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ACS850-04 (0.37 to 45 kW) Manual

1. Frame D Frame C Frame B Frame A E eel 18 69 she 166 6 02 101 13561 93 13 681 tz a OU Lm 8 ecu 18 66 aL 163 16 50 100 394 90 3 04 ns i A t O e EI HOP e e EI DI J QU poy y GE 6 d d d d y MN S in cu Iir ii T _ t E 5 E AR ABB ABB E GC gt m Ens y den qu lt LO ata eo n SO SO Za E ON LD OU GES ANE TANE TNE eel a e D0 e D0 ec e e Za 2 D sl g g S 3 S oe y O Se gt O s E E amp E 8 6 E 6 C gt aoe ot 2 Host Q ae giereg Ework Q a8 Se O O a T cn ER P e Se 5 t Y e e e O e ee e Y EE Planning the cabinet assembly Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 29 Note EMC filters of type JFI x1 mounted directly above the drive module do not increase the free space requirements For EMC filters of type JFI Ox see the dimension drawing of the filters on page 127 a ee 200 mm 7 9 AA AA SAN SNA CRE W Den ji J ooo l L
2. The DriveSize dimensioning tool available from ABB is recommended for selecting the drive motor and gear combination The maximum allowed motor shaft power is limited to 1 5 Pug 1 1 Py or Poort max whichever value is the greatest If the limit is exceeded motor torque and current are automatically restricted The function protects the input bridge of the drive against overload Derating The continuous output currents stated above must be derated if any of the following conditions apply e the ambient temperature exceeds 40 C 104 F e the drive is installed higher than 1000 m above sea level e the parameter adjustable motor noise level is set as low Note The final derating factor is a multiplication of all applicable derating factors Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 80 Ambient temperature derating In the temperature range 40 55 C 104 131 F the rated output current is derated by 1 for every added 1 C 1 8 F as follows Derating factor 1 00 0 85 Ambient temperature 40 C 55 C 104 F 131 F Altitude derating At altitudes from 1000 to 4000 m 3300 to 13123 ft above sea level the derating is 1 for every 100 m 328 ft For a more accurate derating use the DriveSize PC tool Note If the installation site is higher than 2000 m 6600 ft above sea level connection of the drive to an ungrounded IT
3. 250 V AC 30 V DC COM 8 Gi H Lal XD24 24 V DC 24VD Digital input ground DIGND 24 V DC 24VD EN Digital input output ground DIOGND Ground selection jumper gt lt z Digital input DI1 Stop Start Di Digital input DI2 D Digital input DI3 Reset DI3 Digital input DI4 D Digital input DI5 DI5 Digital input DI6 or thermistor input Start interlock 0 Stop DIIL z gt z O Digital input output DIO1 Output Ready DIO1 Digital input output DIO2 Output Running gt l Reference voltage Reference voltage Ground Analog input Al1 Current or voltage selectable by jumper Al1 Speed reference 1 Analog input Al2 Current or voltage selectable by jumper Al2 Al1 current voltage selection jumper Analog output AO2 Speed Drive to drive link termination jumper Drive to drive link Safe torque off Both circuits must be closed for the drive to start Control panel connection Memory unit connection Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 63 Jumpers DI DIO grounding selector located between XD24 and XDI Determines whether the DIGND ground for digital inputs DI1 DI5 floats or if it is connected to DIOGND ground for digital input DI6 and digital input outputs DIO1 and DIO2 If DIGND floats the common of DI1 DI5 either GND or Vec should be connected to XD24 2 See the JCU is
4. 00 eee 36 Mains choke installation 37 EMG leet E e WEE 37 Braking resistor installation NEE EE 37 Planning the electrical installation What this Chapter COnlaINS eet rd a A AA AAA A AA A cake E 39 Motor Selec is A a A e Petes 39 SUDDIY COMECON sesos reco ie Ar 39 Supply disconnecting device 39 BOOS age fa ests haa oe macht le we Docs eke a ce we fst ect ae nde adn ce a aaa cl ts de 39 OMERTCOIONS prada a EE Ge Bee aes eae 40 Thermal overload and short circuit protection 40 Thermal overload protection NEE 40 Protection against short circuit in motor cable 40 Protection against short circuit in the supply cable or the drive 40 Operating time of the fuses and circuit breakers 40 left PCA ENS tia id ido Gd wae dee wae Be ad Sa eS 40 Motor thermal protection 41 Ground taut ProleCliOn a e Ad 41 Emergency Stop devices iso sone elias beet EA Me eRe ek ee ewes Ss 41 Sale Ou ON ENEE 42 Selecting ihe Power Cables suscita asociaba aa arrabal ex eee es 43 OS UA Shs at Ee ee aot a ne BI he ve tee a th od E 43 Alternative power cable types 0 0 ccc ee eee teens 44 MOIOF e ei NEE 44 Protecting the relay output contacts and attenuating disturbances in case of inductive loads 45 Considering the PELV requirements at sites above 2000 m 6562 ft o o 45 Selecting the control Cables 46 Relay CAD di ii RA DEA A ee ee Sane rs 46 eat ge Be H Ce e EEN 46 Connection
5. Web www clrwtr com Email info clrwtr com 41 Motor thermal protection According to regulations the motor must be protected against thermal overload and the current must be switched off when overloading is detected The drive includes a motor thermal protection function that protects the motor and switches off the current when necessary Depending on a drive parameter value the function either monitors a calculated temperature value based on a motor thermal model or an actual temperature indication given by motor temperature sensors The user can tune the thermal model further by feeding in additional motor and load data PTC sensors can be connected directly to the ACS850 04 See page 64 in this manual and the appropriate Firmware Manual tor the parameter settings concerning motor thermal protection Ground fault protection The drive is equipped with an internal ground fault protective function to protect the unit against ground faults in the motor and the motor cable This is not a personal safety or a fire protection feature The ground fault protective function can be disabled with a parameter refer to the appropriate Firmware Manual The optional EMC filter includes capacitors connected between the main circuit and the frame These capacitors and long motor cables increase the ground leakage current and may cause fault current circuit breakers to function Emergency stop devices For safety reasons install the emergency st
6. 018A 2 018A 5 es e 025A 2 025A 5 030A 2 030A 5 JBR 05 20 570 035A 2 035A 5 044A 2 044A 5 050A 2 050A 5 061A 2 061A 5 JBR 06 13 790 078A 2 078A 5 094A 2 094A 5 581898 R Resistance of the listed resistor Pr Continuous power heat dissipation of the listed resistor when cooled naturally in a vertical position Evulse Energy pulse the listed resistor will withstand The braking resistors are protected to IP20 Refer to page 123 for dimensions wire sizes and tightening torques for the resistors Resistor installation and wiring All resistors must be installed outside the drive module in a place where they are cooled sufficiently do not block the airflow to other equipment or dissipate hot air into the air inlets of other equipment WARNING The materials near the braking resistor must be non flammable The surface temperature of the resistor may rise above 200 C 400 F and the temperature of the air flowing from the resistor is hundreds of degrees Celsius Protect the resistor against contact The maximum length of the resistor cable s is 20 m 65 ft For the connections see section Power cable connection on page 52 Resistor braking Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 112 Contactor protection of drive It is highly recommended to equip the drive with a main contactor for safety reasons Wire the contactor so that it opens in case
7. 13 Ibf in Motor cable Braking resistor cable Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 58 Power cable connection frame sizes C and D connector covers removed Supply cable Screw lug detail Below cable clamp cover bare Cable clamp on bare shield shield with insulating tape 1 5 Nem 13 Ibf in 15 N m 11 Ibf ft 7 GC Frame C 3 N m 25 Ibf in p Frame
8. 28 18 21 75 168 75 140 75 osas C 20 25 33 no 23 1 Lang 08045 0 26 30 36 150 28 15 24 110 map C 30 35 44 185 32 15 29 15 0_ oas 0 36 44 53 2 41 22 35 185 o5 ae 50 66 22 a 06145 D 55 ot 78 a 57 30 52 22 076A5 D 65 78 108 37 74 37 68 seas ie 4 ia jas o as 75 877 581898 Nominal ratings with 460 V AC supply Output ratings oo O Ou tp tratinga Input ratings Nominal pri aia Heavy duty Drive type Cas use ACS850 04 in S i S he DA e He HP Ea Soe ailes 38 20 on A ao es es 707 30 jas 20 40120 06405 A 55 94 60 88 30 55 30 50 30 mut A 66 n2 80 105 50 76 50 60 30 oas B 87 13 105 185 50 97 50 90 5 0 map B 12 18 4 ies 75 180 75 10 75_ map B 16 28 18 21 10 168 10 140 10 osas c 20 33 15 23 15 190 10 oas Cc 26 30 36 20 28 20 24 15 osas 0 80 8s ae a j o 80 map C 36 mens c 42 50 6 a 46 30 44 30 Dep D5 et 78 40 87 4082 map D 65 78 104 50 74 50 66 50 map D 82 94 124 60 90 60 75 50 581898 Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 79 Nominal ratings with 500 V AC supply Output ratings Input ratings age e RE
9. 5 Refit the cover in reverse order to the above procedure Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 50 FAN SEAN MINT i A A AAA JONO PAAA Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 51 Checking the insulation of the assembly Drive Do not make any voltage tolerance or insulation resistance tests e g hi pot or megger on any part of the drive as testing can damage the drive Every drive has been tested for insulation between the main circuit and the chassis at the factory Also there are voltage limiting circuits inside the drive which cut down the testing voltage automatically Supply cable Check the insulation of the supply input cable according to local regulations before connecting to the drive Motor and motor cable Check the insulation of the motor and motor cable as follows 1 Check that the motor cable is connected to the motor and disconnected from the drive output terminals U2 V2 and W2 2 Measure the insulation resistance between each phase conductor and the Protective Earth conductor using a measuring voltage of 500 V DC The insulation resistance of an ABB motor must exc
10. Compartment for terminal blocks and manuals ACS850 04 drive module Mechanical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 35 Delivery check and drive module identification Check that there are no signs of damage Before attempting installation and operation check the information on the type designation label of the drive module to verify that the unit is of the correct type The label is located on the left hand side of the drive module Type code options Compliance see page 25 y markings AL UD ED ACS850 04 014A 5 0C168 ARO NANN U1 3 380 500 V E fi 48 63 Hz mas i a en an tA i i im Frame size mul FRAME Gn 14 A D 0 400 H B Pn 5 5 kW 7 5 HP Sg 11 0390 969 Original memory ACS850 04 MU E1 ai D unit data Ml 2 pres Na S N ees CHK 7 AACE TE N A 296 TE N A 3 N 11 03902970 Ratings Serial number The first digit of the serial number refers to the manufacturing plant The 2nd and 3rd digit indicate the year of manufacture while the 4th and 5th digits indicate the week Digits 6 to 10 are a running integer starting every week at 00001 Before installation Check the installation site according to the requirements below Refer to Dimension drawings for frame details Requirements for the installation site See Technical data for the allowed operation conditions of the drive The ACS850 04 is to be mounted in an upright position T
11. obligatory clearances cables and cable support structures all require space For a layout example see section Cooling and degrees of protection below Grounding of mounting structures Make sure all cross members or shelves on which drive system components are mounted are properly grounded and the connecting surfaces left unpainted Note Ensure that the components are properly grounded through their fastening points to the installation base Note It is recommended that the EMC filter if present and the drive module be mounted on the same mounting plate Planning the cabinet assembly Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 28 Main dimensions and free space requirements The modules can be installed side by side The dimensions of the drive modules as well as free space requirements are presented below For more details refer to chapter Dimension drawings
12. the boards unnecessarily Safety instructions Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Start up and operation These warnings are intended for all who plan the operation of the drive start up or operate the drive A A Safety instructions WARNING Ignoring the following instructions can cause physical injury or death or damage to the equipment Before adjusting the drive and putting it into service make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive The drive can be adjusted to operate the motor at speeds above and below the speed provided by connecting the motor directly to the power line Do not activate automatic fault reset functions if dangerous situations can occur When activated these functions will reset the drive and resume operation after a fault Do not control the motor with an AC contactor or disconnecting device disconnecting means instead use the control panel or external commands via the I O board of the drive or a fieldbus adapter The maximum allowed number of charging cycles of the DC capacitors i e power ups by applying power is one per two minutes The maximum total number of chargings is 100000 for frame sizes A and B 50000 for frame sizes C and D Drives controlling a permanent magnet motor Do not run the motor over the rated speed Motor overspeed leads to overvoltage
13. 045 015 KEE 2 75 oo am aso E a a UE ar is ss iz 99 70 078A 2 2 20 2 5047 2 aos oj oa 19 04 09 035 20 EA e ae eee UE e2 26 78 es 66 a 20 030A 5 oA 15 5 8 8 14 7 7 9 12 6 2 EE 5 050A 5 5 ei e J 43 9 13 E 5 40 4 094A 5 5 L Low motor noise mode See section Low motor noise derating on page 80 Pbr5 The drive inverter and chopper will withstand this braking power for 5 seconds per minute Poro The drive inverter and chopper will withstand this braking power for 10 seconds per minute 581898 Resistor braking Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 111 Pbrcont The drive inverter and chopper will withstand this continuous braking power The braking is considered continuous if the braking time exceeds 30 seconds Pormax Maximum braking power of the drive inverter and chopper The drive inverter and chopper will withstand this braking power for 1 second within every 10 seconds Note The listed resistors will withstand this braking power for 1 second within every 120 seconds Rmin The minimum allowed resistance of the braking resistor Resistor selection table The ratings apply at an ambient temperature of 40 C 104 F Drive type Example braking resistor 03A0 2 03A0 5 03A6 2 03A6 5 04A8 2 04A8 5 JBR 01 06A0 2 O6A0 5 08A0 2 08A0 5 010A 2 010A 5 JBR 03 80 135 014A 2 014A 5
14. 300 mm 12 JY The temperature of the cooling air entering the unit must not exceed the maximum allowed ambient temperature see Ambient conditions in chapter Technical data Consider this when installing heat generating components such as other drives mains chokes and braking resistors nearby Cooling and degrees of protection The cabinet must have enough free space for the components to ensure sufficient cooling Observe the minimum clearances given for each component The air inlets and outlets must be equipped with gratings that e guide the air flow e protect against contact e prevent water splashes from entering the cabinet The drawing below shows two typical cabinet cooling solutions The air inlet is at the bottom of the cabinet while the outlet is at the top either on the upper part of the door or on the roof Planning the cabinet assembly Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 30 fei TI Wi Air outlet HTT Air inlet LULU LE a Wm mm a UT e M MT mu ut wm mm Arrange the cooling of the modules so that the requirements given in chapter Technical data are met e cooling air flow Note The values in Technical data apply to continuous nominal load If the load is less than nominal less cooling air is required e allowed ambient temperature Make sure the air inlets and outlets are suffi
15. 4 CPE a oe UDC T 7 Output stage 1 phase shown Notes e The contacts of the activation switch must UDC open close within 200 ms of each other e The maximum cable length between the drive and the activation switch is 25 m 82 ft 24 V Control circuit gt U2 V2 W2 and auxiliary circuits from the drive Therefore maintenance work on electrical parts of the drive or the motor can only be carried out after isolating the drive system from the main supply A WARNING The Safe torque off function does not disconnect the voltage of the main Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 43 Note It is not recommended to stop the drive by using the Safe torque off function If a running drive is stopped by using the function the drive will trip and stop by coasting If this causes danger or is not acceptable the drive and machinery must be stopped using the appropriate stopping mode before using the Safe torque off function Note concerning permanent magnet motor drives in case of a multiple IGBT power semiconductor failure In spite of the activation of the Safe torque off function the drive system can produce an alignment torque which maximally rotates the motor shaft by 180 p degrees p denotes the pole pair number Selecting the power cables General rules Dimension the supply input power and motor cables a
16. 83 282 91 310 100 340 24 14 03A0 5 142 84 262 893 366 1249 485 1654 172 588 030A 5 98 333 200 118 481 1641 646 2205 335 1142 422 1441 209 712 259 884 290 990 317 1081 103 351 126 430 126 430 050A 5 290 171 616 2101 840 2867 737 2514 061A 5 290 171 1020 3481 1200 4096 290 171 494 1685 078A 5 094A 5 126 430 854 2915 560 1910 Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 84 Supply cable fuses Fuses for short circuit protection of the supply cable are listed below The fuses also protect the adjoining equipment of the drive in case of a short circuit Check that the operating time of the fuse is below 0 5 seconds The operating time depends on the supply network impedance and the cross sectional area and length of the supply cable See also chapter Planning the electrical installation Note Fuses with a higher current rating must not be used IEC fuse UL fuse Cross sectional Input area of cable G i Plat Las current Rated Rated UL A current Voltage Class current Voltage Gj mm AWG A V A V e eo T EP ER ee A 1 5 4 1 5 10 03A0 2 03A0 5 4 0 6 500 gG 018A 1 5 0 1 5 10 025A 2 025A 5 20 25 500 gG 25 600 T 6 35 9 2 030A 2 030A 5 26 32 500 gG 3
17. 97 See the type designation label for the valid markings of your drive UL checklist Technical data Input power connection See section AC input supply connection on page 85 Disconnecting device Disconnecting means See section Supply disconnecting device on page 39 Ambient conditions The drive is to be used in a heated indoor controlled environment See section Ambient conditions on page 89 for specific limits Input cable fuses For installation in the United States branch circuit protection must be provided in accordance with the National Electrical Code NEC and any applicable local codes To fulfill this requirement use the UL classified fuses given in section Supply cable fuses on page 84 For installation in Canada branch circuit protection must be provided in accordance with the Canadian Electrical Code and any applicable provincial codes To fulfil this requirement use the UL classified fuses given in section Supply cable fuses on page 84 Power cable selection See section Selecting the power cables on page 43 Power cable connections For the connection diagram and tightening torques see section Power cable connection on page 52 Control connections For the connection diagram and tightening torques see section Connecting the control cables on page 62 Overload protection The drive provides overload protection in accordance with the National Electrical Code US Braking Th
18. Calculate the braking energy during the duty cycle Pre selected resistors are available from ABB as shown in the table on page 111 If the listed resistor is not sufficient for the application a custom resistor can be selected within the limits imposed by the internal braking chopper of the ACS850 04 The following rules apply e The resistance of the custom resistor must be at least Rmin The braking power capacity with different resistance values can be calculated from the following formula 2 Ubc BR 30 V Pmax lt R WARNING Never use a braking resistor with a resistance below the value specified for the particular drive type The drive and the chopper are not able to handle the overcurrent caused by the low resistance Resistor braking Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 110 e The maximum braking power must not exceed Phrmax at any point e The average braking power must not exceed Phrcont e The braking energy must not exceed the energy dissipation capacity of the selected resistor e Itis highly recommended that the resistor be protected from thermal overload see section Contactor protection of drive on page 112 Chopper data table The ratings apply at an ambient temperature of 40 C 104 F Internal braking chopper Drive type Pors Pors Pbr10 Pbr10 Pbrcont Ka Ko ka ACS850 04 KW KW kW kW kW eg kW ohm L L pono os oz os 02
19. Frame A B category C3 installation Installation guidelines e The filter is connected directly to the drive input connectors e For optimal operation of the filter the drive and the filter must be mounted on the same conductive surface Connection diagram AC supply CHK xx mains choke if present JFI x1 EMC filter a A E a UDC UDC EMC filters Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 102 Mounting procedures JFI A1 Remove the UDC and U1 V1 W1 terminal blocks 1 and the upper power cable clamp plate 2 from the drive Fasten the mounting bracket 3 to the drive module base with two screws 4 Tighten to 1 5 N m 13 Ibf in Push the filter into place through the mounting bracket Fasten the filter to the mounting bracket with two screws 5 Tighten to 1 5 N m 13 Ibf in Fasten the top edge of the filter to the mounting base with two screws 6 Fasten the power cable clamp plate at the top of the filter Tighten to 1 5 N m 13 lbf in Attach the terminal blocks to the filter EMC filters Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 103 JFI B1 e Remove the UDC and U1 V1 W1 terminal blocks 1 and the upper power cable clamp plate 2 from the drive e Push the filter into the connectors e Fasten the filter to the drive module base with two screws 3 Tighten to 1 5 Nem 13 Ib
20. Insulation jacket Copper wire screen Helix of copper tape Inner insulation ec CS y eo Cable core Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 45 Protecting the relay output contacts and attenuating disturbances in case of inductive loads Inductive loads relays contactors motors cause voltage transients when switched off The relay outputs on the drive are protected with varistors 250 V against overvoltage peaks In addition it is highly recommended to equip inductive loads with noise attenuating circuits varistors RC filters AC or diodes DC in order to minimize the electromagnetic emissions at switch off If not suppressed the disturbances may connect capacitively or inductively to other conductors in the control cable and form a risk of malfunction in other parts of the system Install the protective component as close to the inductive load as possible not at the relay output Varistor a 230 V AC Relay output HAD RC filter SE 230 V AC Relay output genee Diode 24 VDC Relay output EX Gr oe See Considering the PELV requirements at sites above 2000 m 6562 ft The relay outputs of the drive do not fulfill the Protective Extra Low Voltage PELV requirements at installation sites above 4000 meters 13123 feet if used with a voltage greater than 48 V At installation sites between 20
21. N N m NY I Siz m lt E c vi ro gt PJ O SE zes D lt no ne 2 H o at 253 3 gt Ba 2 0 on lt a2 S Sa ES st E Se os n D v e gt S o S 33 3 et o lt 5 g Ki Ws 32 3 Us Ze gt on 25 S o o gt 3 5 o 2 lt St Sei 3 Dimension drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 121 EMC filters type JFI 0x lt EE O O Lu PES T apa TA KA eg oD ot ESCH E o Kei ole X e A o Cre 7 ad E p oD EA o 2 Rei Re E oO vo aves Fe E C pt O gt ES o rm ll Kei gt ay Ge Wd O ae e zZ ER ES HL S gt 7 EC o H a o o oF alo o O Am iy Lo gt lt a lt 2 o a al En a E J Ss De gt H vw Loes o a3 Lo a i z Rei oO A S Ler gt D l sai TAS LC Cm Ka Lite 5 A ES Les Ka fo Co TI Ww gt x Q a LE e an SS ab o Se Be af o SE s Z R a Oo e o K 1 o EY Dn Lu wm GER gt Pag NI ee EA lt C A o _ o DI Ms Te E oD Be lt TA BE Lo SE of w ee EEN L D gt o gt 3 2 Lo aS CC o L gt At o ON gt gt BZ CH GE s E H SES leg ees e a e az a ev Oo a e oj al of 09
22. PE OR he PES 2 ON alo a D Lee o e oO phe iS CN Kee x lt O NE N j o me ES o SA o DD oD gt o oO gt fom EE o o SS O o E o e e o oj o a SE Sei o mn o IC ore a gt E mn Da v m S oj gt 0 mi O l 1 KC EU 1444 431113 134 OWS Uappl quo Ay dois S Atl soy no ssoJdxo 1noyL IM s lpJod pJiy O JNSOJISI P JO asn UolLonpoudey UloJoyl POU DLUOD UO fOWLOf UT OYf Ul pup fUSWNIOP Siy Ul stub po 9AJISIA M 0 E ENEE ER IN 3 lt L 211 CO O Lu pj Dimension drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 122 6GL EU ESL Eek e zE LO L FM 8 LO 020Mv 0 Feil SE SE SE 0 1 vOMV d 9 0Z9MY 8 y20MV G ES SNE ees over wari ISCH Su 292 vg vol g9z osi ge6e 911 sez 680 no LSO yo Lb a 1 1 Sp 19 1 Gzp e60 sz 680 ess ou MN om its reueg seo se z9 0 22 OO L 70 0 0 v s SIL O LO a 900 sr poor poor Teo 90 s9 entre zors zors gece eez jog erioe 860 sz roor ssz_ Sze sez ro o eez Sz 6 sez Gp 6 Ove 99 8 ozz Sr 6 ore 99 8 ozz 1e6s 0St pge o6 see se 9272 07 yse 06 see se ellos zt Sr 9 01 0z2 vg 6 ose ve6josz r86 osz Zo lur ot eoar Soup IE TT O SUOISUQUuIp XX 4fP eee J gzrg UL Sp OW Urs
23. Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 54 11 With frame size C or D cut suitable slots on the edges of the connector covers to accommodate the supply and motor cables Refit the covers Tighten the screws to 3 N m 25 Ibf in 12 Secure the cables outside the unit mechanically 13 Ground the other end of the supply cable shield or PE conductor s at the distribution board In case a mains choke and or an EMC filter is installed make sure the PE conductor is continuous from the distribution board to the drive Grounding the motor 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 so that the flattened shield is wider than 1 5 of its length b gt 1 5 a Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 55 Installation of power cable clamp plates Two identical power cable clamp plates are included with the drive The picture below depicts a frame size A drive the installation is similar with other frame sizes Note Pay attention to supporting the cables adequately within the installation enclosure especially if not using the cable clamps Frames A and B 1 5 N m 13 Ibf in Frames C and D 3 N m 25 Ibf in
24. See the Firmware Manual of the drive e PTC as well as KTY84 sensors can alternatively be connected to a FEN xx encoder interface See the User s Manual of the interface for wiring information e Pt100 sensors are not to be connected to the thermistor input Instead an analog input and an analog current output located either on the JCU or on an I O extension module are used as shown below The analog input must be set to voltage One Pt100 sensor Three Pt100 sensors 3 3 NF fee V AC the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor If the assembly does not fulfil the WARNING As the inputs pictured above are not insulated according to IEC 60664 requirement e all I O terminals must be protected against contact and must not be connected to other equipment Or Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 65 e the temperature sensor must be isolated from the I O terminals Drive to drive link XD2D The drive to drive link is a daisy chained RS 485 transmission line that allows basic master follower communication with one master drive and multiple followers Termination activation jumper T see section Jumpers above next to this terminal block must be set to the ON position on the drives at the ends of the drive to drive link On intermediate drives the jumper must
25. Use a cabinet heater if there is a risk of condensation in the cabinet Although the primary function of the heater is to keep the air dry it may also be required for heating at low temperatures When placing the heater follow the instructions provided by its manufacturer Planning the cabinet assembly Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 32 Planning the cabinet assembly Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 33 Mechanical installation Contents of the package The drive is delivered in a cardboard box To open remove any banding and lift the top off the box Mechanical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 34 The box contains e ACS850 04 drive module with factory installed options e three cable clamp plates two for power cabling one for control cabling with screws e screw type terminal blocks to be attached to the headers on the JCU Control Unit and the power unit e EMC filter E200 if ordered with frames A and B only e control panel mounting kit J410 if ordered e Printed Quick Guides printed manuals if ordered manuals CD Compartments for EMC RFI filter control panel cable clamp plates mounting kit J gt Underneath the drive module lift out the module and open left hand side flap to access
26. be set to the OFF position Shielded twisted pair cable 100 ohm e g PROFIBUS compatible cable must be used for the wiring For best immunity high quality cable is recommended The cable should be kept as short as possible the maximum length of the link is 100 metres 328 ft Unnecessary loops and running the cable near power cables such as motor cables must be avoided The cable shields are to be grounded to the control cable clamp plate on the drive as shown on page 66 The following diagram shows the wiring of the drive to drive link Termination ON Termination OFF Termination ON JCU JCU JCU Drive 1 Drive 2 Drive n Note The drive to drive link can be used only if the embedded fieldbus interface is disabled For more information on the embedded fieldbus interface see the Firmware Manual Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 66 Safe torque off XSTO For the drive to start both connections OUT1 to IN1 and OUT2 to IN2 must be closed This is implemented by means of a safety switch and related wiring See page 42 By default the terminal block has jumpers to close the circuit Remove the jumpers before connecting an external Safe torque off circuitry to the drive More information is available in Safe torque off function for ACSM1 ACS850 and ACQ810 drives application guide 3AFE68929814 English For related parameter settings see t
27. filter C3 2nd Environment Unrestricted Earthed network External with frames A and B internal with frames C and D Control panel and front D 0C168 No drive module front cover no control panel cover options J400 Control panel mounted on drive module front cover J410 Control panel with door mounting platform kit including 3 m cable J414 Control panel mounting platform on drive module no control panel included FDNA 01 DeviceNet adapter FLON 01 LonWorks adapter FPBA 01 PROFIBUS DP adapter FCAN 01 CANopen adapter FSCA 01 Modbus RTU adapter FENA 01 Ethernet adapter Ethernet IP Modbus TCP FECA 01 EtherCAT adapter UO extensions and D FIO 11 analog I O extension feedback interfaces FIO 01 digital I O extension FEN 31 HTL encoder interface FEN 21 resolver interface FEN 01 TTL encoder interface FEN 11 absolute encoder interface FIO 21 analog digital I O extension N5050 Crane control program Note The following technology library is required with the Crane control program N3050 Crane technology library Specialities P904 Extended warranty Q971 ATEX certified safe disconnection function Operation principle and hardware description Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 26 Alternatives Printed hardware and English firmware manuals in German specified language Italian English manuals may be Dutch delivered even if ano
28. for 230 V or cables in separate ducts inside insulated with an insulation the cabinet sleeving for 230 V Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 48 Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 49 Electrical installation What this chapter contains This chapter describes the electrical installation procedure of the drive electrician Follow the Safety instructions on the first pages of this manual Ignoring A WARNING The work described in this chapter may only be carried out by a qualified the safety instructions can cause injury or death Make sure that the drive is disconnected from the supply input power during installation If the drive is already connected to the supply wait for 5 minutes after disconnecting the input power Removing the cover assembly The cover assembly needs to be removed before the installation of optional modules and the connection of control cabling Follow this procedure to remove the cover assembly The numbers refer to the illustrations below Press the tab 1 slightly with a screwdriver Slide the lower cover plate slightly downwards and pull it out 2 Disconnect the panel cable 3 if present Remove the screw 4 at the top of the cover assembly Carefully pull the lower part of the base outwards by the two tabs
29. is applied After disconnecting the input power always wait for 5 minutes to let the intermediate circuit capacitors discharge before you start working on the drive the motor or the motor cable Always ensure by measuring with a multimeter impedance at least 1 Mohm that 1 There is no voltage between the drive input phases U1 V1 and W1 and the ground 2 There is no voltage between terminals UDC and UDC and the ground 3 There is no voltage between terminals R and R and the ground Drives controlling a permanent magnet motor A rotating permanent magnet motor feeds power to the drive causing the drive to become live even when it is stopped and the supply power switched off Before maintenance work on the drive disconnect the motor from the drive by using a safety switch prevent the start up of any other motors in the same mechanical system lock the motor shaft measure that the motor is in fact de energised then connect the U2 V2 and We terminals of the drive to each other and to the PE Do not work on the control cables when power is applied to the drive or to the external control circuits Externally supplied control circuits may carry dangerous voltages even when the input power of the drive is switched off Do not make any insulation or voltage withstand tests on the drive lf a drive whose varistors or internal EMC filters are not disconnected is installed on an IT power system an ungrounded
30. mm wire Frames C and D Screw lugs for 6 70 mm wire included Suitable crimp lugs can be used instead Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 86 Motor connection Motor types Frequency Current Switching frequency Maximum motor cable length Terminals JCU Control Unit Power supply Relay outputs RO1 RO3 XRO1 XRO3 24 V output XD24 Digital inputs DI1 DI6 XDI 1 XDI 6 Start interlock input DIIL XDI A Technical data Asynchronous induction motors synchronous permanent magnet motors 0 500 Hz See section Ratings 3 kHz default Frames A and B 150 m 492 ft Frames C and D 300 m 984 ft 100 m with EN 61800 3 Category C3 filter Frame A Detachable screw terminal block for 0 25 4 mm wire Frame B Detachable screw terminal block for 0 5 6 mm wire Frames C and D Screw lugs for 6 70 mm wire included Suitable crimp lugs can be used instead 24 V 10 DC 1 6 A Supplied from the power unit of the drive or from an external power supply through connector XPOW pitch 5 mm wire size 2 5 mm Connector pitch 5 mm wire size 2 5 mm 250 VAC 30 V DC 2A Protected by varistors Note The relay outputs of the drive do not fulfill the Protective Extra Low Voltage PELV requirements at installation sites above 4000 meters 13123 feet if used with a voltage greater than 48 V At installation
31. o o o ooooococoornna eee eee 125 Document library on the Internet 125 Table of contents Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ike About this manual What this chapter contains This chapter describes the intended audience and contents of this manual It contains a flowchart of steps in checking the delivery installing and commissioning the drive The flowchart refers to chapters sections in this manual and other manuals Compatibility The manual is compatible with ACS850 04 drive modules of frame sizes A to D Intended audience This manual is intended for people who plan the installation install commission use and service the drive Read the manual before working on the drive The reader is expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols This manual is written for readers worldwide Both SI and imperial units are shown wherever appropriate Categorization according to the frame size Some instructions technical data and dimensional drawings which concern only certain frame sizes are marked with the symbol of the frame size A B C or D The frame size is marked on the drive designation label The frame size of each drive type is also indicated in the rating tables in chapter Technical data Categorization according to the code Contents The instructions technical data and dimensional drawings w
32. power factor compensation capacitors in the motor cable The external control connections to the JCU Control Unit are OK oo O DU There are no tools foreign objects or dust from drilling inside the drive Installation checklist Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 70 Check O The supply input power voltage cannot be applied to the output of the drive through a bypass connection O Motor connection box and other covers are in place Installation checklist Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 71 Maintenance What this chapter contains This chapter contains preventive maintenance instructions Safety WARNING Read the Safety instructions on the first pages of this manual before performing any maintenance on the equipment Ignoring the safety instructions can Cause injury or death Maintenance intervals The table below lists the routine maintenance intervals recommended by ABB Consult a local ABB Service representative for more details On the Internet go to select Drive Services and Maintenance and Field Interval Maintenance Instruction Services Every year of storage DC capacitor reforming See Reforming the capacitors on page 75 Every 6 to 12 months depending on the Heatsink temperature See Heatsink on page 72 dustiness of the environment check and cleaning Every year Inspection of tightness Se
33. sites between 2000 meters 6562 feet and 4000 meters 13123 feet PELV requirements are nat fulfilled if one or two relay outputs are used with a voltage greater than 48 V and the remaining relay output s are used with a voltage lower than 48 V Connector pitch 5 mm wire size 2 5 mm Connector pitch 3 5 mm wire size 1 5 mm 24 V logic levels 0 lt 5 V 1 gt 15 V Ra 2 0 kohm Input type NPN PNP DI1 DI5 NPN DI6 Filtering 0 25 ms DI6 XDI 6 can alternatively be used as an input for 1 3 PTC thermistors 0 gt 4 kohm 1 lt 1 5 kohm Imax 19 MA Wire size 1 5 mm 24 V logic levels 0 lt 5 V 1 gt 15 V Rin 2 0 kohm Input type NPN PNP Filtering 0 25 ms Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 87 D 2 igital inputs outputs DIO1 and DIO2 XDIO 1 and XDIO 2 Input output mode selection by parameters DIO1 can be configured as a frequency input 0 16 kHz for 24 V level square wave signal sinusoidal or other wave form cannot be used DIO2 can be configured as a 24 V level square wave frequency output See Firmware Manual parameter group 12 Reference voltage for analog inputs VREF and VREF XAI 1 and XAI 2 Analog inputs Al1 and Al2 XAI 4 XAI 7 Current voltage input mode selection by jumpers See page 63 Analog outputs AO1 and AO2 XAO Drive to drive link XD2D Safe torqu
34. the case with all drives employing modern IGBT inverter technology The voltage of the pulses can be almost double at the motor terminals depending on the attenuation and reflection properties of the motor cable and the terminals This in turn can cause additional stress on the motor and motor cable insulation Modern variable speed drives with their fast rising voltage pulses and high switching frequencies can generate current pulses that flow through the motor bearings which can gradually erode the bearing races and rolling elements The stress on motor insulation can be avoided by using optional ABB du d filters du dt filters also reduce bearing currents Common mode filtering mainly reduces bearing currents To avoid damage to the motor bearings the cables must be selected and installed according to the instructions given in chapter Electrical installation In addition du dt filtering common mode filtering and insulated N end bearings must be used according to the following table du dt and common mode filtering Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 106 Motor Requirement Motor type Supply Voltage insulation eee Insulated N end Common mode Un du dt filtering A ae system bearing filtering Random wound ABB Form wound ABB HX_ or modular motor Check with motor manufactured before Un lt 500 Y Any manufacturer 1 Jan 1998 Random wound ABB HA and AN motor Enamelled wir
35. the resistor overheats This is essential for safety since the drive will not otherwise be able to interrupt the main supply if the chopper remains conductive in a fault situation Below is a simple example wiring diagram L1 L2 L3 Fuses 2 o Resistor thermal switch Main contactor KE vie a a Braking circuit commissioning For more information see the appropriate Firmware Manual e Enable the braking chopper function Please note that a braking resistor must be connected when the chopper is enabled e Switch off the overvoltage control of the drive e Adjust any other relevant parameters in group 48 enabled by parameter setting the braking resistor must be disconnected because h WARNING If the drive is equipped with a braking chopper but the chopper is not the protection against resistor overheating is then not in use Resistor braking Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 113 Dimension drawings What this chapter contains Dimension drawings of the ACS850 04 and related accessories are shown below The dimensions are given in millimetres and inches Dimension drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 114 Frame size A l T 19301 Laag ct U dy Y OB ej as J WAO y 21038 DO00VNAVE Daa DC 1dapdsay Lev TI 99 49M ON 39a FAV SINS E EC i 3558
36. the short circuit current Protection against short circuit in motor cable The drive protects the motor cable and the motor in a short circuit situation when the motor cable is dimensioned according to the nominal current of the drive No additional protection devices are needed Protection against short circuit in the supply cable or the drive Protect the supply cable with fuses or circuit breakers Fuse recommendations are given in chapter Technical data When placed at the distribution board standard IEC gG fuses or UL type T fuses will protect the input cable in short circuit situations restrict drive damage and prevent damage to adjoining equipment in case of a short circuit inside the drive Operating time of the fuses and circuit breakers Check that the operating time of the fuse is below 0 5 seconds The operating time depends on the type the supply network impedance and the cross sectional area material and length of the supply cable US fuses must be of the non time delay type Circuit breakers The protective characteristics of circuit breakers depend on the supply voltage as well as the type and construction of the breakers There are also limitations pertaining to the short circuit capacity of the supply network Your local ABB representative can help you in selecting the breaker type when the supply network characteristics are known Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773
37. within the EU The new revision of 61800 3 2004 product standard can be applied from now on but from 1st October 2007 at the latest EMC standards such as EN 55011 or EN 61000 6 3 4 apply to industrial and household equipment and systems including drive components inside Drive units complying with the requirements of EN 61800 3 are always compliant with comparable categories in EN 55011 and EN 61000 6 3 4 but not necessarily vice versa EN 55011 and EN 61000 6 3 4 do neither specify cable length nor require a motor to be connected as a load The emission limits are comparable according to the following table EN 55011 product family EN 61800 3 A11 2000 product EN 61800 3 2004 standard for industrial standard product standard scientific and medical ISM equipment 1st environment unrestricted distribution Category C1 Group 1 Class B 1st environment restricted distribution Category C2 Group 1 Class A 2nd environment unrestricted distribution Category C3 Group 2 Class A 2nd environment restricted distribution Category C4 Not applicable Filtering option E200 is required in order to meet the category C3 level with the ACS850 04 drive installation including a motor with a max 100 m cable This level corresponds to the A limits for Group 2 equipment according to EN 55011 With frame sizes A and B option E200 is an external filter of type JFI A1 or JFI B1 with frame sizes C and D the filter is internal An external EMC filter o
38. 0 Stes 21038 DUIAGN ONIAVAC ATENISSV Sep oq 802 82S UOISUAAUOD 4X DA 49330 suojsuauip upp UayM ODIO 9 OIS JIAO y S AJINIDNI OAJ VUN apow umop Joub oN 200 SAA Gay d31 119 303 Y JN 3114 1489 at 80 9NV 90 261 687 aeee OOOO O ONT S318 auou 322044 v0 0S8SIW ee ee ey E NAS INSINNATON IT amis aso 962 G9 G2 2 oga Pao 2h 6l YSE 06 aawogsngj s LIZ 8l uoldafoud auv 95414 yoAouddy 10114 EV SO uappiqvos Dune S Duouum ssaudxa noyzm Say od puy 0 3UNSOIISIP JO aen WASSW Y 331 113 ONT 15318 uo npouday ujauay pauUo UOJIDWAOFU a4 VU PUD JUANIOP Siy Ul SAU L NO aAuasau am G ASaWdd ccl6E0N0000VNVE SECH Dimension drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 120 JFI B1 I 19901 Laag Duo 06 ET0E8T9 SJAL ddy ONT IS Ala awdu 33a Oud ONIMVad A 1aWaSSY sap 50 441 114 144 41 80 9NV 90 INJINNATOAL pouodeud Lei 8r 8811 8Lv se be 0000 ES vee 001 UOISUAUOD 4X DA 49930 suojsuauip Gulppo USyYA J0JI04 21026 3907 y S YIINIDNI O4AJ HUN apow Buimoup Joub ON Joa FAV ON DOG 95N v0 058S3W LL 931 13 953 4 308 EH k gt au035n 5 uo pasog E 19 GGI uolzDef oud afun LSA CH yoaouddy 80 UNY 90 AL IWAJUNAJO alg Mic NVD Flo Kale Zlo mio mis Silke me oS m Mo E bd om gt
39. 0 Deratings with 230 V AC supply in low motor noise mode o o ooo 80 Deratings with 400 V AC supply in low motor noise mode oo ooo 81 Deratings with 460 V AC supply in low motor noise mode 200005 81 Deratings with 500 V AC supply in low motor noise mode o o o ooo 82 SIUMDOS iaa ks th arta ea ire ul a id See Pee Bete 82 Billie Leite Le EE 82 Cooling characteristics noise levels oi A A eRe Re ho eee oS 83 SUDDIY CADISMUSOS paris He oe ote ae e eee eee eee eee aed 84 AG Input SUPplY CONNECUON 2s vunsic c edad Peg e Be Ee BEES eee we eS 85 DC CONNECCION aia adan gcse ne Meee iia 85 MOTOR GOMNECTION sea sms as Gee ak Soe eee a ae ee Se a See ee eee a A 86 JOU CONTOUME tri A a SSS eRe Ss 86 EMICIONC das eed ae eae A raed aa ne bok 88 GOONG EE 88 Degrees OF DIOlCGHOnl EE 88 AMDICHLCONGIIONS EE 89 WATCH ONG tt a1 unde dane pea EE 89 APPICADIESTANd aras vita cord eee eee oe Gl a ee oe ee ee ee is ee 90 GE MARNI eed en de ee ae cena te o A eee een dn at eee eee Da cala ae 91 Compliance with the European Low Voltage Directive 0 0 eee 91 Compliance with the European EMC Directive 0 0 0 ce ees 91 Bizet ei 91 Compliance with EN 61800 3 2004 category Ce 91 Compliance with EN 61800 3 2004 category Ce 92 Compliance with EN 61800 3 2004 category CA 92 Compliance with the Machinery Directive 0 0 eee eee 93 CTE AK e aca amis bes bie Se kets Steen ee d
40. 00 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 67 Routing the control cables Mounting the clamp plate iit 4 PS De N e A Zz ES 7 j N d Up DFA P S POLO A a H II Otter EE 7 SS GEL AL ZP AA P y 7 SSS a D J DAA e h j gt en D gt gt q XA knoe OTER Ke ees L ds dl AERPR l a Use shrink tubing or tape to El hk contain strands A LX P UA i e E UnA ira e Dor 0 7 Nem 6 2 Ibf in Ter RK HAD DK LU _ Run cables through the cover A a mounting bracket D lt Uo Sec dl LE amp gt Ze al ZN y gt Remove outer jacket of cable at clamp to expose cable shield Tighten clamp to 1 5 N m 13 Ibf in Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 68 Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 69 Installation checklist Checklist Check the mechanical and electrical installation of the drive before start up Go through the checklist below together with another person Read the Safety instructions on the first pages of this manual before yo
41. 00 meters 6562 feet and 4000 meters 13123 feet PELV requirements are not fulfilled if one or two relay outputs are used with a voltage greater than 48 V and the remaining relay output s are used with a voltage lower than 48 V Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 46 Selecting the control cables It is recommended that all control cables be shielded Double shielded twisted pair cable is recommended for analog signals For pulse encoder cabling follow the instructions given by the encoder manufacturer Use one individually shielded pair for each signal Do not use a common return for different analog signals Double shielded cable is the best alternative for low voltage digital signals but single shielded twisted multipair cable Figure b is also usable Double shielded twisted Single shielded twisted pair cable multipair cable Run analog and digital signals in separate cables Relay controlled signals providing their voltage does not exceed 48 V can be run in the same cables as digital input signals It is recommended that the relay controlled signals be run as twisted pairs Never mix 24 V DC and 115 230 V AC signals in the same cable Relay cable The cable type with braided metallic screen e g OLFLEX by Lapp Kabel Germany has been tested and approved by ABB Control panel cable The cable connecting the control panel t
42. 1 5 Nem 13 Ibf in Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 56 Power cable connection frame size A Cable clamp on bare shield 1 5 Nem 13 Ibf in Below cable clamp cover bare shield with insulating tape 4 5 Nem 13 In 0 5 0 6 N m 4 4 5 3 Ibf in en NR pen E A pn mem BEE pen E es E E SF A T ADA i Tae AA AS UC H HH EES SE S e gt El 3 Il gt CA FAN AD Di Ly ae esa as ES Be 0 5 0 6 N m 4 4 5 3 Ibf in Above cable clamp cover bare shield with insulating tape Cable clamp on bare shield 1 5 Nem 18 Ibf in Motor cable Braking resistor cable Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 57 Power cable connection frame size B Supply Cable clamp on bare shield E eg 1 5 N m 13 Ibf in ies Below cable clamp cover bare V1 N 4 5 Nem 13 Ibf in Above cable clamp cover bare shield with insulating tape Cable clamp on bare shield 1 5 N m
43. 5 600 T 6 35 9 2 035A2 035A 5 30 40 500 gG 35 600 T 6 35 9 2 044A 2 044A 5 36 50 500 gG 45 600 T 6 35 9 2 _ 050A 2 050A 5 42 50 500 gG 50 600 T 10 70 6 2 0 061A 2 061A 5 55 63 500 gG 70 600 T 10 70 6 2 0 078A 2 078A 5 65 80 500 gG 80 600 T 10 70 6 2 0 094A 2 094A 5 82 100 500 gG 100 600 T 10 70 6 2 0 Without mains choke 600 600 9G 10 600 9G 15 600 9G 15 600 9G 20 600 9G 25 600 A A a A A a A Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 85 AC input supply connection Voltage U Frequency Short circuit withstand strength IEC 60439 1 Network type Imbalance Fundamental power factor cos phiy Terminals DC connection Voltage Ratings fuse recommendations Terminals 200 240 V AC 10 3 phase 380 500 V AC 10 15 3 phase 50 60 Hz 15 Frames A and B Maximum allowable prospective short circuit current is 5 KA when protected by fuses given in the Supply cable fuses table Frames C and D Maximum allowable prospective short circuit current is 10 KA when protected by fuses given in the Supply cable fuses tables Grounded TN TT or ungrounded IT Note Connection to an ungrounded IT or corner grounded delta network is not allo
44. 5 standard 061A 2 061A 5 078A 2 078A 5 044A 2 044A 5 Internal choke as 094A 2 094A 5 581898 The mains chokes are protected to IP20 Refer to page 118 for dimensions wire sizes and tightening torques Mains chokes Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 98 Installation guidelines e If an EMC filter is also installed the mains choke is connected between the supply and the EMC filter See the diagram below e For optimal operation of the choke the drive and the choke must be mounted on the same conductive surface e Ensure the choke does not block the airflow through the drive module and that the air rising from the choke is deflected away from the air inlet of the drive module e Keep the cable between the drive and the choke as short as possible AS WARNING The surface of the mains choke becomes hot when in use Connection diagram AC supply L1 L2 L3 PE CHK xx mains choke Mains chokes Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 99 EMC filters What this chapter contains When is an A This chapter describes how to select and install EMC filters for the ACS850 04 The chapter also contains the relevant technical data EMC filter required The EMC product standard EN 61800 3 Amendment A11 2000 covers the specific EMC requirements stated for drives tested with motor and cable
45. 6 165 6 50 130 5 12 4 7 10 4 NOCH0070 60 261 10 28 180 7 09 150 5 91 9 5 20 9 NOCH0120 60 200 7 87 154 6 06 106 4 17 Dimensions given are per phase Degree of protection IPOO Common mode filters Contact your local ABB representative Installation Follow the instructions included with the filters du dt and common mode filtering Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 108 du dt and common mode filtering Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 109 Resistor braking What this chapter contains This chapter describes how to select protect and wire braking choppers and resistors The chapter also contains the technical data Braking choppers and resistors with the ACS850 04 Braking choppers ACS850 04 frame A D drives have a built in braking chopper as standard equipment to handle the energy generated by a decelerating motor When the braking chopper is enabled and a resistor connected the chopper will start conducting when the DC link voltage of the drive reaches Upc gr 30 V The maximum braking power is achieved at Upc Br 30 V Upc 1 35 x Used AC supply voltage Braking resistor selection A To select a braking resistor 1 Calculate the maximum power generated by the motor during braking 2 Calculate the continuous power based on the braking duty cycle 3
46. 69 Commission the drive Appropriate Firmware Manual Commission the braking chopper if required Resistor braking page 109 Operating of the drive start stop speed control etc Appropriate Firmware Manual About this manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 1 LO Terms and abbreviations FENA 0x Optional Ethernet adapter for the ACS850 Supports the Ethernet IP and Modbus TCP protocols FLON Ox Optional LONWoRks adapter for the ACS850 FPBA 0x Optional PROFIBUS DP adapter for the ACS850 Frame size Size of the drive module This manual deals with ACS850 04 frames A B C and D To determine the frame size of a drive module refer to the drive designation label attached to the drive or the rating tables in chapter Technical data FSCA 0x Optional Modbus RTU adapter for the ACS850 IGBT Insulated Gate Bipolar Transistor a voltage controlled semiconductor type widely used in inverters due to their easy controllability and high switching frequency I O Input Output JBR xx Series of optional braking resistors for the ACS850 JCU The control unit of the drive module The JCU is installed on top of the power unit The external I O control signals are connected to the JCU or optional I O extensions mounted on it JFI xx Series of optional EMC filters for the ACS850 JMU The memory unit attached to the control unit of the drive JPU Power unit se
47. 7 671 548 7 679 425 7 688 845 7 696 532 1 706 396 7 724 503 7 729 148 7 741 796 7 133 048 7 759 901 7 199 897 D503 931 D510 319 D510 320 D511 137 D511 150 D512 026 D512 696 D521 466 D541 743S D541 744S D541 745S D548 182S D548 183S D573 090S D610 553S Other patents pending Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 96 Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 97 Mains chokes What this chapter contains This chapter describes how to select and install mains chokes for the ACS850 04 The chapter also contains the relevant technical data When is a mains choke required Frame C and D drive modules have an internal mains choke With frames A and B the need for an external choke should be determined on a case by case basis The main choke typically reduces harmonics in the input current reduces the r m s input current reduces supply disturbance and low frequency interference increases the allowed DC bus continuous power ensures even current distribution in common DC configurations see page 59 Selection table Mains chokes for ACS850 04 Drive type 03A0 2 03A0 5 03A6 2 03A6 5 e Gees 04A8 2 04A8 5 06A0 2 06A0 5 CHK 02 4610 08A0 2 08A0 5 010A 2 010A 5 014A 2 014A 5 Se lbs 025A 2 025A 5 018A 2 018A 5 CHK 04 1475 030A 2 030A 5 035A2 035A 5 050A 2 050A
48. 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Safety instructions What this chapter contains This chapter contains safety instructions which you must follow when installing operating and servicing the drive If ignored physical injury or death may follow or damage may occur to the drive the motor or driven equipment Read the safety instructions before you work on the unit Use of warnings and notes There are four types of safety instructions used in this manual Electricity warning warns of high voltage which can cause physical injury and or damage to the equipment electricity which can result in physical injury and or damage to the equipment General warning warns about conditions other than those caused by Electrostatic discharge warning warns of electrostatic discharge which bo A can damage the equipment Hot surface warning warns of component surfaces that may become hot enough to cause burns if touched Safety instructions Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Installation and maintenance work These warnings are intended for all who work on the drive motor cable or motor WARNING Ignoring the following instructions can cause physical injury or death or damage to the equipment Only qualified electricians are allowed to install and maintain the drive Never work on the drive the motor cable or the motor when input power
49. 9 PU UR IM 60 NVP E2 Vd JN ONIAVAC SNSWIC e MIL 60 NVP E2 S6 2 GZ 06 1 ESE LESY SI c98 ole Wi Si Dill AGC g H2349 J4awo4zsn PaRa O peso Wi a a H H D PA TT MIA dOL Patol 89E GE6 pS 1 06 Ec vl v9 Trek 81 697 99 811 Lv 60 v vol AULSISJA Avda MIA WOLLOE gt gt S yoaouddy IEA uappiquog Ins si DUOuLng ssaudxa 3noy A Saj3u0d BAU 0 aUNSOYS P JO asn HISSW Oer6E00000VNVE uo DNpouday U3M3YY PauU UO OW4OJU ay Ul PUY FUAWNIOP SUD uJ Su L NO aAuasau M 02y6 000004NWE Dimension drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 170 C Pi IN ETT pass LISCH oyo SAU GE oa rr EE H paxodaJd uo paso Dug dp v0 0S8SIV en DJ ONIAVAC NOISN3NIC d AWVA4 y VD omg sap 200 ONIAVAC SNSWIC SpUIe0 NNT C MIA dal 89111 L62 S6 2 SZ A a Vo STT LO6 ET ESE LECH SIT ETZ II AU 1SISIA DIVE MATA NI UO SUAAUOD 4X DM 49930 suo suauio Dupp UYM 403303 AVIS 13440 2Y 138 JJINIDNI OAH VUN apow Sumoup youu Frame size B 6 v1 08 vv 811 697 ICC 9Lv uol1dafoud afur 35414 yoAouddy orlu ENEE uappiquos A 42 435 S Dunuumg ssaudxa 3noy3 m sajyod puy 0 aunsopsjp vo aen WASSV LEUK Yo INpOuday ulavau PULU UO OWUOJU y u PUD JUAWNIOP SU UU SUBA yO aAuasau AN LLS2v00000VNVE Ea ALA A A O RA Dim
50. ACS850 Hardware Manual ACS850 04 Drive Modules 0 37 to 45 kW S ee e e gg gg Lf of JO J a JO e a e JA LITIO ET III ON a a 6 ES AA ED ED FADED Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ACS850 drive manuals DRIVE HARDWARE MANUALS ACS850 04 Drive Modules 0 37 to 45 kW Hardware Manual 3AUA0000045496 English DRIVE FIRMWARE MANUALS ACS850 Standard Control Program Firmware Manual 3AUA0000045497 English OPTION MANUALS ACS CP U Control Panel IP54 Mounting Platform Kit J410 Installation Guide 3AUA0000049072 English Manuals for UO Extension Modules Fieldbus Adapters etc APPLICATION GUIDES Application programming for ACS850 drives 3AUA0000078664 English ATEX certified safe disconnection function for ACS850 drives 3AUA0000074343 English Safe torque off function for ACSM1 ACS850 and ACQ810 drives 3AFE6892981 4 English The delivery includes a multilingual quick installation guide The delivery includes a multilingual quick start up guide Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ACS850 04 Drive Modules 0 37 to 45 kW Hardware Manual 3AUA0000045496 Rev E EN EFFECTIVE 2010 10 26 2010 ABB Oy All Rights Reserved Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Phone 800
51. ARNING If a drive whose varistors filters are not disconnected is installed on an If a drive whose varistors filters are not disconnected is installed on a corner grounded TN system the drive will be damaged 3 Fasten the two cable clamp plates included to the drive see page 55 one at the top one at the bottom The clamp plates are identical Using the cable clamp plates as shown below will provide better EMC compliance as well as act as a strain relief for the power cables Strip the power cables so that the shields are bare at the cable clamps Twist the ends of the cable shield wires into pigtails Strip the ends of the phase conductors SE AE Connect the phase conductors of the supply cable to the U1 V1 and W1 terminals of the drive Connect the phase conductors of the motor cable to the U2 V2 and W2 terminals Connect the conductors of the resistor cable if present to the R and R terminals With frame size C or D attach the screw terminal lugs included to the conductors first Crimp lugs can be used instead of the screw lugs Tighten the cable clamps onto the bare cable shields Crimp a cable lug onto each shield pigtail Fasten the lugs to ground terminals Note Try to work out a compromise between the length of the pigtail and the length of unshielded phase conductors as both should ideally be as short as possible 10 Cover visible bare shield and pigtail with insulating tape Electrical installation
52. D gt 18 N m 160 Ibf in Ope y w a Ste pai llo SH tte 3 N m Direct lug connection MOMO MONO 25 Ibf in O E E O Instead of using the screw lugs H Ut Vi Wi included the conductors of power cables can be connected to the drive VAR terminals by removing the screw lugs and using crimp lugs U2 V2 We N R R O aA E O O O gt in eelle CB EA WO E HE P H EEE uk AN s Frame C 3 N m 25 Ibf in Frame D 18 N m 160 Ibf in S Above cable clamp cover bare shield with insulating tape Cable clamp on bare shield 1 5 Nem 13 Ibf ft Motor cable Braking resistor cable Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 59 DC connection The UDC and UDC terminals are intended for common DC configurations of a number of ACS850 drives allowing regenerative energy from one drive to be utilised by the other drives in motoring mode One or more drives are connected to the AC supply depending on the power requirement In case two or more drives are connected to the AC supply each AC connection must be equipped with a mains choke to ensure even current distribution between the rectifiers The diagram below shows two configuration examples AC supply UDC UDC UDC UDC UDC
53. EC do therefore not in every respect comply with the provisions of this directive and that the following harmonised European standard has been applied EN 60204 1 1997 corrigendum Sep 1998 Safety of machinery Electrical equipment of machines Part 1 general requirements and that the following technical standard have been used EN 60529 1991 corrigendum May 1993 amendment A1 2000 Degrees of protection provided by enclosures IP codes and furthermore declares that it is not allowed to put the equipment into service until the machinery into which it is to be incorporated or of which it is to be a component has been found and declared to be in conformity with the provisions of the Directive 98 37 EC and with national implementing legislation e as a whole including the equipment referred to in this Declaration Helsinki 31 3 2009 Jukka Poutanen Vice President ABB Oy Drives Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 94 CG C Tick marking UL marking A C Tick mark is attached to each drive in order to verify compliance with the EMC product standard EN 61800 3 2004 required under the Trans Tasman Electromagnetic Compatibility Scheme for levels 1 2 and 3 in Australia and New Zealand Note To meet the standard the installation of the drive must meet the requirements described under section Compliance with the European EMC Directive on page
54. ES Heavy duty Drive type SCHUNS use ACS850 04 i x K e Ma Pra a kW et aa e a A 56 36 53 15 34 15 3 e A so ee a 7071 23 as 122 a 06405 A 55 94 60 88 30 55 30 50 22 mus A 65 112 80 105 40 76 40 60 3 0 oas B 87 13 105 185 55 97 55 9 0 An Dap B 2 18 14 165 75 180 75 1m0 65 map B 16 23 18 21 no 168 75 140 75_ osas C 20 2 33 150 23 11 0 190 11 0 08045 e 26 30 36 185 28 150 24 150 08545 C 30 35 4 2 32 185 29 185 omas C 36 osas 0 42 50 66 30 46 30 46 30 osas D 5 611781 37 far 37 se 30 076A5 D 65 78 104 45 74 45 66 osea 0 62 04 iaa e 00 898 fa 581898 Symbols Without mains choke Nominal output ouer IMax Maximum output current Available for at least 10 seconds at start otherwise as long as allowed by drive temperature Nominal input current rms at 40 C 104 F Typical motor power for no overload use Continuous rms output current 10 overload is allowed for 1 minute every 5 minutes Typical motor power for light overload use Continuous rms output current 50 overload is allowed for 1 minute every 5 minutes Typical motor power for heavy duty use Note To achieve the rated motor power given in the table the rated current of the drive must be higher than or equal to the rated motor current
55. Ground Efficiency Approximately 98 at nominal power level Cooling Method Internal fan flow from bottom to top Air cooled heatsink Free space around the unit See chapter Planning the cabinet assembly Degrees of protection IP20 UL open type See chapter Planning the cabinet assembly Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 89 Ambient conditions Installation site altitude Air temperature Relative humidity Contamination levels IEC 60721 3 3 IEC 60721 3 2 IEC 60721 3 1 Sinusoidal vibration IEC 60721 3 3 Shock IEC 60068 2 27 ISTA 1A Materials Drive enclosure Packaging Disposal Environmental limits for the drive are given below The drive is to be used in a heated indoor controlled environment Operation Storage Transportation installed for stationary use in the protective package in the protective package 0 to 4000 m 13123 ft above sea level See also section Altitude derating on page 80 10 to 55 14 to 131F 40 to 70 C 40 to 158 F 40 to 70 C 40 to 158 F No frost allowed See section Derating on page 79 0 to 95 Max 95 Max 95 No condensation allowed Maximum allowed relative humidity is 60 in the presence of corrosive gases No conductive dust allowed According to IEC 60721 3 3 According to IEC 60721 3 1 According to IEC 60721 3 2 Chemical gases Class 3C2 Chemical ca
56. R EO hed Ra 107 Degrees OF ai rale In xo id ooh hae al ae AA A AI 107 Common mode WES 32252544 isbn dea eet eens 107 Stalin gt Sas ore Be base tide wa yee ee aoe She ee did Ge Se ias 107 Resistor braking What this chapter contains weird oho beh ad e 109 Braking choppers and resistors with the ACS850 04 o o ooccocooococoo ees 109 Braking CHODDENS EE 109 Braking resistor e de EE 109 Ghopperdata e EE 110 RESISTE SClCCHON Re EE EE 111 Resistor installation and wiring 111 Contactor lte ee le Beie EE 112 Braking elef CO MAISSIONINO ova a A Aine eh ed erg a ad 112 Dimension drawings What this chapter CONTAINS riada Yk PERSE ARA AA 113 Frame SIZ SP oh tt e a borate E A DIS ia geod eto cet ies da WR ob aa 114 rs EE 115 RAINE SIZE rio ii Sek EA Sri deh Gadd ede did eh Ske le vec tdt Bd eter ed hts hood ek Sk 116 Frame size mea iaa td ed ete del asa tas ee ta 117 Mains enokes type CHK 0X EENEG 118 EMG e e as aca ais a ao dais 119 A O Ges ces Gath cee ts ee tas Ase es tate 119 len EC WEE 120 Table of contents Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 14 EMG Titers Ype JF os cet tah con calada EEN 121 Braking resistors type JBR xx e 123 Further information Proguct and service INQUIES e 44044044 6d eee heehee he bb rica bibi 125 Bigeielt leet elle Le eames enad AA Rete Bele ese e vane in eked a de ena a aD sho 125 Providing feedback on ABB Drives manuals
57. UDC DATA O O Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 60 Each drive has an independent DC capacitor pre charging circuit UDC UDC U1 Vi Wi J v0 0S8SO0V Pre charging circuit O O O JJ U2 V2 W2 The ratings of the DC connection are given on page 85 Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 61 Installation of optional modules Optional modules such as fieldbus adapters I O extensions and encoder interfaces ordered using option codes see Type designation on page 25 are pre installed at the factory Instructions for installing additional modules into the slots on the JCU Control Unit see page 24 for the available slots are presented below Mechanical installation e Remove the cover assembly from on the JCU Control Unit refer to page 49 e Remove the protective cover if present from the connector of the slot e Insert the module carefully into its position on the drive e Fasten the screw Note Correct installation of the screw is essential for fulfilling the EMC requirements and for proper operation of the module EFRERAR 3 im nana l Electrical installation See section Grounding and routing the control cables on page 62 See the appropriate option m
58. ae aa Oe ead 94 LIM AUN ane eos done A NU O O ak nee tees cee eee ae ee 94 MR mrss tang O INE 94 Patent protection MINES aii E EA AAA A 95 Mains chokes What this chapter contains 2 04 dio avs ion ek oe EE AER E Eege A ia ce ae EE 97 When is a mains choke required o o o oooooooooo ee eee eee teens 97 eleng Ce EE 97 inStallation QUIGCIINGS avs dada 98 elteren Bee le MER 98 EMC filters Wat NS Chapter e In E essa A wa eed en de a eee ee 99 Table of contents Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 13 When is an EMC filter required o ooocooocoonoo o 99 Selection ei 100 JFI A1 JFI B1 Frame A B category C3 installation 101 Jee ei Ee l t Ma 101 Connection dia Maidana ara dada iia eee dee 101 Mounting Procedures cvs circa ie pr A A ise 102 AA a aida ib a 102 JEDI pass tere id a A NS A 103 JFI 0x Frames A D category C2 installation 104 Installation guidelines hsb tdutitokssoidavidiwatdindteeddoeatadtaaedouetaad 104 CONNECT tc iii A ele dla 104 du dt and common mode filtering Wat Ins chapter contains srta arre a aw baw ee ea dle 105 When is du dt or common mode filtering required 0 0 ees 105 POI DeES segan ie cost eae ada AER Se nee eal a eo EE 106 AA eRe oats eis ee ee Be ee eee ores ee ee eae 106 Common on Le Le TEE 107 Cajero AAA 107 GU OUINGNS EEEE EET E EEA A ee eon eee Gat 107 DIMENSIONS and weights ee ett a ER
59. aking chopper is built in the ACS850 04 braking resistors are external options Braking resistor Dissipates the regenerative energy by converting it to heat Capacitor bank Energy storage which stabilizes the intermediate circuit DC voltage du di filter See page 105 Inverter Converts the DC voltage to AC voltage and vice versa The motor is controlled by switching the IGBTs of the inverter EMC filter See page 99 Converts the three phase AC voltage to DC voltage Motor control The motor control is based on direct torque control Two phase currents and DC link voltage are measured and used for the control The third phase current is measured for earth fault protection Product overview The ACS850 04 is an air cooled IP20 drive module for controlling AC motors It is to be installed into a cabinet by the customer The ACS850 04 is available in several frame sizes depending on output power All frame sizes use the same control unit type JCU Operation principle and hardware description Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 23 Layout Drive module frame size A JCU Control Unit with cover assembly removed DC connection AC supply connection a Power unit JCU Control Unit with ABB optional cover assembly gt do ds us vi Wi UDC UDC gt gt gt External 24 V power input Y s A E 1 Relay
60. anual for specific installation and wiring instructions Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 62 Connecting the control cables Control connections to the JCU Control Unit Notes Default setting with ACS850 standard control program Factory macro See Firmware Manual for other macros Total maximum current 200 mA The wiring shown is for demonstrative purposes only Further information of the usage of the connectors and jumpers are given in the text see also chapter Technical data Wire sizes and tightening torques 0 5 2 5 mm 24 12 AWG Torque 0 5 N m 5 Ibf in 0 3 N m 3 Ibf in Order of terminal headers and jumpers XPOW 2 pole 2 5 mm XRO1 3 pole 2 5 mm XRO2 3 pole 2 5 mm XRO3 3 pole 2 5 mm XD24 4 pole 2 5 mm DI DIO grounding selection XDI 7 pole 1 5 mm XDIO 2 pole 1 5 mm XAI 7 pole 1 5 mm Al1 Al2 XAO 4 pole 1 5 mm T XD2D 3 pole 1 5 mm XSTO orange 4 pole 1 5 mm Electrical installation XPOW External power input 24V 24VDC 1 6A GND XRO1 XRO2 XRO3 Relay output RO1 Ready NO 1 D 250 V AC 30 V DC 2A Relay output RO2 Modulating 250 V AC 30 V DC 2A nc 6 Relay output RO3 Fault 1
61. ccording to local regulations e The cable must be able to carry the drive load current See chapter Technical data for the rated currents e The cable must be rated for at least 70 C US 75 C 167 F maximum permissible temperature of conductor in continuous use e The inductance and impedance of the PE conductor cable grounding wire must be rated according to permissible touch voltage appearing under fault conditions so that the fault point voltage will not rise excessively when a ground fault occurs e 600 V AC cable is accepted for up to 500 V AC e Refer to chapter Technical data for EMC requirements Symmetrical shielded motor cable must be used see the figure below to meet the EMC requirements of the CE and C tick marks A four conductor system is allowed for input cabling but shielded symmetrical cable is recommended To operate as a protective conductor the shield conductivity must be as follows when the protective conductor is made of the same metal as the phase conductors Cross sectional area of one phase conductor Minimum cross sectional area of protective S conductor Sp 16 mm lt S lt 35 mm 16 mm Compared to a four conductor system the use of symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as motor bearing currents and wear Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwt
62. cient in size Please note that in addition to the power loss of the drive module the heat dissipated by cables and other additional equipment must also be ventilated The internal cooling fans of the modules are usually sufficient to keep the component temperatures low enough in IP22 cabinets In IP54 cabinets thick filter mats are used to prevent water splashes from entering the cabinet This entails the installation of additional cooling equipment such as a hot air exhaust fan The installation site must be sufficiently ventilated Planning the cabinet assembly Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 31 Preventing the recirculation of hot air Cabinet side view gt SI HOT AREA a Maio J ik R k a Air baffle plates o 4 eg COOL AREA U Main airflow in Outside the cabinet Prevent hot air circulation outside the cabinet by leading the outcoming hot air away from the area where the inlet air to the cabinet is taken Possible solutions are listed below e gratings that guide air flow at the air inlet and outlet e air inlet and outlet at different sides of the cabinet e cool air inlet in the lower part of the front door and an extra exhaust fan on the roof of the cabinet Inside the cabinet Prevent hot air circulation inside the cabinet with leak proof air baffle plates No gaskets are usually required Cabinet heaters
63. e z Un lt 500 V with fiberglass Check with motor manufacturer manufactured before pin 1 Jan 1998 ping Random wound ABB HA l and AN otor Enamelled wire z Un lt 500 V with fiberglass Yes Yes manufactured from lee 1 Jan 1998 ping Standard Other ABB motors or a Standard Yes UL 1300 V random wound or form l wound non ABB motors 420V lt Un lt Reinforced 500 V U 1600 V 0 2 microsecond rise time du dt filters are optional accessories and to be ordered separately For more information on common mode filtering contact your local ABB representative Contact the motor manufacturer for information on the motor construction Filter types du dt filters du dt filters for ACS850 04 Drive type ACS850 04 Filter type 03A0 2 03A0 5 03A6 2 03A6 5 04A8 2 04A8 5 06A0 2 06A0 5 08A0 2 08A0 5 NOCH0016 60 3 phase 010A 2 010A 5 014A 2 014A 5 NOCH0030 60 3 phase NOCH0070 60 3 phase NOCHO0O120 60 1 phase three EN filters included in kit du dt and common mode filtering 018A 2 018A 5 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 107 Common mode filters Contact your local ABB representative Technical data du dt filters Dimensions and weights Height Width Depth Weight mm inches mm inches mm inches kg lbs NOCH0016 60 195 7 68 140 5 51 115 4 53 2 4 5 3 Filter type NOCH0030 60 215 8 4
64. e 1 90 0 Gt 9z 0 59 eyz g9 v0 01 SSZ _ Sv 6 Ove 16 S OSh vS 06 69 01 O22 Omar Ul JQ UN S euJua jo anb10 Duruay L OMV Uu pDopugusl 9ZIS M OMV Uu PIJOS 9ZIS M sql By 1UBISM Cui ww 7 ug Cui ww y wq Jo oWe1ed Dimension drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 123 Braking resistors type JBR xx El uo dia Liu LG AN u Y HERR UI Dy oD o LJ E oD gt x o SS me Ss Y e SE la o Lie a e bi o e sd Ts Co o MR VU A _ o alt SO ARG SS el Cr o E T SC LIDO S atipa alu a o cl v a el ec E KSE Se ze Se SUD de E o Y o o SA a l o ey Cee CS Lie Kg EE bw 2 oO Cy o oss oe La Kei E gt mn XD T or 5 AT un 5 pro YD a LI SES ac l CE Eej et Ke che ee O G O i ee lt CPD SS O pa mS aa ah E o CL a SS af E ES z o SA SC f co co P o Ge l o DE mn Li SZ 1 VU rea S D CS NI noe o oD D wg ES oe oD CF LI Loy lt L ES ot a DE m eal o oO bg ES PRAD So gt OD o oD Z Ce S al Oy oS x oo a O KS Es t oe e ERR D El ES a O oD D a o pas ER
65. e ACS850 04 has an internal braking chopper When applied with appropriately sized braking resistors the braking chopper will allow the drive to dissipate regenerative energy normally associated with quickly decelerating a motor Braking resistor selection is discussed in chapter Resistor braking on page 109 UL standards See section Applicable standards on page 90 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 95 Patent protection in the US This product is protected by one or more of the following US patents 4 920 306 9 301 085 9 463 302 5 921 483 5 532 568 5 589 754 5 612 604 5 654 624 5 799 805 5 940 286 5 942 874 5 952 613 6 094 364 6 147 887 6 175 256 6 184 740 6 195 274 6 229 356 6 252 436 6 265 724 6 305 464 6 313 599 6 316 896 6 335 607 6 370 049 6 396 236 6 448 735 6 498 452 6 592 510 6 597 148 6 600 290 6 741 059 6 774 758 6 844 794 6 856 502 6 899 374 6 922 883 6 940 253 6 934 169 6 956 352 6 958 923 6 967 453 6 972 976 6 977 449 6 984 958 6 985 371 6 992 908 6 999 329 7 023 160 7 034 510 7 036 223 7 045 987 7 057 908 7 059 390 7 067 997 7 082 374 7 084 604 7 098 623 7 102 325 7 109 780 7 164 562 1 176 779 7 190 599 7 215 099 7 221 152 7 227 325 7 245 197 7 250 739 1 262 977 7 271 505 7 274 573 7 219 802 7 280 938 7 330 095 7 349 814 7 352 220 7 365 622 7 372 696 7 388 765 7 408 791 7 417 408 7 446 268 7 456 615 7 508 688 7 515 447 7 560 894 7 589 984 7 652 602 7 663 850 7 670 163
66. e e 29 y de Do a W lt cy a De Le o ie Y Lee gt o EN pa Z lt 2 o eek lt gt 2 De o ic Ge gt Cl vo GG Org o Bei Log al Oo o aa ACTES bi SS ES ve ve ns Pia a WO CO lt a F 0 gv 9 BETS WISSY Y yIIL8S9 uapplquoy pporaps SI prsoypno ssoJdxo JNOYLIM S IfIOd PIU Of IINSOJISIP JO SN VOI FINPOJd9Y UISJAYL PA UIDFUO VOIFDUWJOJUI Yf Ul Dun JUSWNIOP SIU Ul S4yblu JJO 9AJ9S9J M xx 5401515384 JAV48 qa ED cS Eta ES Dimension drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com S 2U411419 1 y9MS IEUUaUL anb 0 BuluaryBi S eU 11419 YIIIMS QUIISY 9ZIS oa Xe S eu111 19 UISIW anb 10 BuluaryBi S 8U 114 19 UIEN 9ZIS JIM EIN uA UA WN OO 90 ZLOMY UU y UJAL 9L U SL W N8 L GL 9 MY UU OL ge ee aoe Ove teo uioezo sq Syiubrem Urri o9 906 oez eco rsp ogr l66 z1 ose zaor I evez ses 1e eL soy B8g s1 Sre o J eoon eer szi ez ooz org9 ssi po Cd 6 8 1 ove LL ge ul u SI po TS ST SUOISUQUuUIp XX Yagr 124 Dimension drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Further information Product and service inquiries Address any inquiries about the product to your local ABB representative quoting the type des
67. e off connection XSTO Control panel PC connection Connector pitch 3 5 mm wire size 1 5 mm As inputs 24 V logic levels 0 lt 5 V 1 gt 15 V Rin 2 0 kohm Filtering 0 25 ms As outputs Total output current limited by auxiliary voltage outputs to 200 mA Output type Open emitter Voc DGND Connector pitch 3 5 mm wire size 1 5 mm 10 V 1 and 10 V 1 Road gt 1 kohm Connector pitch 3 5 mm wire size 1 5 mm Current input 20 20 mA Rin 100 ohm Voltage input 10 10 V Rin 200 kohm Differential inputs common mode 20 V Sampling interval per channel 0 25 ms Filtering 0 25 ms Resolution 11 bit sign bit Inaccuracy 1 of full scale range Connector pitch 3 5 mm wire size 1 5 mm 0 20 mA Rioad lt 500 ohm Frequency range 0 800 Hz Resolution 11 bit sign bit Inaccuracy 2 of full scale range Connector pitch 3 5 mm wire size 1 5 mm Physical layer RS 485 Termination by jumper Connector pitch 3 5 mm wire size 1 5 mm For the drive to start both connections OUT1 to IN1 and OUT2 to IN2 must be closed Connector RJ 45 Cable length lt 3m 2 2 Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 88 Isolation and grounding xPOW diagram j XRO1 XRO3 24VD DIOGND RERE AS NRO lt Z UU O 0 Ces N TSS DIO1 DIO2 RE Common mode voltage between channels 20 V
68. e pages 56 58 of power connections Visual inspection of See Cooling fan on page cooling fan 73 Every 3 years if the ambient temperature Cooling fan See Cooling fan on page is higher than 40 C 104 F replacement Ger Otherwise every 6 years Every 6 years if the ambient temperature DC capacitor Contact your local ABB is higher than 40 C 104 F or if the drive replacement Service representative is subjected to cyclic heavy load or continuous nominal load Otherwise every 9 years Every 10 years Control panel battery The battery is housed on replacement the rear of the control panel Replace with a new CR 2032 battery Maintenance Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 72 Heatsink The heatsink fins pick up dust from the cooling air The drive runs into overtemperature warnings and faults if the heatsink is not clean In a normal environment the heatsink should be checked annually in a dusty environment more often Clean the heatsink as follows when necessary 1 Remove the cooling fan see section Cooling fan 2 Blow clean compressed air not humid from bottom to top and simultaneously use a vacuum cleaner at the air outlet to trap the dust Note If there is a risk of the dust entering adjoining equipment perform the cleaning in another room 3 Refit the cooling fan Maintenance Phone 800 894 0412 Fax 888 723 4773 Web www clrwt
69. e the definition below Power unit Contains the power electronics and connections of the drive module The JCU is connected to the power unit RFI Radio frequency interference About this manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 20 About this manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 21 Operation principle and hardware description What this chapter contains This chapter describes the operating principle and construction of the ACS850 04 drive module in short Operation principle Main circuit The main circuit of the drive module is shown below AC supply die len Ak CHK xx mains choke see chapter Mains chokes d Ets e on page 97 UDG unon real JFI xx EMC filter see chapter EMC filters on page DN ACS850 04 99 Ore Rectifier Capacitor bank Braking chopper see chapter Resistor braking on Inverter RR page 109 AE e J AS 277755 JBR xx braking resistor see chapter Resistor NOCHxxxx xx du dt filter see ee a gt SE chapter du dt and common mode Lo ee filtering on page 105 Motor output Operation principle and hardware description Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 22 Braking chopper Conducts the energy generated by a decelerating motor from the DC bus to a braking resistor The br
70. eavy duty Drive type Sana use Ee l N 2 N p Ld Pud kW kW a EE mer A 26 47 3 53 11 28 11 22 075 EE E 06405 A 46 78 5 88 22 48 15 38 15 oaos A 46 77 55 105 22 562 22 42 15 01045 B 79 12 95 185 4 9 4 68 ora e 10 ts 12 165 55 af 55 68 4 mar B n te 18 at 55 122 55 94 4 oas 0 18 16 38 75 15 55 12 55 08045 0 17 20 86 75 19 75 14 55 Cs EE TEE aia 1 ars a DE IG 24 29 fs mt per pm at 75 os 028 as ee pS a 6 oas o f f 40 78 185 fr fies 31 16 07845 D 43 51 100 2 48 22 41 185 09445 D 53 et tea 30 880 fae 581898 Deratings with 460 V AC supply in low motor noise mode Output ratings p Outputratings Input ratings Nominal e a RE Heavy duty Drive type Sana use Ee N i N e p Ld Pug ge HP HP EA O EEE os A festat ee es 1 fea 1 18 078 2 mg A 40 67 43 88 2 41 2 33 mus A 40 67 48 105 3 44 2 36 5 5 ams 8 67 10 8 15 mz B 9 13 10 165 HE ESCH os 8 o a 2075 11758 5 mt III ia as 10 13 75 10 75 08045 ts 17 38 0 16 10 12 75 osas ct erectos fio is 1 Dr IC 0508 5 IC mar ID 0940 5 TD 581898 Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 82 Deratings with 500 V AC supply in low motor noise mode Outp
71. eed 100 Mohm reference value at 25 C or 77 F For the insulation resistance of other motors please consult the manufacturer s instructions Note Moisture inside the motor casing will reduce the insulation resistance If moisture is suspected dry the motor and repeat the measurement D Braking resistor assembly Check the insulation of the braking resistor assembly if present as follows 1 Check that the resistor cable is connected to the resistor and disconnected from the drive output terminals R and R 2 Atthe drive end connect the R and R conductors of the resistor cable together Measure the insulation resistance between the combined conductors and the PE conductor by using a measuring voltage of 1 kV DC The insulation resistance must be higher than 1 Mohm Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 52 Power cable connection Power cable connection diagram For alternatives see Planning the electrical lio installation Supply disconnecting device iain 4 1 ER I CHK xx mains choke optional See chapter Mains chokes page 97 en ee V JFl xx EMC filter optional See chapter EMC Ka le filters page 99 CO YY L el l The UDC UDC connectors can be used for i i p 1 common DC configurations See page 59 L ACS850 04 du dt filter s optional See chapter du d
72. eer e irae MOLSISIY Iva E r 1MdLAD 3V MIA q a WOLLOG LATA d N Y 0 ETS E UOJSJ3AU0I f P j el D dave eg 3X 9MU 43930 Suojsuaujp Guyppo UayA 409303 IPIS 333440 AY 338 YJINIONI O4 YA apow Gumoup youu uoy2afoud auo 35414 uoganpoaday gaua Eileen y y pun Zaert al d SEU Se BA TY LL WR AN ES SEO ER EN EA IC VAR TOA A eee Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 118 Mains chokes type CHK 0x 68906903 CHK xx dimensions Choke type CHK 04 120 4 72 150 5 91 150 5 91 150 5 91 146 5 75 1175 6 89 175 6 89 175 6 89 79 3 11 86 3 39 100 3 94 5 4 13 105 5 83 77 3 03 105 4 13 105 4 13 105 4 13 dim E mm in 114 4 49 148 5 83 148 5 83 148 5 83 sch gt NS gt gt F screw size M5 Weight kg Ibs 1 8 4 0 3 8 8 4 5 4 11 9 5 2 11 5 Wire size Main terminals 0 5 10 0 5 10 0 5 10 0 5 10 mm AWG 20 6 20 6 20 6 20 6 Tightening torque Main terminals Nem IbFin 1 5 13 1 5 13 1 5 13 1 5 13 PE Chassis terminals M5 M5 M5 Tightening torque PE Chassis terminals Mun Ibf in 3 26 4 35 4 35 4 35 Dimension drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 119 EMC filters type JFI x1 JFI A1 d T Dot E ETS N3 Duo el Y WO y eee bE 00000 UN VE Am
73. ension drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 116 Frame size C 0H 740 24 ON Ja dav ao oa ECKE To 10301 L ag SAAN GUY Se E E aen Wo A es To ui ONIAVYC NOISNNIA 3 IWA 60 NYF E2 pay Aawer vil apos Sap 200 Nitt SNANIC_ anu 60 Nvr ce pasodaud uo pasog I nr AA MIA dol LAdNI Iv 29 C vr S6 L1 9Sp 6y 81 Cp vv 81 69p UC dl LIS 06 S21 869 V so quoddns jauod Nnoy m Lat 6 tO SI 6T t Tu LBE E 401SISIA 3448 ASIA ND UO SUaAUOD A D aave TW CWISSV ST68E00000WNVE 4XC DA 423 40 Suojsuawp Bujppo U3yA 40OZI0J VIS 333440 au 2438 HIINI NI OJd UIA apow Gumoup Yousu uojydafoud aj uo 45414 WE dn tanks as S LOLs Bit WET o e ae prepa TT CI6S8E00000 NVE AAA DEE ts RAE SE EE ENEE EE Dimension drawings info clirwtr com 800 894 0412 Fax 888 723 4773 Web www clrwtr com Ema Phone 117 T Dot T Aas w dv V ES ev NN ONIAVad NOISNSWIC WO y as sap 01 ben ra e mg a SWva4 60 NYr E2 i 43u109SN r O ONIAYAA SNIWIC 21HL 60 NWP E2 Dimension drawings MITA dOl Ti acodlgloel DN MN ON ga ga SINAC WR me EE d LMANI Dv OI NANI 0 2 11 862 6v 811 OL Dron 697 AAA TM AAN AA J Ge V No z jvoddns auod 3noyyM Dar 6 IECH ST 6121 EST
74. f in e Fasten the top edge of the filter to the mounting base with two screws 4 e Fasten the power cable clamp plate at the top of the filter Tighten to 1 5 Nm 13 Ibf in e Attach the terminal blocks to the filter EMC filters Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 104 JFI 0x Frames A D category C2 installation Installation guidelines e fa mains choke is also installed the EMC filter is connected between the mains choke and the drive module See the connection diagram below e For optimal operation of the filter the drive and the filter must be mounted on the same conductive surface e Ensure the filter does not block the airflow through the drive module e Keep the cable between the drive and the filter as short as possible Connection diagram AC supply CHK xx mains choke if present JFI Ox EMC filter ACS850 EMC filters Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 105 du dt and common mode filtering What this chapter contains This chapter describes how to select du dt and common mode filtering for the ACS850 04 The chapter also contains the relevant technical data When is du dt or common mode filtering required The output of the drive comprises regardless of output frequency pulses of approximately 1 35 times the equivalent supply voltage with a very short rise time This is
75. f the type JFI 0x is required in order to meet the category C2 level with the ACS850 04 drive installation including a motor with a max 100 m cable This level corresponds to the A limits for Group 1 equipment according to EN 55011 WARNING An EMC filter must not be installed if the drive is connected to an IT power system i e an ungrounded or a high resistance grounded over 30 ohm power system EMC filters Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 100 Selection table EMC filters for ACS850 04 Drive type Filter type EN 61800 3 2004 EN 61800 3 2004 Category C3 Category C2 ACS850 04 03A0 2 03A0 5 03A6 2 03A6 5 04A8 2 04A8 5 06A0 2 O6A0 5 08A0 2 08A0 5 010A 2 010A 5 014A 2 014A 5 018A 2 018A 5 025A 2 025A 5 030A 2 030A 5 035A2 035A 5 JFI 05 044A 2 044A 5 Option code E200 050A 2 050A 5 internal filter 061A 2 061A 5 078A 2 078A 5 JFI 07 094A 2 094A 5 External filter to be ordered separately Option code E200 external filter JFI A1 JFI 02 Option code E200 external filter JFI B1 All EMC filters are protected to IP20 Refer to page 119 for dimensions of the JFI x1 filters Refer to page 121 for dimensions wire sizes and tightening torques of the JFI 0x filters EMC filters Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 101 JFI A1 JFI B1
76. he appropriate Firmware Manual Grounding and routing the control cables The shields of all control cables connected to the JCU Control Unit must be grounded at the control cable clamp plate Use four M4 screws to fasten the plate as shown below left two of the screws are also used to hold the cover mounting bracket The plate can be fitted either at the top or bottom of the drive Before connecting the wires run the cables through the cover mounting bracket as shown in the drawing below The shields should be continuous as close to the terminals of the JCU as possible Only remove the outer jacket of the cable at the cable clamp so that the clamp presses on the bare shield At the terminal block use shrink tubing or insulating tape to contain any stray strands The shield especially in case of multiple shields can also be terminated with a lug and fastened with a screw at the clamp plate Leave the other end of the shield unconnected or ground it indirectly via a few nanofarads high frequency capacitor e g 3 3 nF 630 V The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points Keep any signal wire pairs twisted as close to the terminals as possible Twisting the wire with its return wire reduces disturbances caused by inductive coupling Re install the cover assembly according to the instructions on page 49 Electrical installation Phone 8
77. he wall the drive is to be mounted on must be as even as possible of non flammable material and strong enough to carry the weight of the drive The floor material below the drive must be non flammable Mechanical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 36 Installation procedure Direct wall mounting 1 Mark the locations for the four holes The mounting points are shown in Dimension drawings 2 Fix the screws or bolts to the marked locations 3 Position the drive onto the screws on the wall Note Only lift the drive by its chassis 4 Tighten the screws DIN rail mounting Frames A and B only 1 Click the drive to the rail as shown in Figure a below To detach the drive press the release lever on top of the drive as shown in Figure b 2 Fasten the lower edge of the drive to the mounting base through the two fastening points SS WANN WA Mechanical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 37 Mains choke installation See chapter Mains chokes on page 97 EMC filter installation See chapter EMC filters on page 99 Braking resistor installation See chapter Resistor braking on page 109 Mechanical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr c
78. hich concern only certain optional selections are marked with codes e g L500 The options included in the drive can be identified from the codes visible on the type designation label of the drive The code selections are listed in chapter Operation principle and hardware description under Type designation The chapters of this manual are briefly described below Safety instructions give safety instructions for the installation commissioning operation and maintenance of the drive About this manual lists the steps in checking the delivery and installing and commissioning the drive and refers to chapters sections in this manual and other manuals for particular tasks About this manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 16 Operation principle and hardware description describes the drive module Planning the cabinet assembly guides in planning the installation of the drive module into a user defined cabinet Mechanical installation instructs how to place and mount the drive Planning the electrical installation instructs on the motor and cable selection the protections and the cable routing Electrical installation instructs on how to wire the drive Installation checklist contains a list for checking the mechanical and electrical installation of the drive Maintenance lists periodic maintenance actions along with work instructions Technical data contains the techn
79. ical specifications of the drive e g the ratings sizes and technical requirements provisions for fulfilling the requirements for CE and other markings and warranty policy Mains chokes details the optional mains chokes available for the drive EMC filters details the EMC filtering options available for the drive du dt and common mode filtering lists the du dt and common mode filtering options available for the drive Resistor braking describes how to select protect and wire braking resistors Dimension drawings contains the dimensional drawings of the drive and connected equipment About this manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 17 Installation and commissioning flowchart Task See Identify the frame size of your drive A B C or D Drive designation label or Technical data Ratings page 77 Plan the installation Planning the cabinet assembly page 27 Check the ambient conditions ratings required Planning the electrical installation page 39 cooling air flow input power connection compatibility of the motor motor connection and other technical data Option manual if optional equipment is included Technical data page 77 Select the cables Unpack and check the units Mechanical installation Contents of the Check that all necessary optional modules and package page 35 equipment are present and correct If the converter has been non ope
80. ignation and serial number of the unit in question A listing of ABB sales support and service contacts can be found by navigating to ABB website and selecting Sales Support and Service network Product training For information on ABB product training navigate to ABB website and select Training courses Providing feedback on ABB Drives manuals Your comments on our manuals are welcome Go to ABB website and select Document Library Manuals feedback form LV AC drives Document library on the Internet You can find manuals and other product documents in PDF format on the Internet Go to ABB website and select Document Library You can browse the library or enter selection criteria for example a document code in the search field Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com
81. lease contact your local ABB distributor Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 90 Applicable standards The drive complies with the following standards The compliance with the European Low EN 50178 1997 e IEC 60204 1 2006 EN 60529 1991 IEC 60529 e IEC 60664 1 2007 IEC 61800 3 2004 e EN 61800 5 1 2003 e EN 61800 5 2 2007 e UL 508C 2002 Third Edition e NEMA 250 2003 e CSA C22 2 No 14 05 2005 Technical data 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 asupply disconnecting device the drive module into a cabinet Degrees of protection provided by enclosures IP code Insulation coordination for equipment within low voltage systems Part 1 Principles requirements and tests Adjustable speed electrical power drive systems Part 3 EMC requirements and specific test methods Adjustable speed electrical power drive systems Part 5 1 Safety requirements Electrical thermal and energy Provisions for compliance The final assembler of the machine is responsible for installing the ACS850 04 in a cabinet that is protected to IP3X for top surfaces for ver
82. nections see page 62 For Digital inputs 6 pcs specifications see page 86 Digital input outputs 2 pcs Programmable Analog inputs Analog outputs XAO Drive to drive link Safe torque off Power unit JPU OPE D Ovi Braking V20 s UDC a AC motor R R _ UDC e e GRENG Operation principle and hardware description Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 25 Type designation The type designation contains information on the specifications and configuration of the drive The first digits from left express the basic configuration e g ACS850 04 04A8 5 The optional selections are given thereafter preceded by signs e g L501 The main selections are described below Not all selections are necessarily available for all types refer to ACS850 Ordering Information available on request See also section Delivery check and drive module identification on page 35 Selection Alternatives Product series CES product series II a ac a rrr re Type Drive module When no options are selected IP20 UL Open Type plain front cover no control panel no mains choke frames A and B internal mains choke frames C and D no EMC filter internal braking chopper coated boards Safe torque off Standard Control Program Quick Installation Guide multilingual Quick Start up Guide multilingual CD containing all manuals Size eevee Rains SSCS 5 380 500 V E E200 EMC
83. nnecting means between the AC power source and the drive The disconnecting device must be of a type that can be locked to the open position for installation and maintenance work Europe If the drive is used in an application which must meet the European Union Machinery Directive according to standard EN 60204 1 Safety of Machinery the disconnecting device must be one of the following types e a switch disconnector of utilization category AC 23B EN 60947 3 e a disconnector that has an auxiliary contact that in all cases causes switching devices to break the load circuit before the opening of the main contacts of the disconnector EN 60947 3 Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 40 e acircuit breaker suitable for isolation in accordance with EN 60947 2 Other regions The disconnecting means must conform to the applicable safety regulations Thermal overload and short circuit protection Thermal overload protection The drive protects itself and the input and motor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive No additional thermal protection devices are needed switch or a circuit breaker must be used for protecting each cable and motor These H WARNING If the drive is connected to multiple motors a separate thermal overload devices may require a separate fuse to cut off
84. ns for fulfilling the requirements for CE and other markings Ratings Nominal ratings with 230 V AC supply Output ratings Biereg geed Lightoverload use Heavy duty use ACS850 04 hn kn bn Max PN ha Pia Pla hHa Pha Pha A A A A kW HP A kW HP A kW HP oas A 37 63 48 70 0 1 45 0 1 40 055 075 sao a 52 39 60 ea ii as 35 ii as sofos a C one A 6s io7 80 1058 a5 2 ve is 2 60 ii 115 oaz B ss 13 ios iss 22 3 97 22 3 oo is 2 oae B 17 4 165 3 3 i30 3 oas B as at e pp a 5 168 4 Koster E E e le El E C 26 30 36 75 10 28 75 EE Ser C 3 44 58 1 gt 15 35 75 10 0504 2 C 42 50 66 1 15 46 11 15 44 11 15 oae Dp 54 fet pe is 20 37 is 20 ee pa 5 a O 1 O ee ee ee eee 094A 2 D 81 94 124 22 30 90 22 30 75 185 25 581898 Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 78 Nominal ratings with 400 V AC supply Output ratings Input ratings Nominal S SES Heavy duty Drive type omna use ACS850 04 i 8 7 Ma DA Ge kW EEE O A 56 36 53 15 34 15 3 E a so os a8 0 2 as 18 a 06405 A 55 94 60 88 22 55 22 50 22 mus A 66 112 80 105 30 76 30 60 2 os e 67113 Hoss 40 or ao joo on oas B 12 te 14 165 55 130 55 Oo 55 osas B 16
85. ns to the JCU Control Un 62 JUMPE 4 ics aval A A A A E E 63 External power supply for the JCU Control Unit XPOW ooooo o 63 DI6 XDI 6 as a thermistor input 64 Drive to drive link DD 65 Sale 1Olgue Ol Kol ate ease be eae a bse eas eee DB eae 66 Grounding and routing the control Cables 66 Installation checklist Ao A essay EE ene eee 69 Maintenance Winat tals Chapter COMLAINS spa 2264 Ee ee tiara 71 O O ene ee beds ea EA ar se ee i ee aaa aie ate eee eles 71 Mamtenance Wer 71 HC AUS MIG eta ii a ic a bo ae daba 72 ele Tala la E q PEOR AO EE 73 Fan replacement Frames A and Bi 73 Fan replacement Frames C and Di 74 Relormming ie ee 75 Other maintenance ACHONS iras ida oi id aaa 75 Transfering the memory unit to a new drive module 75 Technical data What this chapter contains tara a hws A A A 77 AE A O AS E RR ANO 77 Nominal ratings with 230 V AC supply o oooococoocno ee eee ees Vi Table of contents Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 12 Nominal ratings with 400 V AC supply ooooococoeonoa 78 Nominal ratings with 460 V AC supply o oooococoornon eee 78 Nominal ratings with 500 V AC supply o oooocoooonon eee 79 Nee EE EE 79 Detalla sisas tandas A 79 Ambient temperature derating n n annaa aa eee ee eee eens 80 Antudederating 426553 A il A AAA cae eee eos eee es 80 LOW motor NOISE Gerating EEN 8
86. nstall the fan so that the airflow arrow points up C EE EE EE EE EE gt gt gt o f Airflow direction Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 73 Reforming the capacitors The capacitors must be reformed if the drive has been stored for a year or more See page 35 for information on finding out the manufacturing date For information on reforming the capacitors contact your local ABB representative Other maintenance actions Transfering the memory unit to a new drive module When a drive module is replaced the parameter settings can be retained by transferring the memory unit from the defective drive module to the new module WARNING Do not remove or insert a memory unit when the drive module is powered After power up the drive will scan the memory unit If a different application program or different parameter settings are detected they are copied to the drive This takes about 10 to 30 seconds the drive will not respond while copying is in progress Maintenance Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 76 Maintenance Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 77 Technical data What this chapter contains This chapter contains the technical specifications of the drive e g the ratings sizes and technical requirements and provisio
87. nt must not disturb or interfere with any other product or system within its locality First environment includes domestic premises It also includes establishments directly connected without intermediate transformers to a low voltage network which supplies buildings used for domestic purposes Second environment includes all establishments other than those directly connected to a low voltage network which supplies buildings used for domestic purposes Drive of category C2 Power drive system with rated voltage less than 1000 V which is neither a plug in device nor a movable device and when used in the first environment is intended to be installed and commissioned only by a professional Drive of category C3 Power drive system with rated voltage less than 1000 V intended for use in the second environment and not intended for use in the first environment Drive of category C4 Power drive system with rated voltage equal to or above 1000 V or rated current equal to or above 400 A or intended for use in complex systems in the second environment Compliance with EN 61800 3 2004 category C2 The drive meets the requirements of the EMC Directive with the following provisions 1 The drive is equipped with external EMC filter JFI 0x optional accessory 2 The motor and control cables are selected as specified in chapter Planning the electrical installation 3 The drive is installed according to the instructions given in this manual 4 Mo
88. o the drive must not exceed 3 metres in length The cable type tested and approved by ABB is used in control panel option kits Connection of a motor temperature sensor to the drive I O See page 64 Routing the cables Route the motor cable away from other cable routes Motor cables of several drives can be run in parallel installed next to each other It is recommended that the motor cable input power cable and control cables be installed on separate trays Avoid long parallel runs of motor cables with other cables in order to decrease electromagnetic interference caused by the rapid changes in the drive output voltage Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 47 Where control cables must cross power cables make sure they are arranged at an angle as near to 90 degrees as possible Do not run extra cables through the drive The cable trays must have good electrical bonding to each other and to the grounding electrodes Aluminium tray systems can be used to improve local equalizing of potential A diagram of the cable routing is below Supply cable Supply cable min 200 mm 8 Orea min 300 mm 12 Control cables Drive min 500 mm 20 Braking resistor cable Motor cable min 500 mm 20 Control cable ducts 24 V 230 V 24V 230V Not allowed unless the 24 V Lead 24 V and 230 V control cable is insulated
89. of a motor temperature sensor to the drive I O o ooooooooooonoo 46 ROUUNG ING Caples cti E AA A rs 46 COMMON cable GQUCIS sii A A a aa EA 47 Electrical installation Wilat Ins Chapter e ein ET asi dsd seamen oan Rees ewe hk eee owen st 49 Table of contents Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Removing the cover assembly scans cad dede tidad 49 Checking the insulation of the assembly ooooooocooooono eee ens 51 DNS uste o Nod PO aaa ata cate ehh ea al New te ea eee eae 51 eelere el oi ri e o aaa aa Dl bt en 51 MOtor an a MOO caD acicate da dad 51 Braking resistor assembly 51 Power Cable CONMMESCU ON esas A E Sek oe A A eee a EE er 52 Power cable connection diagram 1 2 0 ce teeta 52 PIOCOQUI isan Bucs Onn ken hao teta dd a 53 Grounding the motor cable shield atthe motor end o o ooooooo 54 Installation of power cable clamp plates o oooooocoononoonon o 55 Power cable connection frame ste 56 Power cable connection frame seh 57 Power cable connection frame sizes C and D connector covers removed 58 DO COM CION sud soe wie omens ARO AN AAA A ees 59 Installationi ot optional e el atrio cae ew A A IS AAA eee hee 61 MechanicaliistalatO nicas e il ri a AA 61 Seeler la e vns a il ra rd 61 Connecting the control Cables siess sranie iata RRN da E a Eaa eee eee eee eens 62 Control connectio
90. olation and grounding diagram on page 88 DIGND floats DIGND tied to DIOGND XD24 XD24 2 3 4 ba ER 2 3 4 h mb Al1 Determines whether Analog input Al1 is used as a current or voltage input Current Voltage 7 7 bdo o Al oo od Al Al2 Al2 1 1 Al2 Determines whether Analog input Al2 is used as a current or voltage input Current Voltage 7 7 Alt Alt Ed oo Al2 o o pa Al2 1 1 T Drive to drive link termination Must be set to the ON position when the drive is the last unit on the link Termination ON Termination OFF SH oar External power supply for the JCU Control Unit XPOW External 24 V minimum 1 6 A power supply for the JCU Control Unit can be connected to terminal block XPOW Using an external supply is recommended if e the application requires fast start after connecting the drive to the main supply e fieldbus communication is required when the input power supply is disconnected Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 64 DI6 XDI 6 as a thermistor input 1 3 PTC sensors can be connected to this input for motor temperature measurement One sensor Three sensors Notes e Do not connect both ends of the cable shields directly to ground If a capacitor cannot be used at one end leave that end of the shield unconnected e The connection of temperature sensors involves parameter adjustment
91. om Email info clrwtr com 38 Mechanical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 39 Planning the electrical installation What this chapter contains This chapter contains the instructions that you must follow when selecting the motor cables protections cable routing and way of operation for the drive If the recommendations given by ABB are not followed the drive may experience problems that the warranty does not cover Note The installation must always be designed and made according to applicable local laws and regulations ABB does not assume any liability whatsoever for any installation which breaches the local laws and or other regulations Motor selection Select the 3 phase AC induction motor according to the rating table in chapter Technical data The table lists the typical motor power for each drive type Only one permanent magnet synchronous motor can be connected to the inverter output It is recommended to install a safety switch between the permanent magnet motor and the drive output in order to isolate the motor from the drive during maintenance work on the drive Supply connection Use a fixed connection to the AC power line WARNING As the leakage current of the device typically exceeds 3 5 mA a fixed installation is required according to IEC 61800 5 1 Supply disconnecting device Install a hand operated input disconnecting device disco
92. op devices at each operator control station and at other operating stations where emergency stop may be needed Note Pressing the stop key on the control panel of the drive does not generate an emergency stop of the motor or separate the drive from dangerous potential Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 42 Safe torque off The drive supports the Safe torque off function STO according to standards EN 61800 5 2 2007 EN ISO 13849 1 2008 IEC 61508 IEC 61511 2004 and EN 62061 2005 The function also corresponds to prevention of unexpected start up of EN 1037 The Safe torque off function disables the control voltage of the power semiconductors of the drive output stage thus preventing the inverter from generating the voltage required to rotate the motor see the diagram below By using this function short time operations like cleaning and or maintenance work on non electrical parts of the machinery can be performed without switching off the power supply to the drive Start up and validate the Safe torque off function according to Safe torque off function for ACSM1 ACS850 and ACQ810 drives application guide 3AFE68929814 English The manual includes the safety data for the function ACS850 04 vemoal In a Ti wemel CT Safe torque off E or KK connection on JCU os Activation switch XSTO 3 L j XSTO
93. or corner grounded delta network is not allowed Low motor noise derating Low motor noise is activated with a drive parameter see the Firmware Manual With low motor noise drive loadability is reduced and derating must be applied if a certain constant output current is needed The derated values are given in the tables below Deratings with 230 V AC supply in low motor noise mode Output ratings SE pom prera use Hears es ka 2 ke Pla Pld Pug Pha ka HP kw HP kw HP ao A 1729 EA aa zg 974 5 76 57 115 95 14 12 1 Drive type ACS850 04 D4A8 2 06A0 2 WE A ESAS 1 08A0 2 A SC WC C C Eee Co Cc ED dD Lee po7s 1 38 058 075 oaz B 1 15 13 EE CTA 5 LA ei REES SR CR EE RE 52 0 75 SC 75 90 15 HE 94 22 114 22 5 2 3 PARA 19 22 ole 53 037 70 055 8 8 0 75 105 11 135 15 165 2 mS 53 5 66 7 78 7 mm 5 5 75 EA e WE 2 8 3 5 E SR 10 10 15 20 37 2 5 5 5 5 J 5 aa In ESCH EI 3 2 ps fs s2 3 fs KAES 6 5 21 44 DCI DECO NIE pan ee as EIN a 7 ar 75 st 00 tsa om p re is 20 58 15 581898 Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 81 Deratings with 400 V AC supply in low motor noise mode Output ratings o Outputratings Input ratings Nominal at ES H
94. ormers and cables is sufficient If in doubt a supply transformer with static screening between the primary and secondary windings can be used Medium voltage network Gs d Supply transformer lt Q be LS Neighbouring network A Static screen W Point of measurement Equipment l Equipment Equipment Low voltage Low voltage 2 An EMC plan for preventing disturbances is drawn up for the installation A template is available from the local ABB representative 3 The motor and control cables are selected as specified in chapter Planning the electrical installation 4 The drive is installed according to the instructions given in this manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 93 Compliance with the Machinery Directive The drive complies with the European Machinery Directive requirements for a partly completed machinery AL ED ED PAIDID Declaration of Incorporation According to Machinery Directive 98 37 EC art 4 2 and Annex II Sub B Manufacturer ABB Oy Address P O Box 184 FIN 00381 Helsinki Finland Street address Hiomotie 13 herewith declare under our sole responsibility that the product Frequency converter series ACS850 with current rating from 3 A up to 720 A and type marking ACS850 04 are intended to be incorporated into machinery to constitute machinery covered by the EEC directive 98 37
95. outputs MM AM 24 V output MU MUM SIN Digital inputs Digital input outputs Slots 1 and 2 for optional I O extensions and encoder resolver interface PPP PPP TTT re Analog inputs Analog outputs Drive to drive link Slot 3 for optional aa fieldbus adapter y y eA m X j y y Safe torque off connection Control panel PC connection Memory unit JMU Motor and braking resistor connections Operation principle and hardware description Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 24 Power connections and control interfaces The diagram shows the power connections and control interfaces of the drive FIO 01 Digital I O extension FIO 11 Analog I O extension FIO 21 Digital Analog I O extension FEN 01 Incremental TTL encoder interface FEN 11 Absolute encoder interface FEN 31 Incremental HTL encoder interface Note No two encoder resolver interfaces of the same type can be connected at a time FENA 0x Ethernet IP Modbus TCP FLON 01 LONWORKs 9 01 FSCA 01 Modbus RTU FPBA 0x PROFIBUS DP PE 3 phase power Li suppl SES L2 4H L3 i Braking resistor optional Control unit JCU Es E Slot 2 8 Memory unit see el page 75 Slot 3 External power input XPOW Control panel or PC Relay outputs 3 pcs For more information on these 24 V DC output con
96. power system or a high resistance grounded over 30 ohms power system the drive will be connected to earth potential through the varistors filters This may cause danger or damage the drive lf a drive whose varistors or internal EMC filter are not disconnected is installed on a corner grounded TN system the drive will be damaged Notes Safety instructions Even when the motor is stopped dangerous voltages are present at the power circuit terminals U1 V1 W1 and U2 V2 W2 and UDC UDC R R Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com e Depending on the external wiring dangerous voltages 115 V 220 V or 230 V may be present on the terminals of the relay outputs of the drive e The drive supports the Safe torque off function See page 42 WARNING Ignoring the following instructions can cause physical injury or death or damage to the equipment e The drive is not field repairable Never attempt to repair a malfunctioning drive contact your local ABB representative or Authorized Service Center for replacement e Make sure that dust from drilling does not enter the drive during the installation Electrically conductive dust inside the drive may cause damage or lead to malfunction e Ensure sufficient cooling A WARNING The printed circuit boards contain components sensitive to electrostatic bo A discharge Wear a grounding wrist band when handling the boards Do not touch
97. r com 44 The motor cable and its PE pigtail twisted shield should be kept as short as possible in order to reduce electromagnetic emission as well as stray currents outside the cable and capacitive current Alternative power cable types Power cable types that can be used with the drive are represented below Motor cable also recommended for supply cabling Symmetrical shielded cable three phase conductors and Note A separate PE conductor is required if the a concentric or otherwise symmetrically constructed PE conductivity of the cable shield is not sufficient for the conductor and a shield purpose See section General rules above PE conductor and shield Shield PE Allowed for supply cabling es Shield A four conductor system three phase conductors and a protective conductor PE PE Motor cable shield To function as a protective conductor the shield must have the same cross sectional area as a phase conductor when they are made of the same metal To effectively suppress radiated and conducted radio frequency emissions the shield conductivity must be at least 1 10 of the phase conductor conductivity The requirements are easily met with a copper or aluminium shield The minimum requirement of the motor cable shield of the drive is shown below It consists of a concentric layer of copper wires with an open helix of copper tape The better and tighter the shield the lower the emission level and the bearing currents
98. r com Email info clrwtr com 73 Cooling fan The actual lifespan of the cooling fan depends on the drive usage and ambient temperature 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 Frames A and B Detach the power cable clamp plate and terminal blocks Release the retaining clips arrowed carefully using a screwdriver Pull the fan holder out Disconnect the fan cable Carefully bend the clips on the fan holder to free the fan Install the new fan in reverse order Note The airflow direction is bottom to top Install the fan so that the airflow arrow points up Airflow direction Maintenance Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 74 Maintenance Fan replacement Frames C and D To remove the fan release the retaining clip arrowed carefully using a screwdriver Pull the fan holder out Disconnect the fan cable Carefully bend the clips on the fan holder to free the fan Install the new fan in reverse order Note The airflow direction is bottom to top I
99. rational for more than one year the converter DC link capacitors need to be reformed Ask ABB for more information Only intact units may be started up Check the installation site Mechanical installation Before installation page 35 Y Technical data page 77 Install the drive in a cabinet Mechanical installation Installation procedure page 36 Route the cables Planning the electrical installation Routing the cables page 46 Check the insulation of the supply cable the motor Electrical installation Checking the insulation of and the motor cable and the resistor cable if the assembly page 51 present If the drive is about to be connected to an IT Safety instructions Installation and ungrounded system disconnect the internal maintenance work page 6 ya ane PMG Melo Also note that using an Electrical installation Power cable connection EMC filter is not allowed in an IT ungrounded system page About this manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 18 Task See Connect the power cables Electrical installation Power cable connection Connect the control and the auxiliary control cables Page 52 and Connecting the control cables page 62 For optional equipment Mains chokes page 97 EMC filters page 99 Resistor braking page 109 Manuals for any optional equipment Check the installation Installation checklist page
100. ses Class 1C2 Chemical cases Class 2C2 Solid particles Class 3S2 Solid particles Class 1S2 Solid particles Class 252 The drive must be installed in clean air according to enclosure classification Cooling air must be clean free from corrosive materials and electrically conductive dust Tested according to IEC 60721 3 3 mechanical conditions Class 3M4 2 9 Hz 3 0 mm 0 12 9 200 Hz 10 m s 33 ft s According to ISTA 1A According to ISTA 1A Max 100 m s 330 ft s Max 100 m s 330 ft s 11 ms 11 ms Freefall _ Notalloweg ao EE e PC ABS colour NCS 1502 Y RAL 9002 PMS 420 C e hot dip zinc coated steel sheet e extruded aluminium AlSi Corrugated cardboard PP bands 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 capacitors and printed circuit boards can be landfilled The DC capacitors contain electrolyte which is 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 p
101. t and EE common mode filtering page a Le Optional braking resistor see chapter Resistor braking page 109 Notes e If shielded supply input cable is used and the conductivity of the shield is not sufficient see section Selecting the power cables on page 43 use a cable with a ground conductor 1 or a separate PE cable 2 e For motor cabling use a separate ground cable 3 if the conductivity of the cable shield is not sufficient see section Selecting the power cables on page 43 and the cable has no symmetrical ground conductors Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 53 Procedure Cabling drawings with tightening torques for each frame size are presented on pages 56 to 58 1 Frame sizes C and D only Remove the two plastic connector covers at the top and bottom of the drive Each cover is fastened with two screws 2 On IT ungrounded systems and corner grounded TN systems remove the following screws to disconnect the internal varistors and EMC filters e VAR frames A and B located close to the supply terminals e EMC VAR1 and VAR2 frames C and D located on the front of the power unit IT system an ungrounded power system or a high resistance grounded over 30 ohms power system the system will be connected to earth potential through the varistors filters of the drive This may cause danger or damage the drive h W
102. tains wa sacs Mow teed oan EN ee ea ed bee dw ake ed es 21 OPelallOnONINCIDICs EE 21 I Ela ee EE 21 MOTOR COMMON aia dd A a a a odes ate lide a Pate Bea 22 PIOQUECOVEIVISW sara ea alee a ee ee ba a a ea 22 LAVOUL wae eN eae eae teeta EE 23 Power connections and control Interfaces 0 000 ee ee eee ee 24 JEE cornisa aid cade beans AO a bak se 25 Ordering intOrmalion 6 2 424424464844 444 lt 54856524646 68644544 244445445 42654244 54544 26 Planning the cabinet assembly VWnatinIs chapter contains mira sa sain haus cee ee eka ae ee Bab hare eee Bae 27 Cabinet COASHUCUON ng eet eh eege ao da dead 27 Disposition of the devices 27 Grounding of mounting structures 27 Main dimensions and free space requirements 0 ce eee 28 COoling and degrees OF DIOLECHON ssid eth ae ep ier AA 29 Preventing the recirculation of hot air 2 1 eee 31 Quiside Ihe Cabello 31 inside EE ege A ET A ee A AC 31 Table of contents Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 10 Cabinet heaters setos ox whe ba o el daa pol de ie doi dit de edi 31 Mechanical installation Contents OF ING DaCkKAde vecinas ita A AA eee ee Bees 33 Delivery check and drive module identification 0 0 0 cc eee 35 Belge DC de ENEE 35 Requirements for the installation site 35 installation gelen 36 Direc Wall MOURUNG os an epanau ced Bev EE 36 DIN rail mounting Frames A and B only 0
103. ther Danish language is selected Swedish Finnish French Spanish Portuguese Russian Turkish 00579470 Ordering information For a complete listing of options and accessories available for the ACS850 04 refer to ACS850 Ordering Information available on request Operation principle and hardware description Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 27 Planning the cabinet assembly What this chapter contains This chapter guides in planning the installation of a drive module into a user defined cabinet The issues discussed are essential for safe and trouble free use of the drive system Note The installation examples in this manual are provided only to help the installer in designing the installation Please note that the installation must however always be designed and made according to applicable local laws and regulations ABB does not assume any liability whatsoever for any installation which breaches the local laws and or other regulations Cabinet construction The cabinet frame must be sturdy enough to carry the weight of the drive components control circuitry and other equipment installed in it The cabinet must protect the drive module against contact and meet the requirements for dust and humidity see chapter Technical data Disposition of the devices For easy installation and maintenance a spacious layout is recommended Sufficient cooling air flow
104. tical access Adjustable speed electrical power drive systems Part 5 2 Safety requirements Functional UL Standard for Safety Power Conversion Equipment Enclosures for Electrical Equipment 1000 Volts Maximum Industrial Control Equipment Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 91 CE marking A CE mark is attached to the drive to verify that the drive follows the provisions of the European Low Voltage and EMC Directives Directive 2006 95 EC and Directive 2004 108 EC Compliance with the European Low Voltage Directive The compliance with the European Low Voltage Directive has been verified according to standards EN 50178 EN 61800 5 1 and EN 60204 1 Compliance with the European EMC Directive The cabinet builder is responsible for the compliance of the drive system with the European EMC Directive For information on items to consider see e Subsections Compliance with EN 61800 3 2004 category C2 Compliance with EN 61800 3 2004 category C3 and Compliance with EN 61800 3 2004 category C4 below e Chapter Planning the electrical installation in this manual e Technical Guide No 3 EMC Compliant Installation and Configuration for a Power Drive System 3AFE61348280 English Definitions EMC stands for Electromagnetic Compatibility It is the ability of electrical electronic equipment to operate without problems within an electromagnetic environment Likewise the equipme
105. tor cable length does not exceed 100 metres 328 ft Note It is not allowed to use the optional EMC filter on IT ungrounded systems The supply network becomes connected to ground potential through the EMC filter capacitors which may cause danger or damage the drive Note It is not allowed to use the optional EMC filter on a corner grounded TN system as this would damage the drive Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 92 WARNING The drive may cause radio interference if used in a residential or domestic environment The user is required to take measures to prevent interference in addition to the requirements for CE compliance listed above if necessary Compliance with EN 61800 3 2004 category C3 The drive meets the requirements of the EMC Directive with the following provisions 1 The drive is equipped with filtering option E200 2 The motor and control cables are selected as specified in chapter Planning the electrical installation 3 The drive is installed according to the instructions given in this manual 4 Motor cable length does not exceed 100 metres 328 ft Compliance with EN 61800 3 2004 category C4 Technical data The drive meets the requirements of the EMC Directive with the following provisions 1 It is ensured that no excessive emission is propagated to neighbouring low voltage networks In some cases the natural suppression in transf
106. u work on the unit MECHANICAL INSTALLATION O The ambient operating conditions are allowable See Mechanical installation Technical data Ratings Ambient conditions O The unit is fastened properly to the cabinet See Planning the cabinet assembly and Mechanical installation O The cooling air will flow freely O The motor and the driven equipment are ready for start See Planning the electrical installation Technical data Motor connection ELECTRICAL INSTALLATION See Planning the electrical installation Electrical installation O The VAR frames A and B and EMC VAR1 VAR2 frames C and D screws are removed if the drive is connected to an IT ungrounded supply network O The capacitors are reformed if stored over one year ask local ABB representative for more information O The drive is grounded properly O The supply input power voltage matches the drive nominal input voltage O The supply input power is connected to U1 V1 W1 UDC UDC in case of a DC supply and the terminals are tightened to specified torque Appropriate supply input power fuses and disconnector are installed O The motor is connected to U2 V2 W2 and the terminals are tightened to specified torque O The braking resistor if present is connected to R R and the terminals are tightened to specified torque The motor cable and braking resistor cable if present is routed away from other cables There are no
107. ut ratings Po utput ratings O O Input ratings Nominal A oo Heavy duty Drive type amuna use evened oa e N N ke e d kW ee A Aa 19 To 26 ESE 3 6 1 58 26 53 24 11 omes a 28 as pea 70 ep ae A05 A 40 67 43 88 22 41 15 osA05 A 40 67 48 105 22 44 22 oas B 67 to 8 35 4 77 4 oaas e o ta i088 ep or ap 8 a map B 10 14 12 a 55 ss 8 4_ mar Ill 141381 28 13 55 11 55 0805 0 18 2 17 3601275 te 75 12 mar 0 18 at a Dm Je m 1 75 mp 0 20 e ss mn 28 11 18 75 o5 0 eje ee 152 ee oas D st 34 78 185 31 185 27 15 mar D 36 4 100 22 4 22 34 185 oas D 45 52 124 30 40 30 38 22 581898 Symbols For the symbols used in the tables above see page 79 Dimensions and weights See also chapter Dimension drawings on page 113 Height without Height with Depth Depth cable clamp cable clamp i without control with control pien kaia i VE Leg ER 550 259 298 SE 744 29 29 Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 83 Cooling characteristics noise levels Power loss W BTU h Drive type ACS850 04 290 171 70 290 171 wz Mm O Di OD 00 00 N N T N O Mm Co wz wz wz m N wz 249 851 115 393 078A 2 1054 3597 68 233 75 256
108. wed at altitudes of 2000 m 6600 ft or higher Max 3 of nominal phase to phase input voltage 0 98 at nominal load Frame A Detachable screw terminal block for 0 25 4 mm wire Frame B Detachable screw terminal block for 0 5 6 mm wire Frames C and D Screw lugs for 6 70 mm wire included Suitable crimp lugs can be used instead 243 356 V DC ACS850 04 xxxx 2 drives 436 743 V DC ACS850 04 xxxx 5 drives Joch uF A V 03A0 2 03A0 5 mas 12016 eoo an 03A6 2 03A6 5 3 9 120 16 690 aR 04A8 2 04A8 5 48 240 16 690 aR 06A0 2 06A0 5 6 5 240 16 690 aR 08A0 2 08A0 5 8 7 240 16 690 aR 010A 2 010A 5 12 370 20 690 aR 014A 2 014A 5 IEC fuse UL fuse Drive Wad ACS850 04 OIBAZ 018A 5 20 740 32 60 aR ve 025A 2 025A5 29 670 63 690 aR EE e 690 aR ac 035A 5 44 1000 100 690 aR DAGA2 044A 5 54 1000 100 ap 050A 2 050A 5 54 1000 100 ap 061A 2 061A 5 73 1340 160 690 aR O7BA 2 078A 5 85 2000 160 690 aR D94A2 094A 5 98 2000 160 690 aR Luch Average DC input current requirement when running a typical induction motor at Py at a DC link voltage of 540 V which corresponds to an AC input voltage of 400 V C Capacitance of DC link Frame A Detachable screw terminal block for 0 25 4 mm wire Frame B Detachable screw terminal block for 0 5 6
109. which may permanently damage the drive Notes If an external source for start command is selected and it is ON the drive will start immediately after an input voltage break or a fault reset unless the drive is configured for 3 wire pulse start stop When the control location is not set to local the stop key on the control panel will not stop the drive WARNING The surfaces of drive system components such as the mains choke and braking resistor if present become hot when the system is in use Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Table of contents AGSS0 divemantalS Ae de Eeer ehr e ee rech AE Geen deed ies 2 Safety instructions Wial tals Gnapter Contains lt x icaeme in e A ALA A A eee ewe 5 WJSe OF Warnings and NOleS siones ce sir ride 5 Installation and maintenance work 6 Startup and operation yous Vata vee hae dears eae na MASS a eaten whe a daa 8 Table of contents About this manual Whatthis Chapter contains secas bidding ys 15 GOMPALDWI wae coa da et da a owe ee eine dc E E ees 15 lao le E AAA E A Meee ates seis 15 Categorization according to the frame setze 15 Categorization according to th COde EE 15 COMES underwear sa ee Pomrehn bce are eo heb ere nt we e pd id RE po ads 15 Installation and commissioning flowchart 17 Terms ana GODreVialiOnS s 2 42 4 055 o ea A ee ROS in 19 Operation principle and hardware description What this Chapter con

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