined mounting of frame R2i to R5i inverter modules as exemplified in the chapter Cab
126. 317 900 1026 710 ACS800 104 1820 5 3xR8i 800 104 0610 5 2037 2956 1400 1956 1400 1524 1120 ACS800 104 2430 5 4xR8i 800 104 0610 5 2688 3901 2000 2580 1800 2011 1400 Un 690 V ACS800 104 0210 7 1xR8i ACS800 104 0210 7 170 254 160 163 160 127 90 ACS800 104 0260 7 1xR8i ACS800 104 0260 7 215 322 200 206 200 161 132 ACS800 104 0320 7 1xR8i ACS800 104 0320 7 289 432 250 277 250 216 160 ACS800 104 0400 7 1xR8i 800 104 0400 7 336 503 315 323 315 251 200 ACS800 104 0440 7 1xR8i ACS800 104 0440 7 382 571 355 367 355 286 250 ACS800 104 0580 7 1xR8i ACS800 104 0580 7 486 727 450 467 450 364 315 ACS800 104 0870 7 2xR8i 800 104 0440 7 729 1091 710 700 710 545 500 ACS800 104 1160 7 2xR8i ACS800 104 0580 7 953 1425 900 914 900 713 630 ACS800 104 1740 7 3xR8i 5800 104 0580 7 1414 2116 1400 1358 1400 1058 900 ACS800 104 2320 7 4xR8i 800 104 0580 7 1866 2792 1800 1792 1800 1396 1400 PDM 00184674 Technical data 111 Symbols Nominal ratings lcontmax Continuous RMS output current No overloadability at 40 Maximum output current Allowable for 10 seconds at start otherwise as long as allowed by drive temperature Note Maximum motor shaft power is 150 Py Typical ratings for no overload use Typical motor power The power ratings apply to most IEC 34 motors at nominal voltage 400 500 or 690 V Typical ratings for light overload u
127. 49 22 32e 0ug A I V 00155 719134 JINGOW 304 0 das ct Waddy 0 93 47422495 42401 51 vC wo 21025 sap 062 1804406 IND3J 21311 0 Yr T paaodaug uo 95 4 d SNINV319 9 15934930 0669 32 943101 lt NNE S 9 104104 11 3015 1 NIW 5078 N38 v S8313ATTIIN SNOISNGWIG 44 89 2 DSL 22345 32 431 1 Yad 7 015 3 10 OOTIET 1 961101 9 If 30 0 13315 31902 2 17 dIG 10H v20NGZ2Z SLSE DSL 01199131934 834 1913319 01 5209 10 1319 8 S310N 3 55290172 9 9 9 1 Va a T GZ S SL S4 S S4 S4 GZ S SE 971 529955 Give x es 202 Sy 202 50 n 9 9 T S ly 5 55490 5 0 ei O NEM T S44 ev 559 9 ZB 101 9vi TOI 9vi 55 J Pd 5549 22 m 264 V 50 93 1 03 Sujmoug pappo 8 puo edous J 26920972 aunsopsp o paupsuco aui UI puo 581 ul Yo 3AJ S OA 25920953 8 L 9 S v 2 T 185 2 19301 ON 328 88V m SAND Gang 2 5907 p
128. 5 50 e 55 ge Je 33 ES 35 wa M 48 if d H1 3 EE 55 E vat 8 8 ie cq 2i 14 3 8 Sot EE lt gt 350 SEY 25 A 9 L 2 2 glg E Papa ER ijo 88 88 EXAMPLE MOUNTING CABINE 1 MODULE Connecting of busbars to modules use disclosure to herein Reproduction all rights M this document and M the information contained les without express authority Is strictly Forbidden 68242533 68242533 Connecting switch fuse DESL to modules COMBI M6x12 8pcs BUSBAR SET 2 pcs COMBI 8 12 6pcs DESL prtno 6480 8800 ABB UESL BUSBAR SET ABB prtilst 6825 6771 ABB prtllst 6480 6823 9100 9100 MODULE CABINET ASSEMBLY SWITCH FUSE MODULE CABINET ASSEMBLY WITH FUSE BASES ze EM dies 8 e S 5 S4 602 87 J 3 8 25 als 3273 e 5203 Aue 5 o 3 Eg 2
129. 5 1536 240 3072 475 180 ACS800 104 1740 7 3xR8i 21300 72800 3840 2260 1440 225 2880 445 2304 355 4608 715 180 ACS800 104 2320 7 4xR8i 28100 96000 5120 3010 1920 295 3840 595 3072 475 6144 950 180 Technical data 116 Cable terminals DC input and motor cable terminal sizes accepted cable diameters and tightening torques are given below UDC UDC U2 V2 W2 Earthing PE prame Max wire size Cable Tightening torque Tightening size wire size torque mm AWG mm in Nm mm AWG Nm R2i 16 6 AWG 21 0 83 1 2 1 5 0 9 1 1 10 8 1 5 1 1 R3i 16 6 AWG 29 1 14 1 2 1 5 0 9 1 1 10 8 1 5 1 1 25 4 AWG 35 1 38 2 4 1 5 3 0 16 5 3 0 22 R5i 70 2 0 AWG 35 1 38 15 11 1 70 2 0 15 11 1 prame DC terminals Motor output size 0110 0 43 9 9 R6i e C tese 19 614 0 120 557 Busbars to quick connector M12 Tightening 2 torque 50 Nm 37 Ibf ft R8i Tightening torque 50 Nm 37 Ibf ft Max intrusion into module 20 mm 0 8 Busbars to support insulators M8 Tightening torque 9 Nm 6 5 Ibf ft 16 mm rigid solid cable 10 mm flexible stranded cable Input power connection Voltage Motor co
130. 5 126 124 97 383 368 13 17 M10 30 E NOCH0016 60 NOCH0120 60 NOCH0260 60 214 U1 V1 W1 NDCH0030 60 DE U1 V1 W1 U1 V1 W1 NOCH0400 60 _ 0050 60 4 vava w2 Nene 2 2 2 2 v2 v2 w2 2 SJ 1 o E 10111301 P 1 1 8 m 1 2 9 8 1 aa Ir m jee T B EF ial B I 1 1 Heat 1 2 1 ES LT SEY H I LJ 1 LIT 1 D Ul D C D f Common mode filter toroids 22 30 2108 PDM 58368 B 4 EP SAFE 64809032 REV B EN EFFECTIVE 01 12 2003 ABB Oy AC Drives P O Box 184 FIN 00381 HELSINKI FINLAND Telephone 358 10 22 211 Telefax 358 10 22 22681 Internet http Awww abb com
131. 51881 87 um price ud ci 3 0130 j amp Tana 8 L 9 v t 35 19101 ON 7994 889 8 5 1181 9289 3496 FR S3AIMO eng 201 393 97 w 0997 4594 W2 ON owou 3e 0ud V ONIAVSC ATIHN3SSV IBA 00 BSL 191113 40 23u5 2940351 Woj 21025 Sap 500 NOILINSLSNI 0 das 60 lt 5 1 9 90924 uo pasog 2130 00141 4130 2 8N 1440 559 2 FST STFS TS SSS SST PSS TSS TST PSS TSS STS TSS TSS SST SST TSS SST SST 9 8N 180 00121 9130 ieuigo2 ajnpou j ld AVX 3 ONILNDUW 181493 3 INGOW i 1 1 1 4 130 9130 1545920 140 ns 34 5499 1uo44 24 UN apisu usng 910 040001 94 paysnd s uoo 10817289 upepo Knox s ssaudka proupa 529 0
132. 6 DC fuses and fuse bases DC switch fuses The inverter unit can be connected to the DC bus through either fuses only or a Switch fuse See the chapter Circuit diagrams Fitting a switch fuse enables the isolation and reconnection of an inverter module even when the DC bus is energised On the other hand an external circuit is required for controlled charging of the capacitor bank of the module when the switch fuse is closed For frame R2i to R5i inverter modules only the DC fuses are required in addition to the switch fuse kit since the modules contain an internal charging circuit R6i R7i and R8i and multiples inverter units require the switch fuse kit DC fuses and fuses for the charging circuit The tables below specify the DC fuses DC fuse bases switch fuse kits and charging circuit fuses for the ACS800 104 inverter units DC fuses and fuse bases Switch fuse kits for inverter modules Modus oe DC fuse DC fuse base 800 104 Qty Type Info 2 Qty Info 22 Qty Order code 0003 3 0004 5 0005 3 00085 2 170M 254 1 254258 1 6408960 0006 3 0009 5 0009 3 0011 5 2 170 Sy 58065749 1 64089650 2 170 1 263295 58065749 1 64089650 0040 3 0050 3 2 170M 1604 1 21258
133. 8i 1397 55 00 245 9 65 596 23 46 150 330 72 6130 ACS800 104 0400 7 1xR8i 1397 55 00 245 9 65 596 23 46 150 330 72 6130 ACS800 104 0440 7 1xR8i 1397 55 00 245 9 65 596 23 46 150 330 72 7670 ACS800 104 0580 7 1xR8i 1397 55 00 245 9 65 596 23 46 150 330 72 9200 ACS800 104 0870 7 2xR8i 1397 55 00 245 9 65 596 23 46 150 330 74 15330 ACS800 104 1160 7 2xR8i 1397 55 00 245 9 65 596 23 46 150 330 74 18400 ACS800 104 1740 7 3xR8i 1397 55 00 245 9 65 596 23 46 150 330 76 27600 ACS800 104 2320 7 4xR8i 1397 55 00 245 9 65 596 23 46 150 330 76 36800 Excluding control panel optional Excluding cooling fan Refer to Dimensional drawings Single module only Technical data 114 Power loss and cooling characteristics See the dimensional drawings for free space requirements Minimum effective area Minimum effective area Max pressure 2 of air inlet of air outlet drop of Nominal air Inverter module Powerloss flow with with cabinet at unit type size unfiltered Luftfilter unfiltered Luftfilter nominal air airTex G150 airTex G150 flow W Btu h m h ft8 min cm in cm in 2
134. 9 J9U0 sn5 200 41914 18 4466 enu 6661 49470 paJodeug uo pesog 2055 58050000 0 lt 69 JONVYSIOL LNOHLIM NOISN3NIO 0 1H9I3M O V N GZZZ 0LSX0 ZrLOL 30 IN3AHOVIJO 33HS 13315 0931909 ONIZ 0 10 56 e sody 91 8 sod 2 310HMVM0 am M 9 io asn uon2npoudey uappiqioy 215 S 801 621 Sogl all e91 1 9 6914 6406 602 1 912 EN 022 zm oze 2 622 ez 19 062 sod 2 Gy Sd 6 AARUN DOOM gt 8 9 5 Y f 2 T 168 ss adx NOUJA saiyod Puu aunsopsip gt ay Siy sjubu 0 M 169 Combined mounting plate air baffle 83008 KO Ansnpu 4 OPUNEA SAVE day anai
135. 96 23 46 150 330 72 14350 ACS800 104 0910 5 2xR8i 1397 55 00 245 9 65 596 23 46 150 330 74 24600 ACS800 104 1210 5 2xR8i 1397 55 00 245 9 65 596 23 46 150 330 74 28700 ACS800 104 1820 5 3xR8i 1397 55 00 245 9 65 596 23 46 150 330 76 43050 ACS800 104 2430 5 4xR8i 1397 55 00 245 9 65 596 23 46 150 330 76 57400 Un 690V ACS800 104 0011 7 R4i 525 20 67 240 9 45 252 9 92 15 33 62 670 ACS800 104 0016 7 R4i 525 20 67 240 9 45 252 9 92 15 33 62 670 ACS800 104 0020 7 R4i 525 20 67 240 9 45 252 9 92 15 33 62 670 ACS800 104 0025 7 R4i 525 20 67 240 9 45 252 9 92 15 33 62 670 ACS800 104 0030 7 R4i 525 20 67 240 9 45 252 9 92 15 33 62 670 ACS800 104 0040 7 R4i 525 20 67 240 9 45 252 9 92 15 33 62 670 ACS800 104 0050 7 R5i 673 26 50 265 10 43 276 10 87 23 51 65 1330 ACS800 104 0060 7 R5i 673 26 50 265 10 43 276 10 87 23 51 65 1330 ACS800 104 0070 7 R6i 744 29 29 228 8 98 367 14 45 37 82 64 1570 ACS800 104 0100 7 744 29 29 228 8 98 367 14 45 37 82 64 2200 5800 104 0120 7 744 29 29 228 8 98 367 14 45 37 82 64 2200 ACS800 104 0210 7 1xR8i 1397 55 00 245 9 65 596 23 46 150 330 72 4600 ACS800 104 0260 7 1xR8i 1397 55 00 245 9 65 596 23 46 150 330 72 4600 ACS800 104 0320 7 1xR
136. ACS800 Hardware Manual ACS800 104 Inverter Modules ACS800 104 1 5 to 2000 kW Inverter Modules Hardware Manual 64809032 REV B EN EFFECTIVE 01 12 2003 2003 ABB All Rights Reserved Table of contents Table of contents Introduction to this manual What this chapter contains 1 11 Compatibilty d e e dee af oe Ee eec oe 11 Safety instructions ed e Ce Reli end AGUA ICT Bh CS 11 Int nded audi nce iibro be wade ewe ba ed 11 Contents eo atau id a Meee ued ates Cheha I xm E Nh 11 Related publications us tH Ru ER eee PR Gd 12 Terms and abbreviations 4 13 Hardware description What this chapter contains 15 Typical drive system ix Ca o i Y UR d ie arn 15 Inverter module hardware 16 2 255 Said Rau eee ete ghee kaw 16 Module layout Frame size R3i pictured 16 Gabinet layout woo vb VE EROS ee A ESSA CS 17 Frames Rorand Res Rub ex ERE 18 Module layoUt
137. Disconnect the fan wiring plug 1 Remove the locking screws 2 Pull the fan out along its sliding rails 3 Install a new fan in reverse order Maintenance 92 Power connections Capacitors 1 Read and repeat the steps in the safety instructions above 2 Open the cabinet doors 3 Extract one inverter module from the cabinet as described in the motor cable connection procedures in the chapter Electrical installation 4 Check the tightness of the cable connections at the quick connector Use the tightening torque table in Technical data 5 Clean all contact surfaces of the quick connector and apply a layer of suitable joint compound e g Isoflex9 Topas NB 52 from Kl ber Lubrication onto them Re insert the inverter module N Repeat steps 3 to 6 for all remaining R8i inverter modules The drive intermediate circuit employs several electrolytic capacitors Their lifespan is from 45 000 to 90 000 hours depending on drive loading and 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
138. Isolation test voltage Logical thresholds 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 solation and grounding diagram below N an Thermistor input 5 lt 1 5 kohm 2 normal temperature gt 4 kohm 2 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 lt 8 VDC 0 gt 12 VDC 1 to DI 5 10 mA DI6 5 mA 1 ms Motor control and I O board RMIO 85 Relay outputs Three programmable relay outputs Switching capacity 8 A at 24 VDC or 250 VAC 0 4 A at 120 VDC Minimum continuous current 5 mA rms at 24 VDC Maximum continuous current 2Arms Isolation test voltage 4 kVAC 1 minute DDCS fibre optic link With optional communication adapter module RDCO Protocol DDCS ABB Distributed Drives Communication System 24 VDC power input Voltage 24 VDC x 1096 Typical current consumption 250 mA without optional modules Maximum current consumption 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 Voltage PELV requirem
139. O 11130 524 1 ANN3EAVMIS 2 245542 2940351 7 1 2195 sep 137998 eui 0 92 22 00 pa4odaag pasog 4 529 LAN 1379 h 3 o ES 538p 9N 3 0 6 6 0 eee FZS w y PET vl rm I I I 249 1281 1 5 276 5548 692 ww m e Zg ES o d 19120 1 913 6 Q31UN 3SIAS3HID 553150 SS3NDOIHI WIN31VN OL 190193 1094 9 0104 179 X3GISN gt 5010 4 N38 v S83L3HT TIN SNOISN3WIG 6 u 89 2 DSL 22345 39NvS31L Yad 42980229 TWNOISNIWIC 2 1 961101 V9 50 ww 05 13315 31V02 ONIZ dI 10H 20 6 27 6 66 051 NUIIVOLJIO3dS 834 WIYSLYW 0 S310N J 8 L 9 S 5 181 2 TOL ON 955 88V m UEM SAND GY SE Nj 5991 9595 13 01 awou 044 ED ONI V3O 119130 524 AWBd38 vals addy 2803 2240351 Y 12 wos 21955 200 1340498 21311 0 995 22 lt 95290824 40 pasvg TU 56 2 s ssasdxa vro san 2o vononpouday w
140. ODULE 1 1 A4 Project name 09 Jul 03 CC AM BieBHLaBBAVING EIX Rev IncB Long EN 5 Doc Doc Sheet 2 ker No ABB Drives TEES 177 178 Lower guide 10301 ON 394 88V Lm SIA m Nj Q3ew sH X 95 12 23 awou EXT 119130 INTON E0 AON E1 5849 t0 ON E 32299 2 0 5 9 22402 21925 300 30109 WOLLOG 21311 0 1NF 01 113 0 gaaodaag uo pasog E 9449379 ONISV3N231 u 0669 NIT Joan Die 21 4 1099 9410703 779 KATISNI NIW 501094 ONIA SAJLIWITIIW SNDISN3HIQ 4 89 2 081 72345 3ONVN37DI 34 42980229 WNDISN3WI 2 86600 v9 9I 0 GT 13315 31V02 ONIZ dl 10H 2UNG 22 G G 051 1921412345 34 WIN3lVW 1 SILON 3 Lo 57 X 57 5242 52 1 TIN la 1 5502 1 0 ON m l i po 23 5990715 55492815 z 1 ig Z1 3 0950625 N 1 o IOAN 2 5558 7777 1 S
141. Three frame R2i to R5i inverter units 125 Frame RerandRYZl sseswecaw hele 126 CONNSCHON AG FAM ead oe RU TRUE UC CE eb t It Card 126 R6I Charging circuit s ui ere Exe enit IR dee ds ab een vue ds 127 R7i Charging 1 128 Frame R8i and multiples 24 129 Internal diagram 1 129 Charging wt ec ec Wad Dic de des eng ie 130 unsere rer A S oo een e tg Ro d d 130 2 iuis ese Mem ve e eue ec an we deb 131 9XROI oti aet rooted OUS Gene ced t n reo An Ope t a Pu 132 l O and control ER _ xa ERR ee 133 huc c P 133 EE Reed 134 Cooling fan control inverter modules without optional speed controlled fan 135 Auxiliary voltage distribution 135 doe ene o eres Mcr test t bene d e Lo cM 136 Edo EE 137 Example Emergency stop Category 1 138 Example Prevention of unexpected start 139 Dimensional drawings What
142. aaau UNUAJN Pi A PUO Stay yo 98 2633 ON 52166289 8 4 9 6 v 5 Rittal TS 8 600 mm included kit 68259517 182 2 19301 ON 3833 88V mm 200 ON 500 3592 5997 dsay 524 044 m 59 DNI V3O MYLIC 2 34 415 addy 22403519 woy sap 200 1350 0 de 28 _ 00823 09201824 40 paste 650 8 INN 3 V V lt i a B i D 9 T Di 5547 y 5 5 5 m ds 9 5 o gt g gt H 60 e 911 srz5V S92 S 2 m 548 276 A gv o 5 ev 9 9 Ula 310N 351 4 3 1 5521 SS3NDDIHI OL 79193 1094 9 107104 119 3GISNI NIW SAIGVS N38 S3313ATTTI4 SNDISN3AL 4 89 2 051 72345 3ONV3310Ll 33d 49990999 TWNOISNSWIG 2 1 961101 V9 AD 08 13315 Q31VD2 ONIZ dI 1DH 20 5 227 6 66 05 NOILV213I33dS 33d WIS3IVN S310N si
143. airTex G150 airTex G150 flow W Btu h mJ h ft min cm in 5800 104 0260 5 1xR8i 3300 11300 1280 750 575 90 1150 180 920 140 1840 290 150 5800 104 0320 5 1xR8i 3900 13300 1280 750 575 90 1150 180 920 140 1840 290 150 5800 104 0400 5 1xR8i 4700 16100 1280 750 575 90 1150 180 920 140 1840 290 150 5800 104 0460 5 1xR8i 5700 19500 1280 750 575 90 1150 180 920 140 1840 290 150 5800 104 0610 5 1xR8i 7700 26300 1280 750 575 90 1150 180 920 140 1840 290 150 ACS800 104 0910 5 2xR8i 11300 38600 2560 1510 960 150 1920 295 1536 240 3072 475 180 5800 104 1210 5 2xR8i 14900 50900 2560 1510 960 150 1920 295 1536 240 3072 475 180 ACS800 104 1820 5 3xR8i 22000 75100 3840 2260 1440 225 2880 445 2304 355 4608 715 180 ACS800 104 2430 5 4xR8i 28900 98700 5120 3010 1920 295 3840 595 3072 475 6144 950 180 Uy 690 V ACS800 104 0011 7 R4i 300 1030 103 61 300 47 600 93 480 74 960 149 12 5800 104 0016 7 340 1160 103 61 300 47 600 93 480 74 960 149 12 ACS800 104 0020 7 R4i 440 1500 103 61 300 47 600 93 480 74 960 149 12 5800 104 0025 7 530 1810 103 61 300 47 600 93 480 74 960 149 12 5800 1
144. all 3598 567 165 166 Imensions Cooling fan d 1909 12945 1666 5779 Jive ON 200 N3 pu dep dsey CS 4 7 1 2055 20 sap 200 TVNOISN3NIG 123 194 091329 94100 enu 88V ON 200 1snj 1002 0 80 addy 9849 5 21100 1006 497790 NYVL 1135404 Uo pesog 9e 880 56 DX 904 NOISNJ3NIO 98 96 98 816 oel m lt gay si 5 jnoujm sarod 1002 AWOL Pay eJnsopssip Jo asn uoranpo dey peuibjuo2 au SIY Sjubu 269 M 167 Mounting plate Kit 64138375
145. an is fixed to the rear wall of the cabinet with two M6 screws A separate air baffle must be installed but it does not have to carry the weight of the module DC busbars ss cj i m DC fuses 1 IF Ie E A n ae Module top fixing points 2 8 DC connection 7 4T E rf TI Drive control 101 1 1 unit 170 amp A AC connection Module bottom HET fixing points LL L 2 M6 X Cooling fan 170 Air baffle Air in Module and fan connected by mounting plate 400 3264138375 450 31 Installation without mounting plate 64138375 The module is fastened to the rear wall with two M8 screws and to a combined mounting plate air baffle with four M6 screws The cooling fan is also fixed to the plate which has to be strong enough to carry the weight of the module A suitable design for the mounting plate air baffle is shown in Dimensional drawings DC busbars i Ih DC fuses
146. ant speed 3 4 See parameter 21 09 START INTRL FUNC 83 X20 1 VREF Reference voltage 10 VDC 1 kohm lt lt 2 AGND 10 kohm X21 r 1 VREF Reference voltage 10 VDC 1 kohm lt lt 12 AGND 10 kohm 13 Speed reference 0 2 10 V Rin gt ql 4 1 200 kohm 715 Al2 By default not in use 0 4 20 mA Ri 6 Al2 100 ohm 7 AI3 By default not in use 0 4 20 mA Ri 8 AI3 100 ohm er 9 1 Motor speed 0 4 20 mA 0 motor 10 1 speed R lt 700 ohm 11 2 Output current 0 4 20 mA O motor 12 AO2 nom current lt 700 ohm X22 s 11 npn Start alo 2 DI2 Stop 1 3 DI3 Forward Reverse 7 lt 4 014 Acceleration amp deceleration select 2 5 015 Constant speed select 3 6 DI6 Constant speed select 3 7 24VD 24 VDC max 100 mA 8 24VD 9 DGND 1 Digital ground 10 DGND2 Digital ground 11 DIIL Start interlock 0 stop 7 X23 1 24V Auxiliary voltage output non isolated 2 GND 24 VDC 250 mA X25 1 RO1 D Relay output 1 ready 2 RO1 X26 1 RO2 Relay output 2 running 2 RO2 LS Ro2 X27 1 RO3 Relay output 3 fault 1 ER 2 RO3 EU
147. art of the module The DC voltage is connected to the input busbars either through fuses only or through a switch fuse with charging control circuitry Common mode filtering is implemented by running the DC busbars through ferrite cores optionally available The motor connection is via a quick connector at the back of the module that couples when the module is inserted into the cubicle From the connector the cables can be run directly through the bottom plate of the cubicle Each parallel module is cabled separately to the motor or connected to a common output cubicle by busbars or cables of equal length The modules are available with either an internally supplied speed controlled fan or a fan supplied from an external three phase 400 V source Internal du dt filters are also available For information on whether du dt filtering is necessary see the document ACS800 MultiDrive Planning the Electrical Installation 64783742 English du dt filtering must be selected if a common motor terminal cubicle is used See the chapter Electrical installation The drive control unit type RDCU containing the RMIO board is to be installed separately Hardware description 20 Module layout Item Explanation 1 DC input connections 2 Output busbars To be aligned with the quick connector socket mounted in the cubicle Direct connection of cables without using the quick connector is also possible 3 Fibre o
148. ation GAFE 64783742 English Wiring diagram Inverter module INPUT OUTPUT UDC UDC Common mode filtering optional ASFC 01C Switch fuse controller DC connection The DC connection busbars are located L at the top of the module See the dimensional diagrams for the exact location Busbar sets for the DC connection with holders for common mode filter toroids a Cabinet construction re available and pictured in the chapter WARNING Make sure the M12 screws used for connecting the DC link to the inverter module do not extend into the module farther than 20 mm 59 Charging circuit Installing a switch fuse between the inverter module s and the DC link necessitates a charging circuit The charging circuit contains two resistors per inverter module and a switch fuse controller type ASFC 01C The resistors and the controller are included in the switch fuse kits The minimum wire sizes to be used in the charging circuit are as follows DC bus to fuses 2 5 mm AWG 14 double insulated ASFC to ground 2 5 mm AWG 14 From fuses ASFC to charging resistors 1 5 mm AWG 14 Switch fuse auxiliary contact solenoid wiring auxiliary voltage supply to ASFC 0 75 mm AWG 18 The ASFC is also to be connected to the AINT board of the inverter module s by a
149. ctive material 68 Connecting the shield wires 68 Cabling of I O and fieldbus modules 69 Pulse encoder module cabling 1 69 Installation of optional modules 70 Fibre Optic INKS ss Powe See we 70 Installation of NLMD 01 LED Monitoring Display 71 Mechanical installation 71 lam I 72 Control panel with monitoring display 72 Table of contents Monitoring display 72 Earthing e e ERE ITE qu 73 External 24 V power supply for the RMIO board What this chapter contains 75 Whien to USES 2002 2222 Wane Same RULES QE dat edo qtu dou ree Rouen ee e desta Ere o tma 75 Parameter Settings Gh Se dh ek IR Pato a iad e Rte etes eio gae 4 75 Connecting 24 V external power supply 76 Installation checklist Checklist CHE E Ee 79 Motor control and board RMIO What this chapter contains 0 81 To which pr
150. drive is 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 0 to 4000 m 13123 ft above sea level above 1000 m 3281 ft see Derating on page 111 Air temperature 15 to 50 C 5 to 122 F 40 to 70 40 to 40 to 70 40 to No frost allowed See 158 F 158 F Derating on page 111 Relative humidity 5 to 95 Max 9596 Max 9596 No condensation allowed Maximum allowed relative humidity is 6096 in the presence of corrosive gases Contamination levels IEC 60721 3 3 IEC 60721 3 2 IEC 60721 3 1 No conductive dust allowed Boards without coating Chemical gases Class 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 1S3 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 pressure 70 to 106 kPa 0 7 to 1 05 atmospheres 70 to 106 kPa 0 7 to 1 05 atmospheres 60 to 106 kPa 0 6 to 1 05 atmospheres Vibration IEC 60068 2 Max 1 mm 0 04 in 5 to 13 2 Hz max 7
151. ed from the mains input power during installation If the drive system is already connected to the mains wait for 5 min after disconnecting mains power Measure the voltage between the L and L terminals with a multimeter impedance at least 1 Mohm to ensure that the drive system is discharged before beginning work WARNING Circuit boards contain components sensitive to electrostatic discharge ESD Wear an earthing wrist band when handling the boards Do not touch the boards unnecessarily Notes on Optical Components Handle fibre optic cables with care When unplugging optic cables always 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 specifications of the optic cable are as follows Storage temperature 55 85 C Installation temperature 20 70 C Maximum short term tensile force 50 Minimum short term bend radius 25 mm Minimum long term bend radius 35 mm Maximum long term tensile load 1 N Flexing Max 1000 cycles ABB drive products in general utilise 5 and 10 MBd megabaud optical components from Agilent Technologies Hewlett Packard Versatile Link range Please note that the optical component type is not directly related to the actual communication speed Electrical installation 50 Note The optical components transmitter and receiver on a fibre optic link must be of the
152. ents stated in EN 50178 provided that the external circuits connected to the terminals also fulfil the requirements Motor control and I O board RMIO 86 Isolation and grounding diagram Test voltage 500 V AC X20 1 VREF 2 AGND X21 1 VREF 2 AGND d gt 3 4 Al Common mode voltage between Azi 2 15 7 AI3 8 AI3 1 9 1 10 AO1 11 2 gt 12 AO2 22 1 DH 2 012 3 DI3 gt 4 014 9 DGND1 5 DI5 1 i 6 016 7 240 lt gt 8 24VD 11 DIIL 10 DGND2 x23 1 24 V 2 GND gt X25 1 RO1 A 2 RO1 iS E 3 RO1 X26 1 RO2 A 2 RO2 EP qu 3 RO2 5 X27 1 RO3 A 2 RO3 3 5 Test voltage 4 kV AC Jumper J1 settings All digital inputs share a common ground This is the default setting Grounds of input groups 011 014 and DI5 DI6 DIIL are separate isolation voltage 50 V Ground Motor control and I O board RMIO 87 Maintenance What this chapter contains This chapter contains preventive maintenance instructions and a d
153. er guide Module gu 10401 3838 487 Lem mm GRY UN 5555 5991 dap dsay 9 22 044 am 00 ONIAVSO 7119134 INOW E0 ON v2 Waddy 0 ON v2 WRi29u2 aawo sng 7 2 21025 sap 204 30109 401 0 17 60 INIH 294 24 uo pasig 1 T TOn DNINV319 9NISV38230 0669 NIC aU 5 370H AVa 9W S d 55002795 11093 9NICID3 119 3015 NIW 501093 N38 v S83L3NAT TTIW SNOISNAWIO E 44 89 2 051 72345 39 49701 834 2 Z 1 990101 V9 21 40 13315 131 02 2 17 10 10 ro 3 20 6 227 5 56 051 1921 412345 334 191331 pm p S310N TSSUSUVOR 00121 5500 i 1 1 1 019 gt 001 vi OT 55 986 7 0S Gvv 1 5 5 77 5 gt V 2 5 42 Ww 23019 aui 30 ap s sjy uo 147 uopsna4oud 0 27 8 el 93019 aui 30 29440 aui uo n 50 41044 5242 Le 1 f 5 65 60 02 IND 0319892 NUISS3ANDO 3024 09201
154. er settings In Standard Application Program set parameter 16 9 CTRL BOARD SUPPLY to EXTERNAL 24V if the RMIO board is powered from an external supply External 24 V power supply for the RMIO board 76 Connecting 24 V external power supply Break off the tab covering the 24 VDC power input connector with pliers Lift the connector upwards Disconnect the wires from the connector keep the connector for later use Isolate the ends of the wires individually with insulating tape Cover the isolated ends of the wires with insulating tape Push the wires inside the skeleton 8 DO gt Connect the wires of the 24 V external power supply to the disconnected connector wire to terminal 1 and wire to terminal 2 8 Plug the connector in Frame sizes R2i to R4i Frame sizes R5i External 24 V power supply for the RMIO board 77 External 24 V power supply for the RMIO board 78 External 24 V power supply for the RMIO board 79 Installation checklist Checklist Check the mechanical and electrical installation of the drive before start up Go through the checklist below together with another person Check MECHANICAL INSTALLATION ELECTRICAL INSTALLATION See Electrical installation and separate document ACS 800 MultiDrive Modules Plannin
155. er units consisting of frame R6i R7i and R8i inverter modules employ a separate control unit RDCU 02C containing the RMIO board For the terminals of the RMIO board see the chapter Motor control and I O board RMIO For further information on the RDCU 02C see the document RDCU 02 C Drive Control Unit Hardware Manual 3AFE 64636324 English 24 V DC power Optional module 1 Optional module 2 RMIO X39 for control panel connection LED indicators input Optical link to AINT NINT board of inverter module or branching unit p d SLOT 1 Dg DDCS communication option module 3 2 Detachable terminals A fibre optic link is used to connect the to the NINT R6i R7i or R8i board in the inverter module In case of parallel connected inverter modules a PPCS branching unit type NPBU or APBU distributes the optical control link t
156. escription of the LEDs of the drive Safety instructions Only a qualified electrician is allowed to perform the maintenance Before starting work on the drive system isolate the drive system from the main supply open the switch disconnectors and lock them out in the open position Switch off any voltages connected to the terminals wait for 5 minutes to let the intermediate circuit capacitors discharge ensure there is no dangerous voltage present by measuring the voltage on the input and intermediate circuit terminals Maintenance 88 Maintenance intervals This table lists the routine maintenance intervals recommended by ABB Maintenance Interval Instructions Capacitor reforming Every year when stored See Capacitor reforming Heatsink temperature check and cleaning Depending on the dustiness of the environment every 6 to 12 months See Heatsinks Cabinet air filter check replacement if necessary Every year See Checking and replacing the air filters Frame R4i and R5i inverter modules Change of additional cooling fan Every 3 years See Cooling fans Frame R8i inverter modules Check and cleaning of power connections Every 4 years See Power connections Cooling fan change Every 5 years See Cooling fans Frame R4i and larger inverter modules capacitor renewal Every 10 years See Capacitors Checkin
157. g and replacing the air filters Heatsinks Before replacing the air filters of the cabinet read and repeat the steps in the safety instructions above Heatsink fins pick up dust from the cooling air Inverter modules run into overtemperature warnings faults if the heatsink is not clean In a environment not dusty not clean the heatsink should be checked annually in a dusty environment more often Clean the heatsink as follows when necessary 1 2 Remove the cooling fan as described in Cooling fans elsewhere in this chapter Blow clean dry compressed air from bottom to top and simultaneously use a vacuum cleaner at the air outlet to trap the dust Note Prevent the dust from entering adjoining equipment Refit the cooling fan Maintenance Cooling fans 89 The cooling fan lifespan is about 60 000 operating hours The actual lifespan depends on the drive usage and ambient temperature See the appropriate ACS 800 firmware manual for an actual signal which indicates the hours of usage of the fan Fan failure can be predicted by the increasing noise from fan bearings and the gradual rise in the heatsink temperature in spite of heatsink cleaning If the drive is operated in a critical part of a process fan replacement is recommended once these symptoms start appearing Replacement fans are available from ABB Do not use other than ABB specified spare parts Fan replacement R2i R3i To
158. g the Cabinet Installation 3AFE 64783531 English The ambient operating conditions are allowed See Technical data The unit is properly fastened on a non flammable base See Cabinet construction and separate document ACS 800 MultiDrive Modules Planning the Cabinet Installation SAFE 64783531 English The cooling air is able to flow freely The motor and the driven equipment are ready for start See Technical data Motor connection and separate document ACS 800 MultiDrive Planning the Electrical Installation SAFE 64783742 English The capacitors are reformed if stored over one year refer to ACS 600 800 Capacitor Reforming Guide 64059629 English The module is grounded properly The input voltage matches the nominal input voltage of the module The power connections at UDC and UDC and their tightening torques are OK Appropriate DC fuses are installed The motor connections at U2 V2 and W2 and their tightening torques are OK The motor cable is routed away from other cables There are no power factor compensation capacitors in the motor cable The external control connections to the inverter unit are OK There are no tools foreign objects or dust from drilling inside the module or cubicle shrouds and covers are in place R8i modules with Prevention of unexpected start option only The voltage selection jumper on the AGPS board is correctly set 230 or 115 V The Prevention of unexpected start circuit
159. he hardware of the inverter modules The information is valid for all ACS800 104 inverter modules Typical drive system The diagram below depicts a common DC bus drive system p 8 8 4 H mq lt 5 2 a a LIB 290 6 wal o 2 211111 1 090 E FIE M 3 B O 1 Input AC fuses 2 Supply unit in this example consisting of two supply modules 3 DC bus 4 Inverter DC fuses 5 Inverter units in this example one of the units consists of two inverter modules connected in parallel 6 Brake chopper s optional Hardware description 16 Inverter module hardware The ACS800 104 range of inverter modules contains components for building the inverter unit s of a common DC bus system drive The chapter ACS800 104 ordering information lists the order codes of the inverter module components See also the Dimensional drawings for dimensions of the modules and related equipment The section Control interfaces below shows the available control and I O options The ACS800 104 inverter modules have coated circuit boards as standard A Prevent
160. i 11 64704494 64752626 ACS800 104 0020 5 R3i 15 64704508 64752707 ACS800 104 0025 5 R3i 18 5 64704516 64752758 ACS800 104 0030 5 R4i 22 64704532 64752839 ACS800 104 0040 5 R4i 30 64704541 64752863 ACS800 104 0050 5 R5i 37 64704567 64759990 ACS800 104 0060 5 R5i 45 64704583 64760033 ACS800 104 0070 5 R5i 55 64704591 64760041 ACS800 104 0100 5 R6i 75 68260434 68260469 ACS800 104 0120 5 R7i 90 68260442 68260477 ACS800 104 0140 5 R7i 110 68260451 68260493 Un 690 V 525 575 600 660 690 V 800 104 0011 7 R4i 11 64771116 64772473 800 104 0016 7 R4i 15 64772074 64772481 ACS800 104 0020 7 R4i 18 5 64772082 64772490 ACS800 104 0025 7 R4i 22 64772091 64772503 ACS800 104 0030 7 R4i 30 64772104 64772511 ACS800 104 0040 7 R4i 30 64772171 64772520 ACS800 104 0050 7 R5i 45 64772325 64772538 ACS800 104 0060 7 R5i 55 64772376 64772546 ACS800 104 0070 7 R6i 55 68260515 68260540 ACS800 104 0100 7 R7i 75 68260523 68260558 ACS800 104 0120 7 R7i 90 68260531 68260566 PDM 256538 ACS800 104 ordering information Frame size 8 and multiples 95 Multiple R8i inverter modules can be connected in parallel to produce higher output powers The table below shows the quantity and order code of inverter modules required for each inverter unit Option key C126 Speed controlled cooling fan supplied from the DC bus E205 du dt filtering required for 690 V modules and parallel connected modules 0950 Prevention of unexpected
161. inet construction are available The designs are also shown in Dimensional drawings Inclined mounting plates for R2i to R5i modules SS Frame size Order code R2i 64739328 R3i 64739174 23 64739328 Rai 64739344 E 64739352 Cooling fans R6i and R7i modules Frame R6i inverter modules require an external cooling fan that is to be fed from the 230 115 V AC auxiliary voltage source There are two types available depending on the voltage The inverter module and the cooling fan are connected by either the mounting plate listed below 464138375 a separate air baffle required or a combined air baffle mounting plate Both mounting plates are shown in Dimensional drawings Cooling fans for R6i and R7i modules Kit Information Order code Fan 230 type G2E140 P151 09 Connection cable length 1 5 m 5 ft 64114158 Fan 115 type G2E140 AI32 ABB Connection cable length 1 5 m 5 ft 64114191 Mounting plate Use a separate air baffle 64138375 Common mode filters for R6i to R8i modules Common mode filtering reduces bearing currents and is required for electromagnetic compatibility EMC The filtering is implemented by using toroids With R6i and R7i modules the toroids are installed on the output motor cable according to the instructions given in Electrical installation section Power connection
162. ion of Unexpected Start feature is optionally available consisting of a built in AGPS board Frames R2i to R5i The DC input and motor output cables are connected to screw terminal blocks at the bottom of the module covered by a metal housing Frame R2i to R5i modules do not require an external charging circuit External du dt filters are available see the chapter ACS800 104 ordering information Module layout Frame size R3i pictured Item Explanation 1 Control panel mounting platform and CDP 312R control panel optional Can be turned aside DC input connections Motor output connection Slots for optional modules terminal blocks RMIO obscured Hardware description Cabinet layout Cool area Inverter modules Airflow guides 17 Several modules can be installed in one cubicle The modules can be mounted vertically or in a slightly inclined position to save more vertical space See the chapter Cabinet construction Drawings of mounting accessories for both vertical and inclined mounting suitable for common cabinet systems are shown under Dimensional drawings The plates for inclined mounting can be ordered from ABB Vertical mounting 600 23 62 Hot area Dr o e Mounting plates Q Cool area Inverter modules Inclined mounting 600 23 62
163. itors and printed circuit boards can be landfilled The DC capacitors 1 1 to C 1 x contain electrolyte and the printed circuit boards contain lead both of which will be classified as hazardous waste within the EU They must be removed and handled according to local regulations For further information on environmental aspects and more detailed recycling instructions please contact your local ABB distributor Applicable standards EN 50178 1997 EN 60204 1 1997 EN 60529 1991 IEC 529 IEC 60664 1 1992 EN 61800 3 1996 Amendment A11 2000 UL 508C CSA C222 No 14 95 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 Electronic equipment for use in power installations Safety of machinery Electrical equipment of machines Part 1 General requirements Provisions for compliance The final assembler of the machine is responsible for installing an emergency stop device a supply disconnecting device Degrees of protection provided by enclosures IP code EMC product standard including specific test methods UL Standard for Safety Power Conversion Equipment second edition Industrial control equipment 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 instal
164. lation 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 incidental 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 Auxiliary power consumptions Circuit boards Un Un f 9 Imax Hz A 230 50 01 AGPS 11C 45 60 02 m 230 50 03 AGPS 21C a 115 60 06 44 24 602 230 50 0 04 21 115 60
165. mode filters for R6i to R8i 99 Installation parts for R8i modules 100 Quick connector chassis socket kits 100 101 Upper and lower QuideS as ES 103 Cabinet ventilation kits 105 PPCS branching units for nxR8i inverter units 107 Output du dt filters for frame R2i to R7i inverter modules 107 Other Options aee NR RR IE 107 Technical data What this chapter contains ba aS ee ee RE ES Perte eve ea 109 5 a ccna oes IER MC IE 109 Frame Ree Tuo OE i Ei Ye eB ete 109 Frame R8i and multiples 110 SYMDOIS 5 EDU Se Deep ben ier tue Yr tue a eget ad E eas d 111 EDS sni us et cune DLE 111 Temperature derating 111 Altit de deratlng od e t o os ec atc en ET ORE 111 Dimensions noise DC 112 Power los
166. nisolated type ground the encoder cable at 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 Note 2 Twist the pair cable wires Wrap copper tape around the stripped part of the cable under the clamp Be careful not to cut the grounding wire Clamp as close to the terminals as possible 70 Installation of optional modules and PC Optional modules such as fieldbus adapters I O extension modules and the pulse encoder interface are inserted in the optional module slot of the RMIO board and fixed with two screws See the appropriate optional module manual for cable connections Fibre optic links DDCS fibre optic links are provided by the module optional for PC tools master follower link NDIO NTAC NAIO and fieldbus adapter modules of type Nxxx See RDCO User s Manual for the connections Observe colour coding when installing fibre optic cables blue connectors go to blue terminals and grey connectors to grey terminals When installing multiple modules on the same channel connect them in a ring Installation of NLMD 01 LED Monitoring Display Mechanical installation 160 Width of Panel To 13255 4 pcs 9 Te T e 1 03 2 pcs N Mf N Cy
167. nnection 510 560 V DC for 400 V units 510 675 V DC for 500 V units 710 930 V DC for 690 V units Voltage U2 Frequency Frequency resolution Current Power limit Field weakening point Switching frequency 0 to U4 3 phase symmetrical U max at the field weakening point DTC mode 0 to 3 2 fep Maximum frequency 300 Hz en UNmains fewp 7 Nmotor fNmotor fewp frequency at field weakening point mains input power voltage Unmotor rated motor voltage rated motor frequency 0 01 Hz See IEC ratings starting on page 109 1 5 8 to 300 Hz 3 kHz average In 690 V units 2 kHz average Technical data Maximum recommended motor cable length Efficiency 117 Sizing method Max motor cable length DTC control Scalar control according to and according to cont max in ambient temperatures below 30 C 86 F R2i to R3 100 m 328 ft R4i to 300 m 984 ft R2i 150 m 492 ft R3i to R5i 300 m 984 ft according to max in ambient temperatures above 30 C 86 F R2i 50 m 164 ft R3i and R4i 100 m 328 ft R5i 150 m 492 ft Note With cables longer than 100 m the EMC Directive requirements may not be fulfilled Approximately 98 96 at nominal power level Degree of protection IP 00 Ambient conditions Environmental limits for the drive are given below The
168. ntact your local ABB distributor or office for further information Technical data 112 Dimensions noise DC capacitance Inverter module unit Frame Height Width Depth Weight 1 UN type size mm in mm in mm in kg Ibs dBA Uy 400 V ACS800 104 0003 3 R2i 401 15 79 165 6 50 193 7 60 9 20 62 350 ACS800 104 0004 3 R2i 401 15 79 165 6 50 193 7 60 9 20 62 350 ACS800 104 0005 3 R2i 401 15 79 165 6 50 193 7 60 9 20 62 350 ACS800 104 0006 3 R2i 401 15 79 165 6 50 193 7 60 9 20 62 350 ACS800 104 0009 3 R2i 401 15 79 165 6 50 193 7 60 9 20 62 350 ACS800 104 0011 3 R3i 466 18 35 173 6 81 232 9 13 12 26 62 820 ACS800 104 0016 3 R3i 466 18 35 173 6 81 232 9 13 12 26 62 820 ACS800 104 0020 3 R3i 466 18 35 173 6 81 232 9 13 12 26 62 820 ACS800 104 0025 3 R4i 525 20 67 240 9 45 252 9 92 15 33 62 1000 ACS800 104 0030 3 R4i 525 20 67 240 9 45 252 9 92 15 33 62 1000 ACS800 104 0040 3 R5i 673 26 50 265 10 43 276 10 87 23 51 65 2000 ACS800 104 0050 3 R5i 673 26 50 265 10 43 276 10 87 23 51 65 2000 ACS800 104 0060 3 R5i 673 26 50 265 10 43 276 10 87 23 51 65 2400 ACS800 104 0100 3 744 29 29 228 8 98 367 14 45 37 82 64 3300 ACS80
169. ntrol via analogue digital inputs __ 18555 99 Optional module 4 1 extension RAIO gt pulse encoder interface RTAC fieldbus adapter e g RMBA RDNA RPBA Ln Optional module 2 I O extension RDIO or pulse encoder interface RTAC Optional module 3 DDCS communication and outputs frame sizes R2i to the RMIO board is built in the inverter module instead of a separate RDCU unit option RDCO 0x The fibre optic channels provided by the module can be used for I O extension using NAIO NDIO modules pulse encoder connection NTAC module fieldbus connection Nxxx fieldbus adapter modules PC connection DriveWare PC tools or master follower connection Input power To motor 5 resistors optional Hardware description Type code 23 Each module has a type designation label attached containing e g the type code of the unit The type code contains information on the specifications and configuration of the unit The first 17 digits form the basic code It describes the basic construction of the unit The fields in the basic code are separated with hyphens The option codes follow the basic code Each option code starts with an identifying letter common for the whole product
170. o all the modules The switch fuse controller board ASFC used in conjunction with R8i modules also connects to the AINT board of each inverter module through a fibre optic link The connections between the control unit branching unit if present switch fuse controller and the inverter module are shown in the chapter Circuit diagrams 66 R6i R7i connectors The following picture shows the fibre optic connectors V41 and V42 on the NINT board as well as the NGPS connection optional NGPS X1 Ar oo NINT V42 NINT V41 2 9 9 zu 12 3 LR Terminal no Information di le a 14 39 Prevention of unexpected start 52 optional See also the chapter Circuit 9 ye diagrams e E 1 PE
171. oducts this chapter applies 81 Note for the ACS800 02 with the enclosure extension and the ACS800 07 81 Note for external power supply 81 External control connections non US 82 External control connections US dowd eee whee deen gees ga 83 RMIO board specifications 84 Analogue E Mare CRY Kp eoe Wind ue d ex 84 Constant voltage 84 Auxiliary power output 84 Analogue outputs 84 Digital Inputs un Oe a Gh des aed Ns 84 RelayOutputs St be te RN SS 85 DDGCS fibre optic ER MER EE aed 85 24 VDG power input e Rer EH REL mode uns 85 Maintenance What this chapter contains 87 Safety instructions x reu tox ate ete S Rus Pre Dus eios PROIN dae 87 Maintenance intervals 4 88 Checking and replacing the air filters
172. ons ACS 800 MultiDrive Safety Instructions 64760432 English ACS 800 MultiDrive Planning the Electrical Installation 64783742 English ACS 800 MultiDrive Modules Planning the Cabinet Installation 64783531 English ACS800 304 and ACS800 704 Diode Supply Units User s Manual SAFE 64494023 English ACS 800 Product Reference 3AFE 64813340 English Contains descriptions of ACS 800 drive products and information on generic options Firmware manuals Option specific manuals Introduction to this manual 13 Terms and abbreviations Term Explanation Abbreviation CMF Common mode filtering DDCS Distributed Drives Communication System a protocol used in optical fibre communication inside and between ABB drives Drive unit See Inverter unit DSU Diode supply unit consisting of one or more diode supply modules DTC Direct Torque Control EMC Electromagnetic Compatibility Frame size Relates to the construction type of the component in question For example several supply modules with different nominal powers may have the same basic construction The term is often used in reference to a group of components that share a similar mechanical construction To determine the frame size of a component refer to the rating tables in chapter Technical data IGBT Insulated Gate Bipolar Transistor a voltage controlled semiconductor type widely used in inverte
173. ontains the technical data for the ACS800 104 inverter modules and associated optional equipment Frame R2i to Nominal ratings No overload use Light overload use Heavy duty use Inverter module type Frame jen 1 P 1 size cont max max cont max 2N N 2hd hd A A kW A kW A kW 400 V ACS800 104 0003 3 R2i 5 1 6 5 1 5 4 7 1 5 3 4 1 1 ACS800 104 0004 3 R2i 6 5 8 2 2 2 5 9 2 2 4 3 1 5 5800 104 0005 3 R2i 8 5 10 8 3 7 7 3 0 5 7 2 2 ACS800 104 0006 3 R2i 10 9 13 8 4 10 2 4 0 7 5 3 0 ACS800 104 0009 3 R2i 13 9 17 6 5 5 12 7 5 5 9 3 4 0 ACS800 104 0011 3 R3i 19 24 7 5 18 7 5 14 5 5 ACS800 104 0016 3 R3i 25 32 11 24 11 19 7 5 ACS800 104 0020 3 R3i 34 46 15 31 15 23 11 ACS800 104 0025 3 R4i 44 62 22 41 18 5 32 15 ACS800 104 0030 3 R4i 55 72 30 50 22 37 18 5 ACS800 104 0040 3 R5i 72 86 37 69 30 49 22 ACS800 104 0050 3 R5i 86 112 45 80 37 60 30 ACS800 104 0060 3 R5i 103 138 55 94 45 69 37 ACS800 104 0100 3 147 224 75 141 75 112 55 5800 104 0120 3 178 294 90 171 90 147 75 500V ACS800 104 0004 5 R2i 4 9 6 5 2 2 4 5 2 2 3 4 1 5 ACS800 104 0005 5 R2i 6 2 8 2 3 5 6 3 0 4 2 2 2 ACS800 104 0006 5 R2i 8 1 10 8 4 77 4 0 5 6 3 0 800 104 0009 5 R2i 10 5 13 8 5 5 10 0 5 5 7 5 4 0 ACS800 104 0011 5 R2i 13 2 17 6 7 5 12 0 7 5 9 2 5 5 ACS800 104 0016 5 R3i 19 24 11 18
174. or terminal box English Note 574 360 degrees grounding If there is symmetrically constructed grounding conductor in the motor cable inadditiontothe 077777777 conductive shield connect grounding conductor Conductive gaskets to the grounding terminal at the drive and motor ends or ground the cable by twisting the shield as follows i gt Do not use an asymmetrically constructed motor lang cable Connecting its fourth conductor at the motor end increases bearing currents and causes extra wear b gt 1 5 Common mode filtering optional DC and motor connections DC input UDC L UDC Motor output Charging circuit Installing a switch fuse between the inverter module s and the DC link necessitates a charging circuit In frame R6i units the charging circuit consists of charging resistors and a contactor with R7i the charging is monitored by a charging controller unit type NCHM x1C The main components of the charging circuit apart from the fuses and fuse bases are included in the switch fuse kits For frame R6i the minimum wire sizes to be used in the charging circuit are as follows From contactor to resistors between resistors 690 V units 2 5 mm AWG 14 Charging control wiring to from NPOW 0 75 mm AWG 18 For frame R7i the minimum wire sizes to be used in the charging circuit are as follows DC bus to fuses 2 5 mm
175. ptic connectors of the AINT board Connected to the RDCU drive control unit via an NPBU branching unit in case of parallel inverter modules 4 Retractable support legs 5 Handle Hardware description 21 Cabinet layout Inverter modules can be installed side by side The DC fuses and or switch fuse are to be installed above the modules The control electronics RDCU control unit PPCS branching unit for parallel modules only relays and other auxiliary voltage equipment are to be installed in a separate cubicle See examples in the chapter Cabinet construction Using the quick connectors at the motor output enables quick replacement of a module for maintenance even though direct connection of cables to the module output is also possible Hardware description 22 Control interfaces The following diagram shows the control interfaces and options of the inverter unit The front cover of frame R5i has a platform for the CDP 312R control panel frames R2i to R4i require an additional platform kit if the panel needs to be mounted on the module For frame R6i to R8i and multiples the control panel is to be installed on a door platform available as a separate kit See the chapter Electrical installation for more information Drive control unit RDCU CDP 312R Control panel Esse and related accessories E and board o External co
176. remove the fan release the retaining clips Disconnect the cable Install the fan in reverse order Bottom view Fan replacement R4i 1 Shift the fan mounting plate to the left and pull the fan assembly out amp N Loosen the screws that fasten the fan mounting plate to the frame Disconnect the fan power cable Undo the screws that fasten the fan to the fan mounting plate Install the new fan in reverse order Maintenance 90 Fan replacement 5 To remove the fan undo the fixing screws Disconnect the cable Install the fan in reverse order Bottom view Additional fan Types 0004 2 0005 2 0011 2 to 0020 2 0006 3 0009 3 0020 3 to 0030 3 0009 5 0011 5 0025 5 to 0040 5 have an additional fan Replacement R2i R3i Remove the front cover To remove the fan release the retaining clip 1 Disconnect the cable 2 detachable terminal Install the fan in reverse order o Replacement R4i R5i Remove the front cover fan is located on the lower right hand side of the unit R4 or on the right hand side of the control panel R5 Lift the fan out and disconnect the cable Install the fan in reverse order Maintenance 91 Fan replacement 8 1 Open the inverter cubicle doors Read and repeat the steps in the safety instructions above
177. rs due to their easy controllability and high switching frequency Inverter unit An entity containing all inverter modules controlling a motor together with their control electronics and and auxiliary components Input Output NDBU or Types of optical branching unit for fibre links that use the DDCS protocol ADBU NGPS or Gate driver Power Supply board An optional board within inverter modules used to AGPS implement the Prevention of Unexpected Start function NPBU or Types of optical branching unit used for connecting parallel connected inverter APBU modules to the RDCU PLC Programmable Logic Controller PPCS Power Plate Communication System a protocol used in the optical fibre link that controls the output semiconductors of an inverter module RDCU Drive control unit The RDCU is a separate unit consisting of an RMIO board built in a plastic housing Module sizes R2i to R5i have the RMIO board built in RFI Radio Frequency Interference RMIO Motor control and board Contains the principal inputs and outputs of the drive Module sizes R2i to R5i have the RMIO board built in with larger units the RMIO is contained within a separate RDCU drive control unit THD Total Harmonic Distortion Introduction to this manual 14 Introduction to this manual 15 Hardware description What this chapter contains This chapter describes a typical drive system and t
178. s Frames R6i With R8i modules common mode filtering is implemented by installing three toroidal cores onto the DC input of each module The DC busbar sets listed later in this chapter contain holders for the common mode filters Common mode filters for R6i to R8i modules Kit Contents Quantity Order code Common mode filter kit 1 kit per inverter module 64315811 ACS800 104 ordering information 100 Installation parts for R8i modules The following tables list the R8i installation parts available from ABB Also refer to the drawings in the chapters Cabinet construction and Dimensional drawings Quick connector chassis socket kits The chassis socket part of the quick connector is to be mounted on the rear pillars of the cubicle The socket can also be mounted on the back plate Quick connector kits for R8i modules Kit For Contents of 1 kit Order code Connector only 1 pc Quick connector 64698401 1 pc Quick connector Single R8i 1 pc Mounting plate module 3 pcs Output busbar 00239427 3 pcs Support insulator Connector with Two R8i pcs oai mounting parts modules side 205 041119 68239435 6 pcs Output busbar and output by side busbars 6 pcs Support insulator wee UP modules side P g P 68242231 side 9 pcs Output busbar 5 y 9 pcs Support insulator 01616 0 o 9 9 e o 5 e
179. s and cooling characteristics 114 Cable terminals ovs cad en a Weed IW ERRANT Re RR ER 116 Input power connection oe Oh EL EROR fu De are 116 Motor connection em RR EUER Gk ee Ge ERG M EGO RR Ra 116 ETfICIGn ey iua Sole toe Cee RU ERR DE eere tend went e ides en ut dete 117 Degree of protection 117 e M E uus RA e ee 117 e et est ee e tsp oA EE 118 Applicable standards sca ea e Oe 4 DE EE etit Ee 118 Equipment warranty ene 118 Auxiliary power consumptions 119 Circult Doards Recte rd Mae 119 Cooling fans eee soc DOR eh ee C PD e UR OM deb M wane CM DR a RR 119 Table of contents Circuit diagrams What this chapter contains 121 Frame R2ito RSi issu eR E WEE 122 RA2i R3i Block diagram 122 R4i Block diagram du Ra ve 123 R5r Block diagram coxa res eue edu RERO Pw RE REMO KE RE 124 Example
180. same type Plastic optical fibre POF cables can be used with both 5 MBd and 10 MBd optical components 10 MBd components also enable the use of Hard Clad Silica HCS cables which allow longer connection distances thanks to their lower attenuation HCS cables cannot be used with 5 MBd optical components The maximum lengths of fibre optic links for POF and HCS cables are 20 and 50 metres respectively HCS is a trademark of SpecTran Corporation Checking the insulation of the assembly Every ACS800 104 inverter module has been tested for insulation between the main circuit and the chassis 2500 V rms 50 Hz for 1 second at the factory Therefore do not make any voltage tolerance or insulation resistance tests e g hi pot or megger on the inverter units or modules Check the insulation of the assembly as follows WARNING Check the insulation before connecting the drive to the main supply Make sure that the drive is disconnected from the mains input power 1 Check that the motor cable is disconnected from the drive output terminals U2 V2 and W2 2 Measure the insulation resistances of the motor cable and the motor between each phase and the Protective Earth by using a measuring voltage of 1 kV DC The insulation resistance must be higher than 1 Mohm 6 Electrical installation Power connections Frame R2i to R5i Diagram 51 Inverter module INPUT OUTPUT UDC
181. se 1096 overloadability lon Continuous rms current 10 overload is allowed for 1 minute every 5 minutes PN Typical motor power The power ratings apply to most IEC 34 motors at nominal voltage 400 500 or 690 V Typical ratings for heavy duty use 5096 overloadability Continuous rms current 50 overload is allowed for 1 minute every 5 minutes Pha Typical motor power The power ratings apply to most IEC 34 motors at nominal voltage 400 500 or 690 V Imax P cont max Derating The load capacity current and power decreases if the installation site altitude exceeds 1000 metres 3300 ft or if the ambient temperature exceeds 40 C 104 F Temperature derating In the temperature range 40 C 104 F to 50 C 122 F the rated output current is decreased 1 for every additional 1 C 1 8 F The output current is calculated by multiplying the current given in the rating table by the derating factor Example If the ambient temperature is 50 C 122 F the derating factor is 100 1 109 90 or 0 90 The output current is then 0 90 0 90 12 4 Note cont rating is not allowed above 40 C 104 F Altitude derating In altitudes from 1000 to 4000 m 3300 to 13123 ft above sea level the derating is 196 for every 100 m 328 ft For a more accurate derating use the DriveSize PC tool If the installation site is higher than 2000 m 6600 ft above sea level please co
182. side by pulling this lever Be careful do not use excess force when pulling Optional module 1 cables Ground the control cable shields in the holes with screws See 360 degrees grounding of I O cables on page 63 Optional module 2 DDCS communication option module 3 RDCO Install shroud included on the relay outputs if voltage at the terminals exceeds a 1 IK Prevention of unexpected start optional see Frame R2i to R4i power connections on page 53 64 Frame 5 gt DO EDR P zm Optional module 1 Optional module 2 RMIO X39 for connect DDCS communication option module 3 RDCO Install shroud included on the relay outputs if voltage at the terminals exceeds 50 V AC I O terminals pull upwards Control cable grounding see 360 degrees grounding of I O cables on page 68 Prevention of unexpected start optional see Frame R5i power connections on page 54 External 24 V power supply for the RMIO board The RMIO board of the inverter module can be powered from an external 24 V DC supply This is practical if the board needs to be kept live even if the main power to the drive is off The 24 V supply can be fed by a UPS if necessary Refer to chapter External 24 V power supply for the RMIO board starting on page 75 65 Frame R6i R8i and multiples Invert
183. sod y Sel 5 5 2 B 9vZ 3 o o o o o o 3 5 ab 3 om 5 Ei Qc SE E 8 9 5 4 187 Rittal TS 8 cubicle included kit 68283027 1 le R8 Sing Fuse Fuse switch mounting plates Mounting plate 2 9301 ON 383 889 S3AB QW TSY 1dap 4554 32e foug I V 00721 ONIAVSU 719130 791113 Baxl addy 32805 4 u015n3 91925 sap 201 31914 ONIINDDA DIL 50 29 50 00573 paJodaag 594 3 5 Tar FZ 134 7 b ey NE v 13 Sad 0D 209 uoo 3 2 Os vL N N EIU aoe Ul c n n 1 D zt PT m T ra e T s T 5 amp 0 09 LL e o ZZ 8 d C 5 5 25 vL ver z gt i H m 2 4 amp 00141 P LE 1 61 a 554 8X8W 82425 ONISS3Nd 3SIAW3HIU SSINN SS3NDOIHI 19183194 OL
184. start factory installed in parallel connected modules for more information see the document ACS800 MultiDrive Planning the Electrical Installation 64783742 English Inverter modules R8i and multiples Inverter unit Consists of Order code type modules of type no C126 C126 E205 70128 ACS800 104 Qty options C126 E205 Q950 E205 Q950 Q950 Qty 5800 104 Un 400 V 0170 3 1 68262194 68260906 68262330 68262283 68260949 68260922 68262445 68260965 1 0170 3 0210 3 1 68262208 68260914 68262356 68262291 68260957 68260931 68262526 68260973 1 0210 3 0260 3 1 68262224 68259231 68262364 68262305 68259746 68259762 68262551 68259754 1 0260 3 0320 3 1 68262232 64766058 68262411 68262313 64766121 64766139 68262577 64766031 1 0320 3 0390 3 1 64694383 64793969 64694367 64694375 64793985 64794001 64694332 64793993 1 0390 3 0510 3 1 64694324 64794019 64694294 64694308 64792580 64794051 64694286 64792598 1 0510 3 0770 3 1 68259410 68259436 2 0390 3 1030 3 1 68259461 68259487 2 0510 3 1540 3 1 68259941 68259975 3 0510 3 2050 3 1 68260027 68260051 4 0510 3 Uy 500 V 0210 5 1 68263531 68260981 68263689 68263611 68261023 68261007
185. t 3 a ojo lt fo 98 nouis s Kquoujno ssaido pnoy seniod PAu ensopssip uononpojdey ueJeuj uonpuuoju puo jueunoop Siy 5 ay lt eo e ce ul Lu 155 A SSAINC 88V ON BBV 7 eus 09606 79 JAYE 200 ON 200 1670 Z Pu ey 001X13 dep dsey Da addy 40940 5 Y 7 woy 21055 000 tp 002 9011 hip eS nueq uo pesog oO 912 482 amp le lt 696 gt 858 veppiquo 12145 si sseJdxe nou senjod Pau eunsopsip esn uononpojde ueJeu uonpuuoju Y Siy 5 156 Mounting plate inclined 4 1009 jesus vyvC6t v9 3446 ON 200 N3 j Pu eu 001 dep 4 e 0 uUo 62 21095 20g 019 008 50 enu ON 88V ON 200 1519 addy peu Jeuojsno 00050711 Diss Weg
186. th For example jumpering the cables from one inverter module to another and then to the motor is not allowed U2 m Nc WS n NU oN U2 i V2 W2 NU Inverter unit cubicle Inverter unit cubicle 62 Common motor terminal cubicle Instead of direct cabling from each inverter module to the motor it is also possible to build a common motor terminal cubicle WARNING common motor terminal cubicle is constructed the inverter modules must be equipped with the E205 option internal du dt filters Note that the distance from both modules to the common output should be of roughly equal length U2 2 w21 P E Inverter unit cubicle Common motor terminal cubicle 63 Control connections Frame R2i to R5i These inverter modules have a built in RMIO Motor control and board For descriptions of the terminals see the chapter Motor control and I O board Frame R2i to R4i R3i pictured Detachable terminals pull upwards The control cable connection terminals are exposed when the RMIO X39 for control control panel platform if present is panel cable turned a
187. this chapter contains 141 Fiame 2155 vise Wiha hw pui tok dtben ida de y PM ye eat Vie esta bem stas 142 Module dimensions 2 2 4 142 Mounting plate vertical BES BA Rete rl ae 143 Airflow guide for vertical mounting 1 144 Mounting plate inclined 146 Erame Vd ese ek aE 147 Module dimensions Wasa a eet ak gd ath 147 Mounting plate 148 Airflow guide for vertical 149 Mounting plate 151 Frame mu Na see p E eR uiia 152 Module dimensions iba rues ues p UE E wad 152 Mounting plate vertical RR P 153 Airflow guide for vertical mounting 154 Mounting plate inclined 156 uu qq ee eet Dp YN tate Bund Es 158 Mounting plate vertical ost 159 Airflow guide for vertical
188. to start 3 N 4 PE 5 Strip off the outer sheathing of the cable at the clamp Input DC power Motor cable cable clamp clamp e e 54 Frame R5i power connections Input DC power Motor cable cable clamp clamp Item No Information 1 Connect to PE busbar of cabinet 2 4 Prevention of unexpected start optional See also the chapter Circuit diagrams 2 L 95 265 V AC Voltage must be ON for the inverter to start 3 N 4 PE 5 Strip off the outer sheathing of the cable at the clamp 55 Power connections Frames R6i and Diagram Inverter module INPUT OUTPUT UDC UDC Cabinet Note Charging circuit configuration may differ from type to type See the Qe os chapter Circuit diagrams 01 Switch fuse controller L L Use a separate grounding cable if the conductivity Grounding of the motor cable shield at the motor end of the cable shield is less than 50 of the For minimum radio frequency interference conductivity of the phase conductor in a cable with no symmetrically constructed grounding conductor see the document ACS 800 MultiDrive Planning the Electrical Installation 64783742 ground the cable shield 360 degrees at the lead through of the mot
189. ui you CD o 19 er 16 eL 719 1 LUUD pJ o f a 92 0 692 AN e E g 849 8 5 149 9 I 999 an 592 99 3 Hi Sa pu Eu gt e 8 5 5 8 26 3 oo o z 5 gt 3 8 4 E 2 7 8 68700 719 Q O 92002 692 Le 8 12 75 0 vl v0 01 70 01 1431 64 002 401108 6 001 301 WW SiN3N3NID038 39995 3334 2 5761 092 2 aunsopsp austr 248821 OR 15229499 80 2 9 Y 153 Mounting plate vertical 5 FTT ON Jeu 889 ER 08226109 JAVE 200 sun bud 0 eu 00148 dep D ipUnou 098A 1291044 rum m 011 91018 39905 294101519 PLC opos 900 MH 008 SOV enu 0079011 MPD eS 11494 Padod posog gt ois WG Aet B O t Co T l 0 L b
190. ules use use size used leontmax Imax Poontmax lon Py lond Phd A A kW A kW A kW Un 400 V ACS800 104 0170 3 1xR8i ACS800 104 0170 3 250 342 132 240 110 187 90 ACS800 104 0210 3 1xR8i ACS800 104 0210 3 292 400 160 280 132 218 110 ACS800 104 0260 3 1xR8i 5800 104 0260 3 370 506 200 355 200 277 132 ACS800 104 0320 3 1xR8i 800 104 0320 3 469 642 250 450 250 351 200 ACS800 104 0390 3 1xR8i 800 104 0390 3 565 773 315 542 300 423 220 ACS800 104 0510 3 1xR8i 800 104 0510 3 741 1014 400 711 400 554 315 ACS800 104 0770 3 2xR8i ACS800 104 0390 3 1111 1521 630 1067 560 831 450 ACS800 104 1030 3 2xR8i 800 104 0510 3 1452 1988 900 1394 710 1086 560 ACS800 104 1540 3 3xR8i 800 104 0510 3 2156 2951 1250 2070 1120 1613 900 ACS800 104 2050 3 4xR8i 800 104 0510 3 2845 3894 1600 2731 1600 2128 1120 Un 500 V ACS800 104 0210 5 1xR8i ACS800 104 0210 5 250 363 160 240 160 187 110 ACS800 104 0260 5 1xR8i ACS800 104 0260 5 315 457 200 302 200 236 132 ACS800 104 0320 5 1xR8i ACS800 104 0320 5 365 530 250 350 250 273 160 ACS800 104 0400 5 1xR8i 5800 104 0400 5 455 660 315 437 315 340 200 ACS800 104 0460 5 1xR8i ACS800 104 0460 5 525 762 355 504 355 393 250 ACS800 104 0610 5 1xR8i ACS800 104 0610 5 700 1016 500 672 450 524 355 ACS800 104 0910 5 2xR8i 800 104 0460 5 1050 1524 710 1008 710 785 500 ACS800 104 1210 5 2xR8i 5800 104 0610 5 1372 1991 900 1
191. uo pasog 3j IdNVX3 LJNISVO 410 5 42 5 31914 19099 30109 a3A 01 52d 8 JJHSV 5242 3179 5900 06 X39014 IVNIWJ3L 5308 SW 1901900 51404 ajnpou jo 6uiu20310 M LAN OIN INGOW 434401 Was 438919 3 013 217 31919 1409915 498506 534 8 SeXOIW 1840 5249 4 4 104100 000966 94320 101313 5309 gIX8N 1440 534 2 1302984 134405 5249 ADIY NSNI 1904405 309 G2X2IN 5380 YOLISNNOD MAINO 31919 ONTLNAOW 3934 gt 30110 43440 5540 43843855042 009 9098 001 48 101313 34933 340501283 922198 09420 1013 529 2 1330994 1409918 d aumscusp asn ANIS SI ssasdxa 200 PAAY p3upiuco W U 51408 343534 40 88v O 527 289 5652789 4 39
192. vailability with ABB Output du dt filters for frame R2i to inverter modules For information on the usage of output du dt filters see the document ACS800 MultiDrive Planning the Electrical Installation 64783742 English Output du dt filters for inverter modules Module type ACS800 104 Qty Type Order code 1 5 L uH Power loss W Cable size mm Connection size 0003 3 0004 3 0005 3 0006 3 0009 3 0011 3 0004 5 0005 5 0006 5 0009 5 0011 5 0016 5 0011 7 0016 60 58982784 150 110 0 2 5 0016 3 0020 3 0020 5 0016 7 0020 7 1 0025 7 0030 60 58982792 28 140 167 0 5 5 0025 3 0030 3 0040 3 0050 3 0025 5 0030 5 0040 5 0050 5 0060 5 0030 7 0040 7 0050 7 1 0060 7 0070 7 0070 60 58982806 65 115 210 10 35 M6 0060 3 0100 3 0120 3 0070 5 0100 5 0120 5 0140 5 0100 7 0120 7 0120 60 58982814 105 92 80 8 Other options See the ACS800 Product Reference 3AFE 64813340 English for generic equipment for the ACS800 product family such as control panels options application programs and PC tools ACS800 104 ordering information 108 5800 104 ordering information Technical data What this chapter contains IEC ratings 109 This chapter c

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